PERIODIC
MAINTENANCE
E1.50-1.75XM, E2.00XMS
(E25-40XMS, E25-40XMS
2
) [D114];
E2.00-3.20XM (E45-65XM, E45-65XM
2
) [F108];
J2.00-3.20XM (J40-60XM, J40-60XM
2
) [A216]
PART NO. 897577 8000 SRM 552
hy£2J*
HM210601
SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Periodic Maintenance Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Serial Number Data ...................................................................................................................................... 1
How to Move Disabled Lift Truck ................................................................................................................. 1
How to Tow Lift Truck............................................................................................................................... 1
How to Put Lift Truck on Blocks................................................................................................................... 2
How to Raise Drive Tires .......................................................................................................................... 2
How to Raise Steering Tires ..................................................................................................................... 2
Maintenance Schedule ....................................................................................................................................... 3
Maintenance Procedures Every 8 Hours or Daily ............................................................................................ 11
How to Make Checks With Key OFF ............................................................................................................ 11
Tires and Wheels ....................................................................................................................................... 11
Forks .......................................................................................................................................................... 12
Adjust..................................................................................................................................................... 12
Remove .................................................................................................................................................. 12
Install..................................................................................................................................................... 13
Forks, Mast, and Lift Chains, Inspect ..................................................................................................... 14
Safety Labels ............................................................................................................................................. 15
Steering Column Latch ............................................................................................................................. 15
Operator Restraint System....................................................................................................................... 15
Battery Restraint System E1.50-3.20XM, E2.00XMS (E25-65XM, E25-65XM
2
Lift Truck
Models ........................................................................................................................................................ 16
Battery Restraint System J2.00-3.20XM (J40-60XM and J40-60XM
2
) Lift Truck Models ................... 17
Battery ....................................................................................................................................................... 18
Hydraulic System ...................................................................................................................................... 19
How to Make Checks With Key ON.............................................................................................................. 20
Gauges, Horn, and Fuses .......................................................................................................................... 20
Steering System ........................................................................................................................................ 20
Service Brakes ........................................................................................................................................... 20
Parking Brake ........................................................................................................................................... 20
Control Levers and Pedals ........................................................................................................................ 21
Direction and Speed Control Pedals......................................................................................................... 21
Lift System Operation ............................................................................................................................... 21
Maintenance Procedures Every 250 Hours or 6 Weeks ................................................................................... 21
Steering Tie Rods ........................................................................................................................................... 21
Steering King Pins, Trucks Only .................................................................................................................. 21
Maintenance Procedures Every 500 Hours or 3 Months ................................................................................. 22
Hydraulic Tank Breather .............................................................................................................................. 22
Differential and Speed Reducer .................................................................................................................... 22
Wheel Nut Torques ........................................................................................................................................ 23
Steering Axle Spindles .................................................................................................................................. 23
Steering Tie Rods ........................................................................................................................................... 23
Mast ................................................................................................................................................................ 23
Lift Chains ..................................................................................................................................................... 24
Wear Check ................................................................................................................................................ 24
Forks............................................................................................................................................................... 25
Brake Fluid .................................................................................................................................................... 25
Other Lubrication .......................................................................................................................................... 25
Seat Brake, Models E1.50-3.20XM, E2.00XMS (E25-65XM and E25-65XM
2
) Only ................................. 26
Electrical Inspection ...................................................................................................................................... 26
Contactors .................................................................................................................................................. 26
Motor Brushes ........................................................................................................................................... 27
©2004 HYSTER COMPANY i
Table of Contents Periodic Maintenance
TABLE OF CONTENTS (Continued)
Motor Brushes, General ............................................................................................................................ 27
Maintenance Procedures Every 1000 Hours or 6 Months ............................................................................... 42
Lift Chains ..................................................................................................................................................... 42
Forks............................................................................................................................................................... 42
Check Upper and Lower Bearings, Integral Sideshift Carriage ................................................................. 42
Maintenance Procedures Every 2000 Hours or Yearly .................................................................................... 43
Hydraulic System .......................................................................................................................................... 43
Change Filter for Hydraulic Oil ............................................................................................................... 43
Change Hydraulic Oil ............................................................................................................................... 44
Differential and Speed Reducer .................................................................................................................... 44
Service Brakes ............................................................................................................................................... 45
Contactors ...................................................................................................................................................... 45
Wheel Bearings .............................................................................................................................................. 45
Steer Wheels, Lubrication ........................................................................................................................ 45
Drive Wheels, Lubrication ........................................................................................................................ 45
Lift Chains ..................................................................................................................................................... 46
Replace Upper and Lower Bearings, Integral Sideshift Carriage .............................................................. 46
Steering Axle.................................................................................................................................................. 46
King Pins and Rod Ends (Steering Cylinders)......................................................................................... 46
Other Lubrication .......................................................................................................................................... 46
Battery Maintenance ......................................................................................................................................... 46
How to Charge Battery.................................................................................................................................. 46
How to Change Battery ................................................................................................................................. 48
General....................................................................................................................................................... 48
Change Battery, E1.50-3.20XM, E2.00XMS (E25-65XM and E25-65XM
2
) Models Only...................... 48
Change J2.00-3.20XM (J40-60XM and J40-60XM
2
) Battery .................................................................. 51
Lift and Tilt System Leak Check ...................................................................................................................... 53
Lift Cylinders Leak Check ............................................................................................................................ 53
Tilt Cylinders Leak Check ............................................................................................................................ 53
Safety Procedures When Working Near Mast .................................................................................................. 54
Lift Chain Adjustments ..................................................................................................................................... 56
PMT Circuit Check ............................................................................................................................................ 57
Welding Repairs ................................................................................................................................................. 58
Overhead Guard Changes ................................................................................................................................. 58
Wheels and Tire Maintenance........................................................................................................................... 59
Tires and Wheels, E1.50-3.20XM, E2.00XMS (E25-65XM and E25-65XM
2
) ............................................. 59
Remove Wheels From Lift Truck .............................................................................................................. 59
Remove and Install Tire on Wheel ........................................................................................................... 59
Pneumatic Tires and Wheels J2.00-3.20XM (J40-60XM and J40-60XM
2
) ................................................. 60
Remove Wheels From Lift Truck .............................................................................................................. 60
Remove Wheel From Pneumatic Tire....................................................................................................... 61
Install Wheel in Pneumatic Tire .............................................................................................................. 62
Install Three- or Four-Piece Wheel in Pneumatic Tire ........................................................................... 63
Add Air to Tires ......................................................................................................................................... 64
Wheels, Install ........................................................................................................................................... 64
Solid Rubber Tires on Pneumatic Wheels .................................................................................................... 65
Remove Wheels From Lift Truck .............................................................................................................. 65
Remove Solid Rubber Tire From Pneumatic Wheel ................................................................................ 65
Install Solid Rubber Tire on Pneumatic Wheel ....................................................................................... 67
Wheels, Install ........................................................................................................................................... 68
Solid Rubber Tire, Change ............................................................................................................................ 68
ii
Periodic Maintenance Table of Contents
TABLE OF CONTENTS (Continued)
Remove and Install Tire on Wheel ........................................................................................................... 68
Remove Wheel From Tire ......................................................................................................................... 70
Install Wheel in Tire ................................................................................................................................. 71
SIT Tire, Change ........................................................................................................................................... 72
Remove SIT Solid Tire From Wheel ......................................................................................................... 73
Install SIT Solid Tire on Wheel ................................................................................................................ 74
Adhesives and Sealants ..................................................................................................................................... 75
This section is for the following models:
E1.50-1.75XM, E2.00XMS (E25-40XMS, E25-40XMS
2
) [D114];
E2.00-3.20XM (E45-65XM, E45-65XM
2
) [F108];
J2.00-3.20XM (J40-60XM, J40-60XM
2
) [A216]
iii
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Hyster F108 (E45-65XM2) Service Shop Manual Forklift Workshop Repair Book
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Description
The Hyster F108 (E45-65XM2) Shop Repair Manual is a comprehensive service manual designed to provide detailed servicing instructions for your Hyster Fork Lift. Whether you are a professional mechanic or a DIY enthusiast, this manual offers complete step-by-step information on repair, servicing, preventative maintenance, and troubleshooting procedures. It features photos and illustrations to guide you through the entire repair process, making it an indispensable source of detailed maintenance and repair information. This manual covers a wide range of subjects including the frame, cooling system, LPG fuel system, transmission, steering, brake system, hydraulic system, electrical system, and more.
With easy navigation, you can quickly identify the exact service repair procedures. Detailed illustrations, exploded diagrams, drawings, and photos provide clear guidance for every service repair procedure. The manual is fully printable, allowing you to print pages whenever needed. It covers Hyster Fork Lift models including F108 (E45-65XM2) (Up to SN F108V15840W).
If you are looking to purchase this manual, you can select the instant format. After purchasing, you can instantly view and print the manual. In addition to this manual, we offer a large selection of Hyster Service Manuals & Parts Catalogs for various models.
- FRAME
- COOLING SYSTEM
- LPG FUEL SYSTEM
- TRANSMISSION
- STEERING SYSTEM
- BRAKE SYSTEM
- HYDRAULIC SYSTEM
- ELECTRICAL SYSTEM
- MAINTENANCE
- DIAGRAMS
A forklift, also known as a lift truck, is a powered industrial truck used for lifting and transporting materials. It has become an indispensable piece of equipment in manufacturing and warehousing operations. The manual covers a wide range of forklift types and components, providing valuable information for forklift operators and technicians.
Design types of forklifts include hand pallet trucks, low lift trucks, rider stackers, reach trucks, electric counterbalanced trucks, and various specialized order picking trucks. The manual also details the components of a typical counterbalanced forklift, including the counterweight, cab, overhead guard, power source, tilt cylinders, mast, carriage, load backrest, and attachments.
