Hyster F108 (E45XM E50XM E55XM E60XM E65XM (Pre-SEM)(Up to SN F10840W)) Forklift Service Repair Factory Manual INSTANT
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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
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
8000 SRM 552 General
General
WARNING
Do not make repairs or adjustments unless you
have both authorization and training. Repairs
and adjustments that are not correct can make
a dangerous operating condition.
Do not operate a lift truck that needs repairs.
Report the need for repairs immediately. If re-
pair is necessary, put a DO NOT OPERATE tag
in the operator’s area. Remove the key from
the key switch. Disconnect the battery connec-
tor.
CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
Disposal of batteries must meet local environ-
mental regulations.
On lift trucks before XM
2
, when turning the key
switch to the ON position, the Brush Wear Indicator
and Motor Temperature Indicator will illuminate.
On XM
2
lift trucks, there is no brush wear indicator,
but the LCD screen will show a status code indicat-
ing that the brushes need replacing as described in
the Operating Manual. Contact your dealer if any
LED Indicators do not illuminate during the check
part of initial lift truck operation.
This section contains a Maintenance Schedule and
the instructions for maintenance and inspection.
The Maintenance Schedule has time intervals for in-
spection, lubrication, and maintenance. The time
intervals are based on a normal operation. A nor-
mal operation is considered to be one 8-hour shift
per day in a relatively clean environment on an im-
proved surface. Multiple shifts, dirty operating con-
ditions, etc., will require a reduction in the recom-
mended time periods in the Maintenance Schedule.
Your dealer for Hyster lift trucks has the equipment
and trained service personnel to do a complete pro-
gram of inspection, lubrication, and maintenance. A
regular program of inspection, lubrication, and main-
tenance will help your lift truck provide more effi-
cient performance and operate for a longer period of
time.
Some users have service personnel and equipment
to do the inspection, lubrication, and maintenance
shown in the Maintenance Schedule. Service Man-
uals are available from your dealer for Hyster lift
trucks to help users who do their own maintenance.
SERIAL NUMBER DATA
The serial number code for the lift truck is on the
Nameplate. The code is also stamped on top of the
rear bulkhead of the frame. It is on the bulkhead
inside the right rear leg of the overhead guard.
HOW TO MOVE DISABLED LIFT TRUCK
How to Tow Lift Truck
WARNING
Use extra caution when towing a lift truck if
any of the following conditions exist:
• Brakes do not operate correctly.
• Steering does not operate correctly.
• Tires are damaged.
• Traction conditions are bad.
• The lift truck must be moved on a steep
grade.
If the steering pump motor does not operate,
steering control of the lift truck can be slow
and difficult. Do NOT tow the lift truck if there
is no power. Poor traction can cause the dis-
abled lift truck or towing vehicle to slide. Steep
grades will require additional brake force to
stop the lift truck.
Never carry a disabled lift truck unless the lift
truck MUST be moved and cannot be towed.
The lift truck used to carry the disabled lift
truck MUST have a rated capacity equal to
or greater than the weight of the disabled
lift truck. The capacity must be for a load
center equal to half the width of the disabled
lift truck. See the Nameplate of the disabled
lift truck for the approximate total weight.
The forks must extend the full width of the
disabled lift truck. Put the weight center of
the disabled lift truck on the load center of the
forks. Do not damage the underside of the lift
truck.
1. The towed lift truck must have an operator.
1
General 8000 SRM 552
2. Raise the carriage and forks approximately
300 mm (12 in.) from the surface. Install a chain
to prevent the carriage and mast channels from
moving.
3. Tow with another lift truck of equal or greater ca-
pacity than the disabled lift truck. Install a load
of approximately half-capacity on the forks of the
lift truck that is being used to tow the disabled
lift truck. The half-capacity load will increase the
traction of the lift truck. Keep the load as low as
possible.
4. Use a towing link made of steel that fastens to
the tow pins in the counterweights of both lift
trucks.
5. Release the parking brake.
6. Tow the lift truck slowly.
HOW TO PUT LIFT TRUCK ON BLOCKS
How to Raise Drive Tires
WARNING
The lift truck must be put on blocks for some
types of maintenance and repair. The removal
of the following assemblies will cause large
changes in the center of gravity: mast, drive
axle, battery, or counterweight. When the lift
truck is put on blocks, put additional blocks in
the following positions to maintain stability:
a. Before removing the mast and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
b. Before removing the counterweight, put
blocks under the mast assembly so the lift
truck cannot fall forward.
The surface must be solid, even, and level when
the lift truck is put on blocks. Make sure that
any blocks used to support the lift truck are
solid, one-piece units.
NOTE: Some lift trucks have lifting eyes. These lift
points can be used to raise the lift truck so that blocks
can be installed.
1. Put blocks on each side (front and back) of the
steering tires to prevent movement of the lift
truck. See Figure 1.
2. Put the mast in a vertical position. Put a block
under each outer mast channel.
3. Tilt the mast fully forward until the drive tires
are raised from the surface.
4. Put additional blocks under the frame behind the
drive tires.
5. If the hydraulic system will not operate, use a
hydraulic jack under the side of the frame near
the front. Make sure that the jack has a capacity
equal to at least half the weight of the lift truck.
See the Nameplate.
How to Raise Steering Tires
1. Apply the parking brake. Put blocks on both
sides (front and back) of the drive tires to pre-
vent movement of the lift truck. See Figure 1.
2. Use a hydraulic jack to raise the steering tires.
Make sure that the jack has a capacity of at least
2/3 of the total weight of the lift truck as shown
on the Nameplate.
3. Put the jack under the steering axle or frame to
raise the lift truck. Put blocks under the frame
to support the lift truck.
2
8000 SRM 552 Maintenance Schedule
1. DRIVE TIRES 2. STEERING TIRES
Figure 1. Put Lift Trucks on Blocks
Maintenance Schedule
The Maintenance Schedule has two time periods.
If the lift truck is operated less than eight hours
each day, do maintenance at the 1-DAY, 6-WEEKS,
3-MONTHS, 6-MONTHS, and 1-YEAR periods. If
the lift truck is operated more than eight hours each
day, do maintenance at the periods shown in hours
(8, 250, 500, 1000, 2000). The approximate locations
of the items indicated in the Maintenance Schedule
are shown in Figure 2, Figure 3, and Figure 4.
The Maintenance Schedule, Table 1, has the max-
imum service intervals for average conditions. In-
spect and lubricate more frequently if the lift truck
operates in dirty or difficult conditions.
3
HM210602
Maintenance Schedule 8000 SRM 552
Figure 2. E1.50-1.75XM, E2.00XMS (E25-40XM, E25-40XMS
2
) Maintenance Points
Figure 3. E2.00-3.20XM (E45-65XM, E45-65XM
2
) Maintenance Points
4
HM210603
HM210604
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Get the Hyster F108 (E45XM E50XM E55XM E60XM E65XM (Pre-SEM)(Up to SN F10840W)) Forklift Service Repair Factory Manual for comprehensive maintenance and repair guidance. This electronic manual offers the advantage of zooming in on your computer for clear visibility, making it convenient for professional mechanics and DIY enthusiasts. The manual covers a range of models including E45XM, E50XM, E55XM, E60XM, and E65XM, providing detailed information on various components such as axle housing, brake system, electrical system, hydraulic system, steering system, and more. With step-by-step instructions, it enables easy and cost-effective repairs. The manual is available in PDF format and is compatible with all versions of Windows and Mac, making it accessible to a wide range of users.
