Hyster Service Manual for E2.00-3.20XM (E45-65XM, E45-65XM2), N30XMH, N30XMH2, V30ZMD, and E2.00-3.20XM (E45-65Z) Electric Lift Trucks (Brake System) 2003-2008

Hyster F108 Series Electric Lift Truck Brake System Service Manual

Keep your fleet running safely and efficiently with this professional-grade Service Repair Manual (SRM). This comprehensive technical document is specifically designed for the Hyster F108 series and associated electric lift trucks, focusing on the critical maintenance and repair of the complete braking architecture. Whether you are performing a routine inspection or a full master cylinder overhaul, this manual provides the factory-spec data required to ensure operator safety and vehicle reliability.

Supported Models and Engineering Codes

This manual covers a broad range of Hyster electric lift trucks. It is essential to match your truck's engineering code (found on the data plate) to ensure parts and torque specs are correct:

• E2.00-3.20XM (E45-65XM, E45-65XM2) [Series Code: F108]
• E2.00-3.20XM (E45-65Z) [Series Code: G108]
• N30XMH, N30XMH2 [Series Codes: A210, C210]
• V30ZMD [Series Codes: D210, E210]

Detailed Serial Number Reference

To assist technicians in identifying the correct revision of the braking system, this manual references major Hyster series and mast configurations, including units with specific Mast Serial Numbers:

• Mast S/N C507, C508, C509
• Mast S/N C562, C563, C564

Expert Technical Content for Professional Results

This is not just an overview; it is a deep-dive technical resource (1800 SRM 574) that includes step-by-step instructions for:

Comprehensive Brake Services

• Service Brakes: Complete teardown and reassembly of the wheel-end braking components. Includes precise cleaning and inspection criteria to determine if shoes or drums require replacement.
• Master Cylinder Repair: Detailed bleeding procedures and internal seal replacement to restore firm pedal feel and consistent stopping power.
• Parking Brake Systems: Covers both the adjustable handle designs and the seat-activated brake linkages found on specialized XM and Z series trucks.

Precision Adjustments and Testing Avoid the guesswork with factory-set specifications for:

• Brake Pedal Height and Free Play
• Master Cylinder Push-rod Adjustment
• Parking Brake Holding Force (Adjustment via the tension knob)
• Brake Pressure Applied Service Tests to verify system integrity under load.

Diagnostics and Troubleshooting The dedicated troubleshooting section helps you identify root causes for common issues such as:

• Spongy or soft brake pedals
• Brakes that fail to release or drag during operation
• Parking brakes that do not hold on inclines
• Fluid leaks and air contamination in lines

Why This Manual is Essential

Hyster electric forklifts like the E45-65XM2 are known for their longevity in demanding warehouse environments. However, the braking system is a primary wear item. Utilizing the correct Service Manual ensures that you are using the right torque values and specialized tools, preventing damage to the drive axle and ensuring the truck meets OSHA-required safety standards.

Mobile-Friendly Design

This documentation is organized into clear, concise sections with high-contrast diagrams and indexed tables. It is optimized for viewing on tablets or smartphones right on the shop floor, allowing you to access torque specs and wiring references without leaving the machine.