Hyster G108 (E45Z, E50Z, E55Z, E60Z, E65Z) Forklift Parts Manual

11/2003 UNIT CODE G108 NORTH AMERICA SECTIONS 1 FRAME 2 ELECTRICAL SYSTEM 3 DRIVE UNIT 4 STEERING SYSTEM 5 BRAKE/ACCELERATOR SYSTEM 6 HYDRAULIC SYSTEM 7 MAST-TWO STAGE LIMITED FREE-LIFT 8 MAST-THREE STAGE FULL FREE-LIFT 9 MAST-TWO STAGE FULL FREE-LIFT 10 MAST-FOUR STAGE FULL FREE-LIFT 11 OPTIONS 12 NUMERICAL INDEX This Parts Manual is divided into 12 major sections which are listed above. Quick reference to these sections can be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages to the corresponding tab.

11/2003 UNIT CODE G108 NORTH AMERICA TABLE OF CONTENTS DESCRIPTION PAGE A ACCELERATOR ................................................................................................................................................. 5-16 ACCELERATOR PEDAL..................................................................................................................................... 5-18 AUXILIARY TUBES FOUR STAGE FULL FREE-LIFT FOUR FUNCTION GROUP ...................................................................................................................... 11-16 TWO AND THREE STAGE FULL FREE-LIFT FOUR FUNCTION GROUP ...................................................................................................................... 11-14 B BACKUP ALARM ............................................................................................................................................. 11-30 BATTERY SLIDE AND ROLLER TRAY ............................................................................................................ 11-18 BRAKE ................................................................................................................................................................. 5-6 BRAKE AND BACKUP LIGHT ......................................................................................................................... 11-22 BRAKE PEDAL LINKAGE .................................................................................................................................... 5-2 BRAKE SWITCH HARNESS .............................................................................................................................. 5-20 C CARRIAGE FOUR STAGE FULL FREE-LIFT .................................................................................................................. 10-22 SIX ROLLER THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-34 TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-20 TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 7-18 CONTACTOR LINE ................................................................................................................................................................ 2-12 POWER STEERING ....................................................................................................................................... 2-14 CONTACTOR PANEL CONTACTOR (LINE AND POWER STEERING) ............................................................................................ 2-10 CONTACTOR HYDRAULIC ............................................................................................................................ 2-16 CONTROL PANEL CONTACTOR HYDRAULIC .............................................................................................................................. 2-8 TRACTION AND PUMP CONTROLLER .......................................................................................................... 2-6 CONTROL VALVE FOUR FUNCTION .......................................................................................................................................... 6-30 THREE FUNCTION ........................................................................................................................................ 6-26 CONTROL VALVE ATTACHING PARTS ............................................................................................................. 6-20 COUNTERWEIGHT ........................................................................................................................................... 1-14 COVERS .............................................................................................................................................................. 1-6 D DASH DISPLAY .................................................................................................................................................... 2-5 DC CONVERTOR 36/48 VOLT TO 12 VOLT .............................................................................................................................. 11-29 DRIVE AND REAR LIGHTS ............................................................................................................................. 11-24 DRIVE AXLE ........................................................................................................................................................ 3-2 DRIVE UNIT INSTALLATION E/EE/ES AND CRE/FRE................................................................................................................................... 3-8 ©2003 HYSTER COMPANY i See Service Manual for service procedures.

UNIT CODE G108 NORTH AMERICA 11/2003 TABLE OF CONTENTS (Continued) DESCRIPTION PAGE E ELECTRICAL ....................................................................................................................................................... 2-2 F FORK.................................................................................................................................................................. 1-30 FRAME ................................................................................................................................................................. 1-2 FREE-LIFT E45-55Z TWO STAGE FULL FREE-LIFT .................................................................................................................... 9-8 E60-65Z TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-10 FOUR STAGE FULL FREE-LIFT .................................................................................................................. 10-12 THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-18 FREE-LIFT CYLINDER FOUR STAGE FULL FREE-LIFT .................................................................................................................. 10-20 THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-30 TWO STAGE FULL FREE-LIFT ...................................................................................................................... 9-17 FULL SUSPENSION SEAT SHEET 1 OF 2 ................................................................................................................................................ 1-20 SHEET 2 OF 2 ................................................................................................................................................ 1-22 G GEAR PUMP ...................................................................................................................................................... 4-12 H HAND LEVER..................................................................................................................................................... 6-24 HEADER HOSE FOUR STAGE FULL FREE-LIFT .................................................................................................................. 10-24 THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-36 TWO STAGE FULL FREE-LIFT ...................................................................................................................... 9-22 TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7-20 HOOD................................................................................................................................................................... 1-8 HYDRAULIC ......................................................................................................................................................... 6-2 HYDRAULIC MOTOR ......................................................................................................................................... 6-12 CLOSED CONSTRUCTION ........................................................................................................................... 6-16 OPEN CONSTRUCTION ................................................................................................................................ 6-14 HYDRAULIC MOTOR MOUNT........................................................................................................................... 6-10 HYDRAULIC PUMP 12 CC................................................................................................................................................................ 6-5 19 CC................................................................................................................................................................ 6-8 LOW NOISE 19 CC ............................................................................................................................................................ 6-6 HYDRAULIC TANK ............................................................................................................................................. 6-34 I INNER MAST FOUR STAGE FULL FREE-LIFT .................................................................................................................... 10-8 THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-10 TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9-4 TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-4 INTEGRAL SIDE-SHIFT ii ©2003 HYSTER COMPANY See Service Manual for service procedures.

11/2003 UNIT CODE G108 NORTH AMERICA TABLE OF CONTENTS (Continued) DESCRIPTION PAGE I (continued) CARRIAGE THREE STAGE FULL FREE-LIFT .............................................................................................................. 11-4 TWO AND FOUR STAGE FULL FREE-LIFT............................................................................................... 11-6 TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 11-2 HYDRAULIC HOSES THREE STAGE FULL FREE-LIFT ............................................................................................................ 11-11 TWO AND FOUR STAGE FULL FREE-LIFT............................................................................................. 11-12 TWO STAGE LIMITED FREE-LIFT ........................................................................................................... 11-10 INTEGRAL SIDE-SHIFT CYLINDER ................................................................................................................. 11-8 INTERMEDIATE MAST NO. 1 FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-4 NO. 2 FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-6 THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-6 L LABELS .............................................................................................................................................................. 1-25 LIFT TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-8 LIFT CYLINDER E45-55Z TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 7-11 E60-65Z TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 7-14 LOAD BACKREST EXTENSION........................................................................................................................ 1-28 M MAIN CYLINDER LEFT HAND FOUR STAGE FULL FREE-LIFT .............................................................................................................. 10-15 RIGHT HAND FOUR STAGE FULL FREE-LIFT .............................................................................................................. 10-18 THREE STAGE FULL FREE LIFT LEFT HAND ................................................................................................................................................ 8-26 THREE STAGE FULL FREE-LIFT RIGHT HAND .............................................................................................................................................. 8-22 MAIN LIFT FOUR STAGE FULL FREE-LIFT .................................................................................................................. 10-10 THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-14 TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9-6 MAIN LIFT CYLINDER LEFT HAND TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-13 RIGHT HAND TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-15 MAST INSTALLATION ........................................................................................................................................ 6-36 MASTER CYLINDER ........................................................................................................................................... 5-4 ©2003 HYSTER COMPANY iii See Service Manual for service procedures.

UNIT CODE G108 NORTH AMERICA 11/2003 TABLE OF CONTENTS (Continued) DESCRIPTION PAGE N NON-SUSPENSION SEAT ................................................................................................................................. 1-16 O OUTER MAST FOUR STAGE FULL FREE-LIFT .................................................................................................................... 10-2 THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-2 TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9-2 TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-2 OVERHEAD GUARD.......................................................................................................................................... 1-12 P PARK BRAKE SEAT ACTUATED ........................................................................................................................................... 5-14 PARK BRAKE LINKAGE LEVER ACTUATED .......................................................................................................................................... 5-8 SEAT ACTUATED ........................................................................................................................................... 5-12 S SHIFT LEVER ...................................................................................................................................................... 4-4 SPOTLIGHT ..................................................................................................................................................... 11-28 STEERING AXLE ............................................................................................................................................... 4-16 STEERING CONTROL UNIT ............................................................................................................................... 4-6 STEERING CYLINDER ...................................................................................................................................... 4-10 STEERING HYDRAULIC...................................................................................................................................... 4-8 STEERING MOTOR ........................................................................................................................................... 4-14 STEERING POD .................................................................................................................................................. 4-2 STROBE LIGHT ............................................................................................................................................... 11-26 SUSPENSION SEAT .......................................................................................................................................... 1-18 T TILT CYLINDER ................................................................................................................................................. 6-18 TIRE AND WHEEL DRIVE WHEEL ............................................................................................................................................... 3-12 STEER WHEEL .............................................................................................................................................. 4-18 TRACTION MOTOR 11.0-INCH ....................................................................................................................................................... 3-10 TRANSMISSION AND DIFFERENTIAL ............................................................................................................... 3-4 W WIRE HARNESS LIGHT ............................................................................................................................................................. 2-20 MAIN ............................................................................................................................................................... 2-18 REAR LIGHTS .............................................................................................................................................. 11-32 SWITCH........................................................................................................................................................ 11-33 TRACTION CUT-OUT .................................................................................................................................. 11-34 iv ©2003 HYSTER COMPANY See Service Manual for service procedures.

11/2003 UNIT CODE G108 NORTH AMERICA ABBREVIATIONS QUICK REFERENCE SHEET Listed below are abbreviations used in parts manuals to denote the following expressions: TERM DEFINITION Amp Amperes AR As Required BDI Battery Discharge Indicators BWI Brush Wear Indicator CE Communicator End CRE Corrosive Environment D/B Date Break dbA Decibel "A" Scale DE Drive End ECH Empty Container Handler ECH-3 Empty Container Handler - 3 High Stacking ECH-4 Empty Container Handler - 4 High Stacking ECH-5 Empty Container Handler - 5 High Stacking ECH-6 Empty Container Handler - 6 High Stacking ECH-7 Empty Container Handler - 7 High Stacking ECM Electronic Control Module ECN Engineering Change Notice EEPROM Electrically Erasable Programmable Read Only Memory EPROM Electrically Programmable Read Only Memory TERM DEFINITION FRE Freezer Environment in. inches LPG Liquefied Petroleum Gas MAP Manifold Absolute Pressure mm millimeters MSTS Microprocessor Spark Timing System NPT National Pipe Threads O/S Oversize PTO Power Take Off RPM Revolutions per Minute S/N Serial Number TMM Truck Management Module UL Type D Diesel-Powered Safety Rating UL Type DS Diesel-Powered Safety Rating UL Type E Battery-Powered Safety Rating UL Type EE Battery-Powered Safety Rating UL Type ES Battery-Powered Safety Rating UL Type G Gasoline-Powered Safety Rating UL Type GS Gasoline-Powered Safety Rating UL Type LP Gas-Powered Safety Rating UL Type LPS LP Gas-Powered Safety Rating U/S Undersize UL Underwriters Laboratory V Volts ©2003 HYSTER COMPANY v See Service Manual for service procedures.

UNIT CODE G108 NORTH AMERICA 11/2003 HOW TO USE THE ILLUSTRATED PARTS MANUAL This parts manual describes and illustrates assemblies, subassemblies, and detail parts needed for service replacement. The different constructions are indicated by keys and footnotes. The callouts correspond to descriptions found on the next page. vi ©2003 HYSTER COMPANY See Service Manual for service procedures. T CODE 0001 NORTHAMERICA table of contents DESCRIPTION AIR INTAKE AND FILTER DIESEL (=5 D/B AIR INTAKE AND FILTER DIESEL (D/8 11/96=>) AIR INTAKE AND FILTER GASOLINE AND LPG ALTERNATOR GASOLINE. LPG. AND DIESEL - SECTION 13 NUMERICAL INDEX ALTERNATOR TYPES GS. LPS. AND OS ITEM PAGE NO. PART ITEM PART ITEM PAGE NO. NO. PAGE NO ITEM PAGE NO AUXILIARY FUNCTION TUBE TWO AND THREE STAGE FULL F 11-27 SECTIONS 9-11 10-10 36 10-13 32 11-7 11-9 FRAME ELECTRICAL SYSTEM TRANSMISSION HOUSING S/N D001H-2628 BRAKE/ACl KEY A: Diesel B: Gasoline and LPG MAST-TWO STAGI PART NO. DESCRIPTION MAST-THREE STA TiaisrvsSiOP Transmission Case Bea.'ng cap Washer VW1670 MAST-TWO ST/ 2023418 Cover Collet Pin D-Ring 3'ug Housing 1371656 2021329 2021915 2021675 2021336 287860 22 22 39 39 Lockwasher Hydtai.l-c Pump •* Figure 5-3 . i i Washer Temperature Switch Breaker Qipshc* 296418 Capscrew Lockwasher Transmission Kit (Includes Item7) 996405 Transmission Kit (Includes Item 1 4) This Parts Manual is divided into 11 major sections which are listed above. Quick be made by placing the right thumb on the tab ol the desired section, bending the pages to the corresponding tab. SCopy Rinhl Date HYSTERCOMPANY HP990004

Hyster G108 (E45Z, E50Z, E55Z, E60Z, E65Z) Forklift Parts Manual

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