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Hyster E40-65Z (G108) Parts Manual – PDF DOWNLOAD
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Hyster E40-65Z (G108) Parts Manual – PDF DOWNLOAD
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Description
Hyster E40-65Z (G108) Parts Manual – PDF DOWNLOAD
TABLE OF CONTENTS:
Hyster E40-65Z (G108) Parts Manual – PDF DOWNLOAD
Frame...................................................................................................... 19 COWL AND FLOOR PLATES.................................................................................. 22 COVERS................................................................................................. 26 HOOD MANUAL HYDRAULICS (→ S/N G108N02839C) ........................................................... 30 HOOD MANUAL HYDRAULICS (S/N G108N02840C →) ........................................................... 34 HOOD ELECTRONIC HYDRAULICS (S/N G108N02840C →) ....................................................... 38 OVERHEAD GUARD......................................................................................... 42 COUNTERWEIGHT.......................................................................................... 44 NON-SUSPENSION SEAT.................................................................................... 46 NON-SUSPENSION SEAT MANUAL HYDRAULICS (7/2005 ↔ 3/2006) .............................................. 48 NON SUSPENSION SEAT.................................................................................... 50 SUSPENSION SEAT........................................................................................ 52 SEMI-SUSPENSION SEAT MANUAL HYDRAULICS (7/2005 ↔ 3/2006) ............................................. 54 SEMI-SUSPENSION SEAT ELECTRONIC HYDRAULICS (S/N G108N02840C ↔ 4/2006) ................................ 55 SEMI-SUSPENSION SEAT WITH AND WITHOUT ELECTRONIC CONTROLS (4/2006 →) ................................. 56 FULL SUSPENSION SEAT SHEET 1 OF 2 (→ 7/2005) ......................................................... 58 FULL SUSPENSION SEAT SHEET 2 OF 2 (→ 7/2005) ......................................................... 62 FULL SUSPENSION SEAT MANUAL HYDRAULICS (7/2005 ↔ 3/2006) ............................................. 64 FULL SUSPENSION SEAT WITH ELECTRONIC CONTROLS (S/N G108N02840C ↔ 3/2005) ............................. 65 FULL SUSPENSION SEAT WITH AND WITHOUT ELECTRONIC CONTROLS (4/2006 →) ................................. 66 FULL SUSPENSION SWIVEL SEAT ELECTRONIC HYDRAULICS (S/N G108N02840C ↔ 3/2006) ......................... 68 FULL SUSPENSION SWIVEL SEAT ELECTRONIC HYDRAULICS (3/2006 →) ......................................... 70 LABELS................................................................................................. 72 JOYSTICK LABELS........................................................................................ 76 MINI LEVER LABELS...................................................................................... 78 LOAD BACKREST EXTENSION................................................................................ 80 FORKS.................................................................................................. 82 FORKS OPTIONAL......................................................................................... 84 ELECTRICAL SYSTEM.......................................................................................... 87 ELECTRICAL SYSTEM...................................................................................... 90 ELECTRICAL SYSTEM ELECTRONIC HYDRAULICS (S/N G108N02840C →) .......................................... 94 JOYSTICK............................................................................................... 96 ELECTRONIC CONTROL LEVERS MINI-LEVER MODULES - DATE CODE 0724 ......................................... 98 ELECTRONIC CONTROL LEVERS MINI-LEVER MODULES (THREE FUNCTION) - DATE CODE 0725 THRU 0743 ..............100 ELECTRONIC CONTROL LEVERS MINI-LEVER MODULES (FOUR fUNCTION) - DATE CODE 0725 THRU 0743 ...............102 ELECTRONIC CONTROL LEVERS MINI-LEVER MODULES (THREE FUNCTION) - DATE CODE 0744 ........................104 ELECTRONIC CONTROL LEVERS MINI-LEVER MODULE (FOUR FUNCTION) - DATE CODE 0744 ..........................106 DASH DISPLAY...........................................................................................108 CONTROL PANEL TRACTION AND PUMP CONTROLLER.............................................................110 CONTROL PANEL CONTACTOR HYDRAULIC......................................................................112 CONTACTOR PANEL CONTACTOR (LINE AND POWER STEERING)....................................................116 CONTACTOR LINE.........................................................................................118 CONTACTOR POWER STEERING...............................................................................120 CONTACTOR PANEL CONTACTOR HYDRAULIC....................................................................122 WIRE HARNESS MAIN (→ S/N G108V03421C) ................................................................124 WIRE HARNESS MAIN - WITHOUT ELECTRONIC HYDRAULICS (S/N G108V03422C →) ...............................126 WIRE HARNESS MAIN - WITH ELECTRONIC HYDRAULICS (S/N G108N02840C →) ..................................128 WIRE HARNESS ELECTRONIC HYDRAULIC CONTROL VALVES (S/N G108N02840C →) .................................132 WIRE HARNESS LIGHT.....................................................................................134 WIRE HARNESS PRESSURE SWITCH (4/2004 →) ..............................................................136 WIRE HARNESS HOOD (S/N G108N02840C →) ................................................................138 WIRE HARNESS JOYSTICK (S/N G108N02840C →) ............................................................139 MAIN WIRE HARNESS ALTERNATE PART - SHEET 1 OF 2 .......................................................140 MAIN WIRE HARNESS ALTERNATE PART - SHEET 2 OF 2 .......................................................144 WIRE HARNESS CONTROL VALVE SWITCH......................................................................148 DRIVE UNIT.................................................................................................151 DRIVE AXLE.............................................................................................154 TRANSMISSION AND DIFFERENTIAL..........................................................................158 DRIVE UNIT INSTALLATION TRACTION AND PUMP MOTOR BANDS - E/EE/ES AND CRE/FRE ...........................162 TRACTION MOTOR 11.0-INCH...............................................................................164 TIRES AND WHEELS DRIVE WHEELS..........................................................................166 DRIVE UNIT INSTALLATION TRACTION AND PUMP MOTOR BANDS - E/EE/ES AND CRE/FRE ...........................168 STEERING SYSTEM............................................................................................171 STEERING POD...........................................................................................174 SHIFT LEVER............................................................................................178 STEERING CONTROL UNIT..................................................................................180 STEERING HYDRAULICS....................................................................................182 STEERING CYLINDER......................................................................................184 GEAR PUMP..............................................................................................186 STEERING MOTOR.........................................................................................188 STEERING AXLE..........................................................................................190 STEERING AXLE OPTIONAL.................................................................................192 TIRES AND WHEELS STEER WHEELS..........................................................................194 BRAKE/ACCELERATOR SYSTEM...................................................................................195 BRAKE PEDAL LINKAGE....................................................................................198 MASTER CYLINDER........................................................................................200 BRAKE..................................................................................................202 BRAKE..................................................................................................204 PARK BRAKE LINKAGE LEVER ACTUATED......................................................................206 PARK BRAKE LINKAGE SEAT ACTUATED (→ S/N G108V03421C) .................................................210 PARK BRAKE LINKAGE SEAT ACTUATED (S/N G108V03422C ↔ S/N G108N05935E) .................................212 PARK BRAKE LINKAGE SEAT ACTUATED (S/N G108N05936E →) .................................................216 PARK BRAKE SEAT ACTUATED...............................................................................220 ACCELERATOR............................................................................................222 ACCELERATOR PEDAL......................................................................................224 BRAKE SWITCH HARNESS...................................................................................226 HYDRAULIC SYSTEM...........................................................................................229 HYDRAULIC SUPPLY AND RETURN MANUAL HYDRAULICS (→ S/N G108N02839C) ....................................232 HYDRAULIC SUPPLY AND RETURN MANUAL HYDRAULICS (S/N G108N02840C →) ....................................236 HYDRAULIC SUPPLY AND RETURN ELECTRONIC HYDRAULICS (S/N G108N02840C →) ................................240 HYDRAULIC PUMP 12 CC...................................................................................243 HYDRAULIC PUMP 19 CC (→ S/N G108N02839C) .............................................................244 HYDRAULIC GEAR PUMP 19 CC (S/N G108N02840C →) ........................................................246 HYDRAULIC PUMP MOTOR...................................................................................248 HYDRAULIC PUMP MOTOR OPEN CONSTRUCTION - WITH BWI AND TEMPERATURE SENSOR ..............................250 HYDRAULIC PUMP MOTOR CLOSED CONSTRUCTION - WITH BWI AND TEMPERATURE SENSOR ............................252 HYDRAULIC PUMP MOTOR MOUNT.............................................................................254 HYDRAULIC HAND LEVERS MANUAL HYDRAULICS................................................................256 HYDRAULIC CONTROL VALVE AND ATTACHING PARTS MANUAL HYDRAULICS - SHEET 1 OF 2 ..........................260 HYDRAULIC CONTROL VALVE AND ATTACHING PARTS MANUAL HYDRAULICS - SHEET 2 OF 2 ..........................264 HYDRAULIC CONTROL VALVE THREE FUNCTION - MANUAL HYDRAULICS ............................................266 HYDRAULIC CONTROL VALVE FOUR FUNCTION - MANUAL HYDRAULICS .............................................270 ELECTRONIC HYDRAULIC CONTROL VALVE ATTACHING PARTS.....................................................274 ELECTRONIC HYDRAULIC CONTROL VALVE ASSEMBLY............................................................276 MAIN SECTION ELECTRONIC HYDRAULIC CONTROL VALVE (S/N G108N02840C →) ..................................278 AUXILIARY SECTION STANDARD FLOW - ELECTRONIC HYDRAULIC CONTROL VALVE (S/N G108N02840C →) ............280 AUXILIARY SECTION HIGH FLOW - ELECTRONIC HYDRAULIC CONTROL VALVE (S/N G108N02840C →) ................282 HYDRAULIC TANK AND ATTACHING PARTS.....................................................................284 HYDRAULIC TANK AND ATTACHING PARTS.....................................................................286 HYDRAULIC FILTER.......................................................................................288 MAST INSTALLATION......................................................................................290 TILT CYLINDERS.........................................................................................292 Mast-Two Stage Limited Free-Lift...........................................................................295 OUTER MAST TWO STAGE LIMITED FREE-LIFT.................................................................298 INNER MAST TWO STAGE LIMITED FREE-LIFT.................................................................302 LIFT TWO STAGE LIMITED FREE-LIFT.......................................................................306 LIFT CYLINDER E45-55Z - TWO STAGE LIMITED FREE-LIFT ...................................................309 LIFT CYLINDER E60-65Z - TWO STAGE LIMITED FREE-LIFT ...................................................312 CARRIAGE SIX ROLLER - TWO STAGE LIMITED FREE-LIFT .....................................................316 HEADER HOSE TWO STAGE LIMITED FREE-LIFT................................................................318 Mast-Three Stage Full Free-Lift............................................................................321 OUTER MAST THREE STAGE FULL FREE-LIFT..................................................................324 INTERMEDIATE MAST THREE STAGE FULL FREE-LIFT...........................................................328 INNER MAST THREE STAGE FULL FREE-LIFT..................................................................332 MAIN LIFT THREE STAGE FULL FREE-LIFT...................................................................336 FREE-LIFT THREE STAGE FULL FREE-LIFT...................................................................340 MAIN CYLINDER THREE STAGE FULL FREE-LIFT - RIGHT HAND .................................................344 MAIN CYLINDER THREE STAGE FULL FREE-LIFT - LEFT HAND ..................................................349 FREE-LIFT CYLINDER THREE STAGE FULL FREE-LIFT..........................................................354 CARRIAGE SIX ROLLER - THREE STAGE FULL FREE-LIFT ......................................................360 CARRIAGE HEAVY DUTY - THREE STAGE FULL FREE-LIFT ......................................................362 HEADER HOSE THREE STAGE FULL FREE-LIFT.................................................................364 Mast-Two Stage Full Free-Lift..............................................................................369 OUTER MAST TWO STAGE FULL FREE-LIFT....................................................................372 INNER MAST TWO STAGE FULL FREE-LIFT....................................................................374 MAIN LIFT TWO STAGE FULL FREE-LIFT.....................................................................376 FREE-LIFT E45-55Z - TWO STAGE FULL FREE-LIFT ..........................................................378 FREE-LIFT E60-65Z - TWO STAGE FULL FREE-LIFT ..........................................................382 MAIN LIFT CYLINDER LEFT HAND - TWO STAGE FULL FREE-LIFT ...............................................385 MAIN LIFT CYLINDER RIGHT HAND - TWO STAGE FULL FREE-LIFT ..............................................387 FREE-LIFT CYLINDER TWO STAGE FULL FREE-LIFT............................................................389 CARRIAGE SIX ROLLER - TWO STAGE FULL FREE-LIFT ........................................................392 CARRIAGE ASSEMBLY HEAVY DUTY - TWO STAGE FULL FREE-LIFT ...............................................394 HEADER HOSE TWO STAGE FULL FREE-LIFT...................................................................396 MAST-FOUR STAGE FULL FREE-LIFT.............................................................................399 OUTER MAST FOUR STAGE FULL FREE-LIFT...................................................................402 INTERMEDIATE 2 MAST FOUR STAGE FULL FREE-LIFT..........................................................404 INTERMEDIATE 3 MAST FOUR STAGE FULL FREE-LIFT..........................................................408 INNER MAST FOUR STAGE FULL FREE-LIFT...................................................................412 MAIN LIFT FOUR STAGE FULL FREE-LIFT....................................................................414 FREE-LIFT FOUR STAGE FULL FREE-LIFT....................................................................416 MAIN CYLINDER LEFT HAND - FOUR STAGE FULL FREE-LIFT ...................................................419 MAIN CYLINDER RIGHT HAND - FOUR STAGE FULL FREE-LIFT ..................................................422 FREE-LIFT CYLINDER FOUR STAGE FULL FREE-LIFT...........................................................425 CARRIAGE FOUR STAGE FULL FREE-LIFT.....................................................................428 CARRIAGE ASSEMBLY HEAVY DUTY - FOUR STAGE FULL FREE-LIFT ..............................................430 HEADER HOSE FOUR STAGE FULL FREE-LIFT - WITH CABLES ...................................................432 OPTIONS....................................................................................................435 INTEGRAL SIDE-SHIFT CARRIAGE - TWO STAGE LIMITED FREE-LIFT ............................................438 INTEGRAL SIDE-SHIFT CARRIAGE - THREE STAGE FULL FREE-LIFT .............................................440 INTEGRAL SIDE-SHIFT CARRIAGE - TWO AND FOUR STAGE FULL FREE-LIFT ......................................442 INTEGRAL SIDE-SHIFT CYLINDER...........................................................................445 INTEGRAL SIDE-SHIFT HYDRAULIC HOSES - TWO STAGE LIMITED FREE-LIFT .....................................446 INTEGRAL SIDE-SHIFT HYDRAULIC HOSES - THREE STAGE FULL FREE-LIFT ......................................447 INTEGRAL SIDE-SHIFT HYDRAULIC HOSES - TWO AND FOUR STAGE FULL FREE-LIFT ...............................448 AUXILIARY TUBE EXTENSION KIT TWO STAGE LIMITED FREE-LIFT...............................................450 AUXILIARY TUBE EXTENSION KIT TWO AND THREE STAGE FULL FREE-LIFT........................................452 AUXILIARY TUBE EXTENSION KIT FOUR STAGE FULL FREE-LIFT.................................................454 AUXILIARY TUBES TWO AND THREE STAGE FULL FREE-LIFT - FOUR FUNCTION GROUP WITH INTERGRAL SIDE-SHIFT ....456 AUXILIARY TUBES FOUR STAGE FULL FREE-LIFT - FOUR FUNCTION GROUP WITH INTERGRAL SIDE-SHIFT .............458 BATTERY ROLLER TRAY, SLIDES, AND SPACERS...............................................................460 BRAKE AND BACK-UP LIGHTS...............................................................................464 LIGHTS, LED BACK-UP AND BRAKE..........................................................................466 DRIVE AND REAR LIGHTS..................................................................................468 STROBE LIGHT...........................................................................................470 SPOTLIGHT..............................................................................................472 DC TO DC CONVERTER 36/48 VOLT TO 12 VOLT...............................................................473 BACK-UP ALARM..........................................................................................474 WIRE HARNESS REAR LIGHTS (→ S/N G108N09895F) .........................................................475 WIRE HARNESS REAR LIGHTS (S/N G108N09896F →) .........................................................476 WIRE HARNESS SWITCH....................................................................................478 WIRE HARNESS TRACTION CUT-OUT (→ S/N G108N03309D) ....................................................480 WIRE HARNESS TRACTION CUT-OUT (S/N G108N03310D →) ....................................................482 FIELD CONVERSION KITS......................................................................................485 AUXILIARY TUBE EXTENSION KIT TWO STAGE LIMITED FREE-LIFT...............................................488 AUXILIARY TUBE EXTENSION KIT TWO AND THREE STAGE FULL FREE-LIFT........................................488 AUXILIARY TUBE EXTENSION KIT FOUR STAGE FULL FREE-LIFT.................................................488 CONTROL VALVE..........................................................................................488 CONTROL VALVES CONVERSION KITS ELECTRONIC HYDRAULICS...................................................489 DIRECTIONAL CONTROL CONVERSION.........................................................................489 ELECTRICAL CONVERSIONS SEAT BRAKE......................................................................489 ELECTRICAL CONVERSIONS LIGHTS..........................................................................489 FENDER KITS............................................................................................490 MAST TILT CONVERSION KITS..............................................................................490 WIDE TREAD KITS........................................................................................490 HEADER HOSE CONVERSION KITS TWO STAGE LIMITED FREE-LIFT - E45-55Z .....................................491 HEADER HOSE CONVERSION KITS TWO STAGE LIMITED FREE-LIFT - E60-65Z .....................................492 HEADER HOSE CONVERSION KITS TWO STAGE FULL FREE-LIFT - E45-55Z ........................................493 HEADER HOSE CONVERSION KITS TWO STAGE FULL FREE-LIFT - E60-65Z ........................................494 HEADER HOSE CONVERSION KITS THREE STAGE FULL FREE-LIFT - E45-55Z ......................................495 HEADER HOSE CONVERSION KITS THREE STAGE FULL FREE-LIFT - E60-65Z ......................................496 HEADER HOSE CONVERSION KITS FOUR STAGE FULL FREE-LIFT..................................................497 NUMERICAL INDEX............................................................................................499
DESCRIPTION:
Hyster E40-65Z (G108) Parts Manual – PDF DOWNLOAD
HOW TO USE THE ILLUSTRATED PARTS MANUAL :
- This parts manual describes and illustrates assemblies, sub-assemblies, and detail parts needed for service replacement.
- The different constructions are indicated by keys and footnotes. The call outs correspond to descriptions found on the next page.
HOW TO FIND THE DESIRED PART NUMBER
WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN:
1. Determine the function and application of the part required. Turn to the Sections Page. Choose the general area of reference most likely to include the part.
WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN:
1. Determine the function and application of the part required. Turn to the Sections Page. Choose the general area of reference most likely to include the part.
2. Turn to the section you chose. Use the Section Table of Contents to determine the assembly which would normally contain the part required. Then locate the part on the assembly breakdown page.
WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN:
3. Determine the assembly the required part is used on. Turn to the Table of Contents (Page i).
WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN:
3. Determine the assembly the required part is used on. Turn to the Table of Contents (Page i).
4. Locate the assembly the required part is used on and turn to the page indicated for that assembly. Then locate the part on the assembly breakdown page.
WHEN THE PART NUMBER IS KNOWN:
5. Use the Numerical Index (Page 13-1) to find the part number. Turn to the page listed and locate the part as indicated by the item number.
GENERAL:
The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.
WHEN THE PART NUMBER IS KNOWN:
5. Use the Numerical Index (Page 13-1) to find the part number. Turn to the page listed and locate the part as indicated by the item number.
GENERAL:
The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.
6. Parts Super session Information. Part numbers that have this history will be displayed in the parts list in the order that they were superseded (from oldest to newest). The superseded part numbers will be shown with a line through them.
- Five periods in the PART NO. column (. . . . .) indicate that the part is either Not Serviced Separately or there is a reference to another figure. A figure reference is denoted by a pointing hand followed by a figure number in the DESCRIPTION column (Figure 10)
7. Keys are used to show two or more similar assemblies, RH and LH assembly parts, etc. Select the appropriate key, “A”, “B”, “C”, “D”, or “E” and the corresponding quantity column to find the required parts. Two periods in the QTY column (..) indicate that the part is not used for that assembly.
IMAGES PREVIEW OF THE MANUAL:
HYSTER E40-65Z (G108) PARTS MANUAL – PDF DOWNLOAD:
PLEASE NOTE:
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