Hyster G108 Service & Repair Manual
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Hyster G108 Service & Repair Manual

Hyster G108 Service & Repair Manual

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

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Summary of Contents for Hyster G108

  • Page 1 Hyster G108 (E45Z, E50Z, E55Z, E60Z, E65Z) Forklift...
  • Page 2 S/J2.00-3.00XL With Mast S/N C507, C508, C509, C562, C563, and C564 (S/E/J40-60XL) [A187, B187, C187, C108, B168]; J1.60-2.00XMT (J30-40XMT) [C160, F160]; H2.00-3.20XM (H45-65XM) [H177]; J30-40XMT [H160]; E1.50-2.00XM (E25-35Z, E40ZS) [E114]; E2.00-3.20XM (E40-65Z) [G108]; J1.60-2.00XMT (J30-40ZT) [J160] PART NO. 897507 4000 SRM 522...
  • Page 3 • 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.

  • Page 4: Table Of Contents

    Three-Stage FFL Mast, New Hose Install ....................Three-Stage FFL Mast, Adjust Hoses After Install..................Lift and Tilt System Leak Check ........................Lift Cylinders Leak Check ..........................Tilt Cylinders Leak Check ..........................Tilt Cylinders Adjustment..........................Lift Chains Adjustment ............................. ©2003 HYSTER COMPANY...
  • Page 5 Thanks very much for your reading, Want to get more information, Please click here, Then get the complete manual NOTE: If there is no response to click on the link above, please download the PDF document first, and then click on it. Have any questions please write to me: admin@servicemanualperfect.com...
  • Page 6 ) [A216]; J2.00-3.20XM (J40-60Z) [A416]; S/J2.00-3.00XL With Mast S/N C507, C508, C509, C562, C563, and C564 (S/E/J40-60XL) [A187, B187, C187, C108, B168]; J1.60-2.00XMT (J30-40XMT) [C160, F160]; H2.00-3.20XM (H45-65XM) [H177]; J30-40XMT [H160]; E1.50-2.00XM (E25-35Z, E40ZS) [E114]; E2.00-3.20XM (E40-65Z) [G108]; J1.60-2.00XMT (J30-40ZT) [J160]...

  • Page 7: General

    4000 SRM 522 Safety Procedures When Working Near Mast General 4000 SRM 521 for the description and operation of WARNING the masts. Before working on or near the mast, see Safety NOTE: Hoses have a service life that is determined Procedures When Working Near Mast in this by application and time.
  • Page 8 Safety Procedures When Working Near Mast 4000 SRM 522 A. TWO-STAGE LFL MAST B. TWO-STAGE FFL MAST C. THREE-STAGE FFL MAST 1. OUTER WELDMENT 4. HOOK 7. CROSSMEMBER 2. INNER WELDMENT 5. FREE-LIFT CYLINDER 3. INTERMEDIATE WELDMENT 6. CROSSMEMBER Figure 1. Two-Stage LFL, Two-Stage FFL, and Three-Stage FFL Masts...

  • Page 9: Forks Repair

    4000 SRM 522 Forks Repair Forks Repair INSTALL The forks are held on the carriage by hooks. The forks are kept in position by latch pins that fit Move the fork and carriage so the top hook on the through the top fork hooks and into slots in the top fork can engage the upper carriage bar.

  • Page 10: Carriages Repair

    Carriages Repair 4000 SRM 522 Legend for Figure 3 A. EARLIER MODELS B. LATER MODELS 1. FORKS 6. LEVER 2. CARRIAGE 7. WASHER 3. LOAD BACKREST EXTENSION 8. SPRING 4. FORK REMOVAL NOTCH 9. PIN 5. LATCH PIN ASSEMBLY 10. KNOB Carriages Repair STANDARD CARRIAGE, REMOVE 1.

  • Page 11: Hang-On Sideshift Carriage, Remove

    4000 SRM 522 Carriages Repair HANG-ON SIDESHIFT CARRIAGE, bracket and cylinder will stay on the standard carriage. Remove the bearings. REMOVE 1. Lower the carriage completely. Remove the forks WARNING and the load backrest extension. Hydraulic oil is hot after system operation and can cause burns.

  • Page 12: Standard Carriage And Hang-On Sideshift Carriage, Repair

    Carriages Repair 4000 SRM 522 STANDARD CARRIAGE AND HANG-ON SIDESHIFT CARRIAGE, REPAIR NOTE: The carriage can have four or six load rollers. When the carriage has four load rollers, shims are used behind all of the load rollers. When the carriage has six load rollers, shims are installed on the bottom and middle rollers only.

  • Page 13: Hang-On Sideshift Carriage, Install

    0.6 mm (0.024 in.). Install the 3.20XM (J60XM) [A216], J3.00-3.20XM (J60Z) threaded rods to hold the cylinder in position and [A416], E2.00-3.20XM (E40-65Z) [G108], and tighten to 18 N•m (159 lbf in). S/E/J3.00XL (S/E/J60XL) units, tighten all of the capscrews to 755 N•m (557 lbf ft).
  • Page 14 Carriages Repair 4000 SRM 522 NOTE: TWO AND THREE-STAGE FFL IS SHOWN. 1. INNER CARRIAGE 9. CLEVIS PIN 17. COTTER PIN 2. OUTER FRAME 10. HAIRPIN 18. LOAD ROLLER 3. SIDESHIFT CYLINDER 11. PIN 19. SHIMS 4. UPPER BEARING 12. LUBE FITTING 20.

  • Page 15: Clean And Inspect

    4000 SRM 522 Carriages Repair WARNING Hydraulic oil is hot after system operation and can cause burns. Do not disconnect any hy- draulic lines of the system until the oil for the system is cool and the pressure is relieved. 2.

  • Page 16: Install

    Mast Repair 4000 SRM 522 Proper lower hook clearance requires the upper bear- WARNING ings be fully seated. Cleaning solvents may be flammable and toxic 1. If necessary, install the lower sideshift bearings. and can cause severe skin irritation. When Then install the upper sideshift bearings.
  • Page 17 H/S2.00XMS (H/S25-35XM, H/S40XMS), E1.50-1.75XM (E25-35XM, E25-35XM ) (D114), Figure 9. Mast Mounting H/S2.00-3.20XM E2.00XMS (E40XMS, E40XM S (D114), (H/S40-65XM), E2.00-3.20XM (E40-65XM, E1.50-2.00XM (E25-35Z, E40ZS) (E114), and E40-65XM ) (F108), E2.00-3.20XM (E40-65Z) J1.60-2.00XMT (J30-40XMT) (G108), J2.00-3.20XM (J40-60XM, J40-60XM (A216), and J2.00-3.20XM (J40-60Z) (A416),...

  • Page 18: Two-Stage Lfl And Two-Stage Ffl Masts, Disassemble

    Mast Repair 4000 SRM 522 Legend for Figure 12 1. RETAINER CAP 6. NUT 2. LOCKWASHER 7. PIN 3. TILT CYLINDER 8. ROD END 4. OUTER MAST 9. WASHER WELDMENT 10. CAPSCREW 5. BUSHING WARNING The mast is heavy. The mast can weigh approx- imately 907.2 kg (2000 lb).
  • Page 19 4. On H/S2.00-3.20XM (H/S40-65XM), WARNING E2.00-3.20XM (E40-65XM, E40-65XM ) (F108), E2.00-3.20XM (E40-65Z) (G108), J2.00-3.20XM The mast is heavy. The mast can weigh ap- (J40-60XM, J40-60XM ) (A216), J2.00-3.20XM proximately 681 kg (1501 lb). Make sure all lift- (J40-60Z) (A416), S/E/J2.00-3.00XL...
  • Page 20 Mast Repair 4000 SRM 522 Figure 13. Two-Stage, Limited Free-Lift Mast (Sheet 1 of 2)
  • Page 21 4000 SRM 522 Mast Repair Figure 13. Two-Stage, Limited Free-Lift Mast (Sheet 2 of 2)

This manual is also suitable for:

E45zE50zE55zE60zE65z

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