2006–2008 Hyster G108 E45Z, E50Z, E55Z, E60Z, E65Z Forklift Service Manual Set (P/N 1534734, 1534735)

Hyster service and repair sections for E2.00-3.20XM (E45-65Z) [G108], including electrical publications P/N 1534734 and 1534735, with section editions spanning 2004–2008. Shared chapters list J2.00-3.20XM (J40-65Z) [A416/B416], V30ZMD [D210/E210], E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114], and E3.50-5.50XL/E4.50XLS (E70-120Z, E100ZS) [D098/E098]. For these trucks, match the chapter's chassis code and installed equipment.

Text search and diagram navigation: Running text is searchable; text within some diagrams, illustrated tables and ETACC screenshots is not. Service chapters have section bookmarks; Electrical Diagrams has only cover-level entries. Small wiring labels require zooming.

• AC control diagnosis: Master, traction and pump controller checks, CANbus fault tracing, status-code charts, Standard/Premium display functions and performance adjustments.

• Electric motor repair: AC motor disassembly and bearing service, plus DC brush, commutator, field and armature inspection and testing.

• Hydraulic repair: Pump and tank service, electro-hydraulic valve disassembly, component checks, mini-lever/joystick tests and lift, tilt and auxiliary calibration.

• Brakes and steering: Wheel/master cylinder repair, parking and seat-brake adjustment, steering axle/control-unit overhaul, pressure testing and system bleeding.

• Drive axle and frame: Speed reducer/differential overhaul, bearing preload, axle replacement, counterweight removal and battery/operator restraint-system service.

• Masts and cylinders: Mast/carriage disassembly, lift-chain and header-hose adjustment, lift/tilt cylinder rebuilding and leakage checks.

• Service references: Periodic maintenance, industrial battery care, capacity and mast-speed data, wear limits, electrical/hydraulic test specifications, torque tables, sealants and fastener guidance.

These sections suit trained, authorized lift-truck service personnel equipped for electrical diagnosis, hydraulic testing and heavy-component handling.

AC Controls and Wiring Coverage

Drawings distinguish early Gen IV and later Gen V panels, AC-pump controls and AC-traction/DC-lift-pump arrangements. Matching the layout to the truck helps avoid tracing the wrong fuse, contactor or controller-pin circuit.

Control settings cover BDI/lift interrupt, regenerative braking, auto-deceleration, speed limits, steering delay, service reminders and pump-speed parameters. Status charts address seat-switch and brake-pressure inputs, valve-coil current, motor-temperature faults, overheating, seat-brake faults and controller communication.

Electrical service covers displays, switches, sensors, lights, relays, alarms, fuses and harness splices. Motor controllers are replacement units when an internal fault occurs.

Representative drawings include G108 36/48V manual-hydraulic wiring, G108/V30ZMD 36/48V electro-hydraulic wiring, G108 72/80V wiring, standard/high-flow valve schematics, ring-and-pinion contact-pattern views and mast header-hose arrangements. Traction and hydraulic motor power-cable routing is also shown.

Diagram book 8000 SRM 1059 covers A416, D210/E210, E114/F114 and G108. The referenced B416 and D098/E098 diagram publications, 8000 SRM 1225 and 8000 SRM 1203, are not included.

ETACC Setup and Diagnostics

ETACC documentation covers legacy PC setup, truck connection, factory-default/custom configurations, serial-number and hourmeter changes, display-language downloads, password/inspection functions, reports, logs and live diagnostics.

It references Interface Cable Kit P/N 1534010 and installation CD P/N 1539240; the controller diagnostic chapter also identifies breakout kit P/N 1397311. Software, CDs, cables, breakout hardware and password files are not supplied with the manuals.

AC and DC Motor Repair Limits

AC procedures address bearing replacement, the traction-motor seal, encoder-bearing orientation and sensor checks. Serviceable internal parts are limited to bearings and the seal on the traction motor, and bearings on the AC hydraulic pump motor.

The motor chapter warns that incorrect end-bell handling can damage the encoder wire; its troubleshooting chart links encoder faults to slow or jerky travel. DC procedures cover applicable pump/steering motors, while brushless DC steering motors are identified as nonrepairable.

Hydraulics, Brakes and Steering

Hydraulic coverage separates early/later G108 layouts and manual/electro-hydraulic controls, including separate steering and lift pumps. Valve troubleshooting and repair cover EHPR and compensator cartridges, relief/check valves, the tilt counterbalance valve, mini-lever module and joystick. Cartridge repair is limited to seal replacement; the sealed valve driver has no serviceable internal components.

Manual-hydraulic descriptions and schematics are included; the separate Manual Hydraulic Control Valve 2000 SRM 562 repair section is not.

Brake procedures cover service-brake disassembly, parking-brake linkage, seat-brake variants and switch tests. They explain the service-brake adjustment required before parking-brake setup and warn that a dragging seat-brake drum can damage the brakes and overheat the traction motor.

Steering coverage includes cylinder repair and control-unit overhaul, with air-removal procedures and pressure checks.

Masts, Carriages and Maintenance

Both 4000 SRM 522 and 4000 SRM 1148 mast repair sections are supplied. Coverage spans two-stage LFL, two-stage FFL, three-stage FFL and four-stage FFL masts, with standard, hang-on and integral sideshift carriages, forks, lift chains and header hoses.

Periodic Maintenance distinguishes V30ZMD attachment S/N D210V from D210N/E210 for attachment service. Industrial Battery covers battery selection, counterweight requirements, hydrometer checks and charging; internal battery repair requires specialized training and equipment.

For work around high-current circuits, heavy components, raised masts and pressurized hydraulics, follow the applicable Hyster isolation, blocking, lifting and pressure-release precautions.

Printable PDF Sections and Page Breakdown

The ZIP contains these separate English SRM publications, each with its own part number.

This 1,008-page set comprises 23 printable PDFs. The total already includes 23 title pages, 34 contents pages, 12 notes pages and 21 blank pages; all are included in the listed file counts.