Hyster Z943 (E30-50FR) Service Manual

Description

• Model List:
  • Z943 (E30-50FR)

• 1. INTRODUCTION
• 2. GENERAL
• 3. LEAD-ACID BATTERIES
• 4. SPECIFIC GRAVITY
• 5. THE CHEMICAL REACTION IN A CELL
• 6. ELECTRICAL TERMS
• 7. HOW TO SELECT THE BATTERY
• 8. VOLTAGE OF A BATTERY
• 9. THE BATTERY AS A COUNTERWEIGHT
• 10. BATTERY RATINGS
• 11. Kilowatt-Hours
• 12. BATTERY MAINTENANCE
• 13. SAFETY PROCEDURES
• 14. MAINTENACE RECORDS
• 15. THE NEW BATTERY
• 16. HOW TO CLEAN THE BATTERY
• 17. HOW TO ADD WATER
• 18. THE HYDROMETER
• 19. BATTERY TEMPERATURE
• 20. CHARGING THE BATTERY
• 21. Types Of Battery Charges
• 22. Methods Of Charging
• 23. Troubleshooting The Charger
• 24. How To Know When The Battery Is Fully Charged
• 25. WHERE TO CHARGE THE BATTERIES
• 26. Equipment Needed
• 27. BATTERY CONNECTORS
• 28. BATTERY CARE
• 29. INTRODUCTION
• 30. GENERAL
• 31. DESCRIPTION
• 32. DISASSEMBLY AND ASSEMBLY
• 33. OVERHEAD GUARD
• 34. Removal
• 35. Installation
• 36. OVERHEAD GUARD REAR POST
• 37. Removal
• 38. Installation
• 39. BATTERY RETAINERS
• 40. Removal
• 41. Installation
• 42. BATTERY ROLLERS
• 43. Removal
• 44. Installation
• 45. FRONT COVER
• 46. Removal
• 47. Installation
• 48. TOP COVER
• 49. Removal
• 50. Installation
• 51. CONTROL COVER
• 52. Removal
• 53. Installation
• 54. OPERATOR COMPARTMENT PADS
• 55. Removal
• 56. Installation
• 57. FLOOR MAT/BRAKE PEDAL PAD
• 58. Removal
• 59. Installation
• 60. LABOR REPLACEMENT
• 61. PAINTING INSTRUCTIONS
• 62. INTRODUCTION
• 63. ELECTRIC MOTOR MAINTENANCE, GENERAL
• 64. DRIVE MOTOR AND HYDRAULIC PUMP MOTOR
• 65. Disassembly
• 66. Assembly
• 67. POWER STEERING PUMP MOTOR
• 68. Disassembly
• 69. Assembly
• 70. BRUSH AND COMMUTATOR INSPECTION
• 71. Normal Commutator Surface
• 72. Commutator Problems
• 73. DRIVE MOTOR BRUSHES
• 74. Removal
• 75. Installation
• 76. LIFT PUMP MOTOR BRUSHES
• 77. Removal
• 78. Installation
• 79. Untitled
• 80. STONING THE COMMUTATOR
• 81. TEST FOR A DAMAGED FIELD AND ARMATURE
• 82. Test for an Open-Circuit in the Armature
• 83. Test for a Short-Circuit in an Armature Winding
• 84. Test for a Short-Circuit in the Armature
• 85. Test for an Open-Circuit in a Field Coil
• 86. Test for a Short-Circuit in a Field Coil
• 87. Test for a Short-Circuit Between the Field and the Motor Case
• 88. Brush Holder Test
• 89. INTRODUCTION
• 90. DESCRIPTION
• 91. REPAIRS
• 92. DRIVE UNIT
• 93. Removal
• 94. Installation
• 95. DRIVE MOTOR
• 96. Brush Removal and Installation
• 97. GEARBOX
• 98. Oil Change
• 99. DRIVE WHEEL ASSEMBLY
• 100. Removal and Installation
• 101. DRIVE WHEEL SEAL
• 102. Removal
• 103. Installation
• 104. DRIVE WHEEL SPINDLE
• 105. Removal
• 106. Installation
• 107. ENCODER ASSEMBLY
• 108. Removal
• 109. Installation
• 110. ENCODER BELT ADJUSTMENT
• 111. DRIVE SHAFT INSERT
• 112. DRIVE UNIT REBUILD
• 113. Disassembly
• 114. Pinion Gear to Motor Assembly
• 115. Gear Housing to Motor Assembly
• 116. PROCEDURE I
• 117. Gear Housing to Motor Assembly
• 118. PROCEDURE II
• 119. Gear Housing to Motor Assembly
• 120. Carrier to Gear Housing Assembly
• 121. CARRIER REBUILD
• 122. Carrier Disassembly
• 123. Carrier Assembly
• 124.
• 124.1. INTRODUCTION
• 124.1.1. GENERAL
• 124.1.2. DESCRIPTION
• 124.2. REPAIRS
• 124.2.1. STEER PUMP MOTOR ASSEMBLY
• 124.2.2. STEER PUMP
• 124.2.3. STEER CONTROL VALVE
• 124.2.4. HYDRAULIC MOTOR
• 124.2.5. STEERING GEAR
• 124.2.6. STEER FORK ASSEMBLY
• 124.2.7. STEER WHEEL ASSEMBLY
• 124.2.8. STEER POSITION POTENTIOMETER
• 124.2.9. CHANGING STEER TIRES
• 124.3. CHECKS AND ADJUSTMENTS
• 124.3.1. STEER POTENTIOMETER ADJUSTMENT
• 124.3.2. STEERING PRESSURE
• 125.
• 125.1. INTRODUCTION
• 125.1.1. GENERAL
• 125.1.2. DESCRIPTION AND OPERATION
• 125.1.3. THEORY OF OPERATION
• 125.2. REPAIRS
• 125.2.1. DISC BRAKE UNIT
• 125.2.2. BRAKE ACTUATOR ASSEMBLY
• 125.2.3. MASTER CYLINDER
• 125.2.4. BRAKE PEDAL
• 125.2.5. BLEEDING THE BRAKE SYSTEM
• 125.3. CHECKS AND ADJUSTMENTS
• 125.3.1. BRAKE ADJUSTMENTS
• 125.4. TROUBLESHOOTING
• 126.
• 126.1. INTRODUCTION
• 126.1.1. GENERAL
• 126.1.2. DESCRIPTION
• 126.1.3. FLOW CONTROL VALVE
• 126.1.4. RELIEF VALVE
• 126.2. REPAIRS
• 126.2.1. DISASSEMBLY
• 126.2.2. CLEANING
• 126.2.3. INSPECTION
• 126.2.4. ASSEMBLY
• 126.3. CHECKS AND ADJUSTMENTS
• 126.3.1. CHECKING THE OUTPUT OF THE PUMP
• 126.3.2. CHECKING FOR AIR IN THE HYDRAULIC SYSTEM
• 126.3.3. SPECIFICATIONS
• 126.3.4. TROUBLESHOOTING
• 127.
• 127.1. INTRODUCTION
• 127.1.1. GENERAL
• 127.1.2. DESCRIPTION
• 127.1.3. OPERATION
• 127.1.4. MULTI-FUNCTION CONTROL HANDLE
• 127.2. REPAIRS
• 127.2.1. LIFT PUMP MOTOR ASSEMBLY
• 127.2.2. LIFT PUMP
• 127.2.3. STEER PUMP MOTOR ASSEMBLY
• 127.2.4. STEER PUMP
• 127.2.5. HYDRAULIC VALVE CARTRIDGE
• 127.2.6. PRESSURE RELIEF VALVE
• 127.2.7. MANUAL LOWERING VALVE
• 127.2.8. FLOW REGULATOR
• 127.2.9. PROPORTIONAL VALVE CARTRIDGE
• 127.2.10. HYDRAULIC OIL FILTER
• 127.2.11. HYDRAULIC OIL
• 127.2.12. TILT CYLINDERS
• 127.2.13. HYDRAULIC TANK REPAIRS
• 127.2.14. CLEANING THE HYDRAULIC TANK
• 127.3. CHECKS AND ADJUSTMENTS
• 127.3.1. RELIEF VALVE
• 127.4. TROUBLESHOOTING
• 128.
• 129.
• 129.1. INTRODUCTION
• 129.1.1. GENERAL
• 129.1.2. DESCRIPTION
• 129.2. REPAIRS
• 129.2.1. REMOVAL
• 129.2.2. DISASSEMBLY
• 129.2.3. CLEANING AND INSPECTION
• 129.2.4. ASSEMBLY
• 129.2.5. INSTALLATION
• 129.3. CHECKS AND ADJUSTMENTS
• 129.3.1. CHECKING FOR LEAKAGE
• 129.3.2. ADJUSTMENT-TILT ANGLE (E30ER, E40ER, E50ER)
• 129.3.3. ADJUSTMENT-TILT CYLINDER (E30FR-24, E30FR, E35FR, E40FR, E45FR, E50FR)
• 129.4. TROUBLESHOOTING
• 130.
• 131.
• 132.
• 132.1. INTRODUCTION
• 132.1.1. GENERAL
• 132.1.2. TWO-STAGE MAST
• 132.1.3. THREE-STAGE MASTS
• 133.
• 133.1. INTRODUCTION
• 133.1.1. GENERAL
• 133.2. REPAIRS
• 133.2.1. CARRIAGE
• 133.2.2. MAST ASSEMBLY
• 133.2.3. LIFT CHAIN REMOVAL AND INSTALLATION
• 133.2.4. LIFT CYLINDER REMOVAL AND INSTALLATION
• 133.2.5. LIFT CYLINDER SHEAVES
• 133.2.6. HYDRAULIC COMPONENTS
• 133.3. CHECKS AND ADJUSTMENTS
• 133.3.1. BLEEDING AIR FROM THE LIFT CYLINDERS
• 133.3.2. CARRIAGE ADJUSTMENT
• 133.3.3. MAST ADJUSTMENT
• 133.3.4. LIFT CHAIN ADJUSTMENT
• 133.3.5. TILT ANGLE ADJUSTMENT
• 133.4. TROUBLESHOOTING
• 134.
• 134.1. INTRODUCTION
• 134.1.1. GENERAL
• 134.1.2. DESCRIPTION
• 134.1.3. FLOW CONTROL VALVE AND FLOW FUSES
• 134.2. REPAIRS
• 134.2.1. REMOVAL
• 134.2.2. DISASSEMBLY
• 134.2.3. ASSEMBLY
• 134.2.4. INSTALLATION
• 134.3. CHECKS AND ADJUSTMENTS
• 134.3.1. BLEEDING AIR FROM LIFT CYLINDERS
• 134.4. TROUBLESHOOTING
• 135.
• 136.
• 136.1. INTRODUCTION
• 136.1.1. GENERAL
• 136.1.2. TOWING A DISABLED LIFT TRUCK
• 136.1.3. HOW TO LIFT A DISABLED LIFT TRUCK
• 136.1.4. HOW TO PUT A LIFT TRUCK ON TO BLOCKS
• 136.2. MAINTENANCE SCHEDULE
• 136.3. MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY
• 136.3.1. CHECKS BEFORE OPERATION
• 136.3.2. SRO CIRCUIT
• 136.3.3. GENERAL FUNCTIONS
• 136.3.4. BATTERY
• 136.3.5. BATTERY CONNECTOR
• 136.3.6. BATTERY RETAINERS
• 136.3.7. CONTROL HANDLE
• 136.3.8. SAFETY LABELS
• 136.3.9. GEARBOX
• 136.3.10. HYDRAULIC SYSTEM
• 136.3.11. LIGHTS (OPTIONAL)
• 136.3.12. STEERING
• 136.3.13. TIRES AND WHEELS
• 136.3.14. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 136.3.15. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 136.3.16. MAST AND LIFT CHAINS
• 136.3.17. LIFT CHAIN ADJUSTMENTS
• 136.3.18. CHECK THE OPERATION
• 136.4. EVERY 350 HOURS OR TWO MONTHS
• 136.4.1. HYDRAULIC TANK BREATHER
• 136.4.2. BRAKE FLUID
• 136.4.3. GEARBOX
• 136.4.4. LIFT SYSTEM OPERATION
• 136.4.5. LIFT CHAINS
• 136.4.6. OTHER LUBRICATION
• 136.4.7. ELECTRICAL INSPECTION
• 136.5. HOURS OR YEARLY
• 136.5.1. HYDRAULIC SYSTEM
• 136.5.2. WHEEL BEARINGS
• 136.5.3. GEARBOX
• 136.6. GENERAL PROCEDURES
• 136.6.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
• 136.6.2. HOW TO CHARGE THE BATTERY
• 136.6.3. CHANGING THE BATTERY
• 136.6.4. WHEELS AND TIRES
• 136.6.5. CHANGING THE SOLID TIRE
• 136.6.6. CHANGES TO THE OVERHEAD GUARD
• 137.
• 137.1. FIGURE 1. E30FR-24, E30-35-40-45-50FR WIRING DIAGRAM
• 137.2. SYSTEM ELECTRICAL BLOCK DIAGRAM LEGEND
• 137.3. FIGURE 2. HYDRAULIC SCHEMATIC DIAGRAM-LIFT FUNCTION
• 137.4. FIGURE 3. HYDRAULIC SCHEMATIC DIAGRAM-LOWER FUNCTION
• 137.5. FIGURE 4. HYDRAULIC SCHEMATIC DIAGRAM-TILT FORWARD FUNCTION
• 137.6. FIGURE 5. HYDRAULIC SCHEMATIC DIAGRAM-TILT BACK FUNCTION
• 137.7. FIGURE 6. HYDRAULIC SCHEMATIC DIAGRAM-SIDESHIFT LEFT FUNCTION
• 137.8. FIGURE 7. HYDRAULIC SCHEMATIC DIAGRAM-SIDESHIFT RIGHT FUNCTION
• 137.9. FIGURE 8. HYDRAULIC SCHEMATIC DIAGRAM-AUX DIRECTION A FUNCTION
• 137.10. FIGURE 9. HYDRAULIC SCHEMATIC DIAGRAM-AUX DIRECTION B FUNCTION
• 138.