Hyster Z943 (E30FR-50FR, E30FR-24) Service Manual

Description

• Model List:
  • Z943 (E30FR-50FR, E30FR-24)

• 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. _2
• 29.1. INTRODUCTION
• 29.1.1. GENERAL
• 29.1.2. DESCRIPTION
• 29.2. DISASSEMBLY AND ASSEMBLY
• 29.2.1. OVERHEAD GUARD
• 29.2.1.1. Removal
• 29.2.1.2. Installation
• 29.2.2. OVERHEAD GUARD REAR POST
• 29.2.2.1. Removal
• 29.2.2.2. Installation
• 29.2.3. BATTERY RETAINERS
• 29.2.3.1. Removal
• 29.2.3.2. Installation
• 29.2.4. BATTERY ROLLERS
• 29.2.4.1. Removal
• 29.2.4.2. Installation
• 29.2.5. FRONT COVER
• 29.2.5.1. Removal
• 29.2.5.2. Installation
• 29.2.6. TOP COVER
• 29.2.6.1. Removal
• 29.2.6.2. Installation
• 29.2.7. CONTROL COVER
• 29.2.7.1. Removal
• 29.2.7.2. Installation
• 29.2.8. OPERATOR COMPARTMENT PADS
• 29.2.8.1. Removal
• 29.2.8.2. Installation
• 29.2.9. FLOOR MAT/BRAKE PEDAL PAD
• 29.2.9.1. Removal
• 29.2.9.2. Installation
• 29.2.10. LABOR REPLACEMENT
• 29.2.11. PAINTING INSTRUCTIONS
• 30. _2
• 30.1. INTRODUCTION
• 30.1.1. ELECTRIC MOTOR MAINTENANCE, GENERAL
• 30.1.2. DRIVE MOTOR AND HYDRAULIC PUMP MOTOR
• 30.1.2.1. Disassembly
• 30.1.2.2. Assembly
• 30.1.3. POWER STEERING PUMP MOTOR
• 30.1.3.1. Disassembly
• 30.1.3.2. Assembly
• 30.1.4. BRUSH AND COMMUTATOR INSPECTION
• 30.1.4.1. Normal Commutator Surface
• 30.1.4.2. Commutator Problems
• 30.1.5. DRIVE MOTOR BRUSHES
• 30.1.5.1. Removal
• 30.1.5.2. Installation
• 30.1.6. LIFT PUMP MOTOR BRUSHES
• 30.1.6.1. Removal
• 30.1.6.2. Installation
• 30.1.6.3. Untitled
• 30.1.7. STONING THE COMMUTATOR
• 30.1.8. TEST FOR A DAMAGED FIELD AND ARMATURE
• 30.1.8.1. Test for an Open-Circuit in the Armature
• 30.1.8.2. Test for a Short-Circuit in an Armature Winding
• 30.1.8.3. Test for a Short-Circuit in the Armature
• 30.1.8.4. Test for an Open-Circuit in a Field Coil
• 30.1.8.5. Test for a Short-Circuit in a Field Coil
• 30.1.8.6. Test for a Short-Circuit Between the Field and the Motor Case
• 30.1.8.7. Brush Holder Test
• 31. _2
• 31.1. INTRODUCTION
• 31.1.1. DESCRIPTION
• 31.2. REPAIRS
• 31.2.1. DRIVE UNIT
• 31.2.1.1. Removal
• 31.2.1.2. Installation
• 31.2.2. DRIVE MOTOR
• 31.2.2.1. Brush Removal and Installation
• 31.2.3. GEARBOX
• 31.2.3.1. Oil Change
• 31.2.4. DRIVE WHEEL ASSEMBLY
• 31.2.4.1. Removal and Installation
• 31.2.5. DRIVE WHEEL SEAL
• 31.2.5.1. Removal
• 31.2.5.2. Installation
• 31.2.6. DRIVE WHEEL SPINDLE
• 31.2.6.1. Removal
• 31.2.6.2. Installation
• 31.2.7. ENCODER ASSEMBLY
• 31.2.7.1. Removal
• 31.2.7.2. Installation
• 31.2.8. ENCODER BELT ADJUSTMENT
• 31.2.9. DRIVE SHAFT INSERT
• 31.2.10. DRIVE UNIT REBUILD
• 31.2.10.1. Disassembly
• 31.2.10.2. Pinion Gear to Motor Assembly
• 31.2.10.3. Gear Housing to Motor Assembly
• 31.2.11. PROCEDURE I
• 31.2.11.1. Gear Housing to Motor Assembly
• 31.2.12. PROCEDURE II
• 31.2.12.1. Gear Housing to Motor Assembly
• 31.2.12.2. Carrier to Gear Housing Assembly
• 31.2.13. CARRIER REBUILD
• 31.2.13.1. Carrier Disassembly
• 31.2.13.2. Carrier Assembly
• 32. _2
• 32.1. INTRODUCTION
• 32.1.1. GENERAL
• 32.1.2. DESCRIPTION
• 32.2. REPAIRS
• 32.2.1. STEER PUMP MOTOR ASSEMBLY
• 32.2.1.1. Removal
• 32.2.1.2. Installation
• 32.2.2. STEER PUMP
• 32.2.2.1. Removal
• 32.2.2.2. Installation
• 32.2.3. STEER CONTROL VALVE
• 32.2.3.1. Removal
• 32.2.3.2. Installation
• 32.2.4. HYDRAULIC MOTOR
• 32.2.4.1. Removal
• 32.2.4.2. Installation
• 32.2.5. STEERING GEAR
• 32.2.5.1. Removal
• 32.2.5.2. Installation
• 32.2.6. STEER FORK ASSEMBLY
• 32.2.6.1. Removal
• 32.2.6.2. Installation
• 32.2.7. STEER WHEEL ASSEMBLY
• 32.2.7.1. Removal
• 32.2.7.2. Installation
• 32.2.8. STEER POSITION POTENTIOMETER
• 32.2.8.1. Removal
• 32.2.8.2. Installation
• 32.2.9. CHANGING STEER TIRES
• 32.3. CHECKS AND ADJUSTMENTS
• 32.3.1. STEER POTENTIOMETER ADJUSTMENT
• 32.3.2. STEERING PRESSURE
• 33. _2
• 33.1. INTRODUCTION
• 33.1.1. GENERAL
• 33.1.2. DESCRIPTION AND OPERATION
• 33.1.3. THEORY OF OPERATION
• 33.2. REPAIRS
• 33.2.1. DISC BRAKE UNIT
• 33.2.1.1. Removal
• 33.2.1.2. Installation
• 33.2.2. BRAKE ACTUATOR ASSEMBLY
• 33.2.2.1. Removal
• 33.2.2.2. Installation
• 33.2.3. MASTER CYLINDER
• 33.2.3.1. Removal
• 33.2.3.2. Installation
• 33.2.3.3. Cleaning and Inspection
• 33.2.3.4. Disassembly
• 33.2.3.5. Assembly
• 33.2.4. BRAKE PEDAL
• 33.2.4.1. Removal
• 33.2.4.2. Installation
• 33.2.5. BLEEDING THE BRAKE SYSTEM
• 33.3. CHECKS AND ADJUSTMENTS
• 33.3.1. BRAKE ADJUSTMENTS
• 33.3.1.1. Brake Pedal Height
• 33.3.1.2. Brake Switch
• 33.3.1.3. Brake Push Rod Length
• 33.3.1.4. Disc Brake Clearance
• 33.3.1.5. Brake Pressure
• 33.4. TROUBLESHOOTING
• 34. _2
• 34.1. INTRODUCTION
• 34.1.1. GENERAL
• 34.1.2. DESCRIPTION
• 34.1.3. FLOW CONTROL VALVE
• 34.1.4. RELIEF VALVE
• 34.2. REPAIRS
• 34.2.1. DISASSEMBLY
• 34.2.2. CLEANING
• 34.2.3. INSPECTION
• 34.2.4. ASSEMBLY
• 34.3. CHECKS AND ADJUSTMENTS
• 34.3.1. CHECKING THE OUTPUT OF THE PUMP
• 34.3.2. CHECKING FOR AIR IN THE HYDRAULIC SYSTEM
• 34.3.3. SPECIFICATIONS
• 34.3.4. TROUBLESHOOTING
• 35. _2
• 35.1. INTRODUCTION
• 35.1.1. GENERAL
• 35.1.2. DESCRIPTION
• 35.1.3. OPERATION
• 35.1.4. MULTI-FUNCTION CONTROL HANDLE
• 35.2. REPAIRS
• 35.2.1. LIFT PUMP MOTOR ASSEMBLY
• 35.2.1.1. Removal
• 35.2.1.2. Installation
• 35.2.2. LIFT PUMP
• 35.2.2.1. Removal
• 35.2.2.2. Installation
• 35.2.3. STEER PUMP MOTOR ASSEMBLY
• 35.2.3.1. Removal
• 35.2.3.2. Installation
• 35.2.4. STEER PUMP
• 35.2.4.1. Removal
• 35.2.4.2. Installation
• 35.2.5. HYDRAULIC VALVE CARTRIDGE
• 35.2.5.1. Removal
• 35.2.5.2. Installation
• 35.2.6. PRESSURE RELIEF VALVE
• 35.2.6.1. Removal
• 35.2.6.2. Installation
• 35.2.7. MANUAL LOWERING VALVE
• 35.2.7.1. Removal
• 35.2.7.2. Installation
• 35.2.8. FLOW REGULATOR
• 35.2.8.1. Removal
• 35.2.8.2. Installation
• 35.2.9. PROPORTIONAL VALVE CARTRIDGE
• 35.2.9.1. Removal
• 35.2.9.2. Installation
• 35.2.10. HYDRAULIC OIL FILTER
• 35.2.10.1. Removal
• 35.2.10.2. Installation
• 35.2.11. HYDRAULIC OIL
• 35.2.11.1. Removal
• 35.2.11.2. Installation
• 35.2.12. TILT CYLINDERS
• 35.2.12.1. Removal
• 35.2.12.2. Installation
• 35.2.13. HYDRAULIC TANK REPAIRS
• 35.2.13.1. Inspection
• 35.2.13.2. Small Leaks
• 35.2.13.3. Large Leaks
• 35.2.14. CLEANING THE HYDRAULIC TANK
• 35.2.14.1. Steam Method of Cleaning
• 35.2.14.2. Chemical Solution Method of Cleaning
• 35.2.14.3. Other Methods
• 35.3. CHECKS AND ADJUSTMENTS
• 35.3.1. RELIEF VALVE
• 35.4. TROUBLESHOOTING
• 36.
• 37. _2
• 37.1. INTRODUCTION
• 37.1.1. GENERAL
• 37.1.2. DESCRIPTION
• 37.2. REPAIRS
• 37.2.1. REMOVAL
• 37.2.2. DISASSEMBLY
• 37.2.3. CLEANING AND INSPECTION
• 37.2.4. ASSEMBLY
• 37.2.5. INSTALLATION
• 37.3. CHECKS AND ADJUSTMENTS
• 37.3.1. CHECKING FOR LEAKAGE
• 37.3.2. ADJUSTMENT-TILT ANGLE (E30ER, E40ER, E50ER)
• 37.3.3. ADJUSTMENT-TILT CYLINDER (E30FR-24, E30FR, E35FR, E40FR, E45FR, E50FR)
• 37.3.3.1. Test Procedure
• 37.3.3.2. Adjustment
• 37.3.3.3. Tilt Cylinder Seal Installation
• 37.4. TROUBLESHOOTING
• 38. _2
• 39.
• 40. _2
• 40.1. INTRODUCTION
• 40.1.1. GENERAL
• 40.1.2. TWO-STAGE MAST
• 40.1.2.1. Description
• 40.1.2.2. Operation
• 40.1.3. THREE-STAGE MASTS
• 40.1.3.1. Description
• 40.1.3.2. Operation
• 41. _2
• 41.1. INTRODUCTION
• 41.1.1. GENERAL
• 41.2. REPAIRS
• 41.2.1. CARRIAGE
• 41.2.1.1. Removal
• 41.2.1.2. Installation
• 41.2.2. MAST ASSEMBLY
• 41.2.2.1. Removal
• 41.2.2.2. Installation
• 41.2.3. LIFT CHAIN REMOVAL AND INSTALLATION
• 41.2.3.1. Removal-Inner Chains
• 41.2.3.2. Installation-Inner Chains
• 41.2.3.3. Removal-Outer Lift Chains (Three Stage)
• 41.2.3.4. Installation-Outer Lift Chains (Three Stage)
• 41.2.4. LIFT CYLINDER REMOVAL AND INSTALLATION
• 41.2.4.1. Removal-Free Lift Cylinder
• 41.2.4.2. Installation-Free Lift Cylinder
• 41.2.4.3. Removal-Main Lift Cylinders (Three Stage)
• 41.2.4.4. Installation-Main Lift Cylinders (Three Stage)
• 41.2.5. LIFT CYLINDER SHEAVES
• 41.2.5.1. Removal-Free Lift Cylinder Sheaves
• 41.2.5.2. Installation-Free Lift Cylinder Sheaves
• 41.2.5.3. Removal-Intermediate Mast Sheaves
• 41.2.5.4. Installation-Intermediate Mast Sheaves
• 41.2.6. HYDRAULIC COMPONENTS
• 41.2.6.1. Removal-Main Hydraulic Manifold Block
• 41.2.6.2. Installation-Main Hydraulic Manifold Block
• 41.2.6.3. Removal-Free Lift Cylinder Manifold Block
• 41.2.6.4. Installation-Free Lift Cylinder Manifold Block
• 41.2.6.5. Removal-Optional Auxiliary Hose Take-up
• 41.2.6.6. Installation-Optional Auxiliary Hose Take-up
• 41.2.6.7. Removal-Standard Hose Assembly
• 41.2.6.8. Installation-Standard Hose Assembly
• 41.3. CHECKS AND ADJUSTMENTS
• 41.3.1. BLEEDING AIR FROM THE LIFT CYLINDERS
• 41.3.2. CARRIAGE ADJUSTMENT
• 41.3.3. MAST ADJUSTMENT
• 41.3.3.1. Load Roller Shims
• 41.3.3.2. Brass Setscrew Adjustment
• 41.3.4. LIFT CHAIN ADJUSTMENT
• 41.3.5. TILT ANGLE ADJUSTMENT
• 41.3.5.1. Test Procedure
• 41.3.5.2. Adjustment
• 41.4. TROUBLESHOOTING
• 42.
• 42.1. INTRODUCTION
• 42.1.1. GENERAL
• 42.1.2. DESCRIPTION
• 42.1.3. FLOW CONTROL VALVE AND FLOW FUSES
• 42.2. REPAIRS
• 42.2.1. REMOVAL
• 42.2.1.1. Two Stage (LFL) Mast-Main Lift Cylinder
• 42.2.1.2. Three Stage (FFL) Mast-Free Lift Cylinder
• 42.2.1.3. Three Stage (FFL) Mast-Main Lift Cylinders
• 42.2.2. DISASSEMBLY
• 42.2.3. ASSEMBLY
• 42.2.4. INSTALLATION
• 42.2.4.1. Two Stage (LFL) Mast-Main Lift Cylinder
• 42.2.4.2. Three Stage (FFL) Mast-Free Lift Cylinder
• 42.2.4.3. Three Stage (FFL) Mast-Main Lift Cylinders
• 42.3. CHECKS AND ADJUSTMENTS
• 42.3.1. BLEEDING AIR FROM LIFT CYLINDERS
• 42.4. TROUBLESHOOTING
• 43.
• 44.
• 44.1. INTRODUCTION
• 44.1.1. GENERAL
• 44.1.2. TOWING A DISABLED LIFT TRUCK
• 44.1.3. HOW TO LIFT A DISABLED LIFT TRUCK
• 44.1.4. HOW TO PUT A LIFT TRUCK ON TO BLOCKS
• 44.1.4.1. How to Raise the Drive Tires
• 44.1.4.2. How to Raise the Steer Tire(s)
• 44.2. MAINTENANCE SCHEDULE
• 44.3. MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY
• 44.3.1. CHECKS BEFORE OPERATION
• 44.3.2. SRO CIRCUIT
• 44.3.3. GENERAL FUNCTIONS
• 44.3.4. BATTERY
• 44.3.5. BATTERY CONNECTOR
• 44.3.6. BATTERY RETAINERS
• 44.3.7. CONTROL HANDLE
• 44.3.8. SAFETY LABELS
• 44.3.9. GEARBOX
• 44.3.10. HYDRAULIC SYSTEM
• 44.3.11. LIGHTS (OPTIONAL)
• 44.3.12. STEERING
• 44.3.13. TIRES AND WHEELS
• 44.3.14. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 44.3.15. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 44.3.15.1. Adjustment
• 44.3.15.2. Removal
• 44.3.15.3. Inspection
• 44.3.15.4. Installation
• 44.3.16. MAST AND LIFT CHAINS
• 44.3.17. LIFT CHAIN ADJUSTMENTS
• 44.3.18. CHECK THE OPERATION
• 44.3.18.1. Gauges and Horn
• 44.3.18.2. Control Levers and Pedals
• 44.3.18.3. Brake Switch
• 44.3.18.4. Steering System
• 44.4. EVERY 350 HOURS OR TWO MONTHS
• 44.4.1. HYDRAULIC TANK BREATHER
• 44.4.2. BRAKE FLUID
• 44.4.3. GEARBOX
• 44.4.4. LIFT SYSTEM OPERATION
• 44.4.5. LIFT CHAINS
• 44.4.6. OTHER LUBRICATION
• 44.4.7. ELECTRICAL INSPECTION
• 44.4.7.1. Contactor
• 44.4.7.2. Drive Motor Brushes
• 44.4.7.3. Lift Pump Motor Brushes
• 44.4.7.4. Steering Pump Motor Brushes
• 44.5. HOURS OR YEARLY
• 44.5.1. HYDRAULIC SYSTEM
• 44.5.1.1. Hydraulic Oil-Removal
• 44.5.1.2. Hydraulic Oil-Installation
• 44.5.1.3. Hydraulic Oil Filter-Removal
• 44.5.1.4. Hydraulic Oil Filter-Installation
• 44.5.1.5. Breather Cap
• 44.5.2. WHEEL BEARINGS
• 44.5.3. GEARBOX
• 44.6. GENERAL PROCEDURES
• 44.6.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
• 44.6.1.1. Lift System
• 44.6.1.2. Tilt System
• 44.6.2. HOW TO CHARGE THE BATTERY
• 44.6.3. CHANGING THE BATTERY
• 44.6.4. WHEELS AND TIRES
• 44.6.4.1. Drive Wheel-Removal
• 44.6.4.2. Steer Tire-Removal
• 44.6.5. CHANGING THE SOLID TIRE
• 44.6.5.1. Tire-Removal and Installation