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

Hyster Z943 (E30FR-50FR, E30FR-24) Service Manual - Image 2

Hyster Z943 (E30FR-50FR, E30FR-24) Service Manual - Image 3

Hyster Z943 (E30FR-50FR, E30FR-24) Service Manual - Image 4

Hyster Z943 (E30FR-50FR, E30FR-24) Service Manual - Image 5

hyster z943 e30fr 50fr e30fr 24 service manual 2

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

$30.00

Type Of Manual: Service Manual
Number of Pages: 328
Size: 11.4MB
Format: PDF

Category: Hyster Service Manual PDF

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

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