Hyster E30-35-40HSD (A219) Forklift Service Manual
362 pages · Publication 1495902
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- Models
- E30-35-40HSD (A219)
- Manual type
- Service Manual
- Pages
- 362
- Publication
- 1495902
- Condition
- Brand new
What's inside
From the manual's own table of contents: 131 sections, 370 entries. See sample pages (PDF, 213 KB)
DC Motor Maintenance
Safety Precautions Maintenance and Repair
General
Brush and Commutator Inspection4 topics
- Hydraulic Pump Motor and Traction Motor
- Steering Pump Motor
- Normal Commutator Surface
- Commutator Problems
Brush Replacement
Stoning the Commutator
Motors Repair6 topics
- Disassemble
- Traction Motor and Hydraulic Pump Motor
- Steering Pump Motor
- Assemble
- Traction Motor and Hydraulic Pump Motor
- Steering Pump Motor
Brush Alignment, Traction and Hydraulic Motors
Tests for Damaged Field and Armature7 topics
- Test for an Open Circuit in Armature
- Test for Short Circuit in One Armature Winding
- Test for Short Circuit to Armature Shaft
- Test for Open Circuit in Field Coil
- Test for Short Circuit in Field Coil
- Test for Short Circuit between Field and Motor Case
- Brush Holder Test
Troubleshooting
Table 1. Normal Commutator Surfaces
Table 2. Commutator Problems
Table 3. Brush Wear Replacement Guide
Industrial Battery
Lead-Acid Batteries
Specific Gravity
Chemical Reaction in a Cell
Electrical Terms
Battery Selection
Battery Voltage
Battery as a Counterweight
Battery Ratings1 topic
- Kilowatt-Hours
Battery Maintenance16 topics
- Safety Procedures
- Maintenance Records
- New Battery
- Cleaning Battery
- Adding Water to Battery
- Hydrometer
- Battery Temperature
- Charging Battery
- Types of Battery Charges
- Methods of Charging
- Troubleshooting Charger
- Knowing When Battery Is Fully Charged
- Where to Charge Batteries
- Equipment Needed
- Battery Connectors
- Battery Care
Table 1. Battery Capacity Terms
Show all 131 sections
Metric and Inch (SAE) Fasteners6 topics
- Threaded Fasteners
- Nomenclature, Threads
- Strength Identification
- Cotter (Split) Pins
- Fastener Torque Tables
- Conversion Table
Table 1. Bolts and Screws
Table 2. Studs and Nuts
Table 3. Torque Nuts
Table 4. Torque Nuts With Nylon Insert
Table 5. Torque Values for Metric Fasteners*
Table 6. Torque Values for Inch Fasteners*
Table 7. Conversion Table for Metric and English units
Table 8. Cotter Pin Dimensional Data
Periodic Maintenance5 topics
- How to Move Disabled Lift Truck
- How to Tow Lift Truck
- How to Put Lift Truck on Blocks
- How to Raise Load Wheels
- How to Raise Steer Wheel
Lift and Tilt System Leak Checks2 topics
- Lift System
- Tilt System
Safety Procedures When Working Near Mast
Check Operation3 topics
- Gauges and Horn
- Control Handle
- Steering System
Maintenance Schedule
Maintenance Procedures Every 8 Hours or Daily5 topics
- Before Operation Checks
- Hydraulic System
- Battery
- Battery Restraint System
- Tires and Wheels
Maintenance Procedures Every 350 Hours or 3 Months13 topics
- Hydraulic Tank Breather
- Wheel Nut Torque
- Transaxle
- Lift System Operation
- Mast
- Lift Chains
- Forks
- Safety Labels
- Other Lubrication
- Electrical Inspection
- Special Precautions
- Contactors
- Motor Brushes
Maintenance Procedures Every 2000 Hours or Yearly7 topics
- Hydraulic System
- Change the Hydraulic Oil Filter
- Check the Hydraulic Oil Strainer
- Change the Hydraulic Oil
- Brakes
- How to Charge the Battery
- How to Change the Battery
Wheels and Tires Maintenance5 topics
- General
- Wheels and Tires
- Remove the Wheel From Lift Truck
- Install the Tire on Wheel
- Install the Wheel and Tire
Mast and Lift Chains
Forks4 topics
- Adjust
- Remove
- Inspect
- Install
Table 1. Maintenance Schedule
Table 2. Transaxle Capacity
Diagrams
Master Drive Unit
Lubrication
Repair4 topics
- Intermediate Shaft Installation
- Axle Shaft Installation
- Pinion Gear Installation
- Final Assembly
Tooth Contact Pattern Adjustment
Table 1. Tooth Contact Pattern
Frame2 topics
- Size
- Painting Instructions
Covers and Pads6 topics
- Covers
- Remove
- Install
- Pads
- Remove
- Install
Overhead Guard2 topics
- Description
- Repair
Battery1 topic
- Battery Sizes
Labels and Decals
Table 1. 3000 lb Capacity, 43.9-inch Wheel Base
Table 2. 3500 lb Capacity, 43.9-inch Wheel Base
Table 3. 3500 lb Capacity, 46.4-inch Wheel Base
Table 4. 4000 lb Capacity, 46.4-inch Wheel Base
Electrical System
Major Electrical System Features11 topics
- Integrated System
- CAN Bus Advantages
- CAN Bus Communications
- Steering
- Traction
- Master Control Unit
- Multifunction Control Handle
- Operator Input Devices
- Multifunction Displays
- Standard Display
- Premium Display (Optional)
Setup8 topics
- Setup Instructions
- Curtis 1310 Master Control Unit
- Normal Operation
- Standard Display
- Premium Display
- Diagnostics
- Power-On Self-Test
- Run-Time Diagnostic
Checking Transistor Controller3 topics
- Component Repair and Testing
- Troubleshooting
- Fault Codes and Display Messages
SEM Traction Motor Controller6 topics
- Curtis 1243 Traction Controller
- Hydraulic Pump Controller (Optional)
- Adjusting the Curtis 1254 Pump Controller Parameters
- Controller Removal
- Low-Voltage Protection Function
- Checking Contactor Coils
Contactor and Electrical Panel Checks6 topics
- Fuses
- Contactors
- General
- Test
- Tips
- Disassemble and Assemble
Steer Position Sensor5 topics
- Operation
- Position Steer Tire for Straight Travel
- Dash Display Method
- Digital Voltmeter Method
- Test
Causes of Motor Failure9 topics
- Overload
- Shock Loading
- Short in Field Coils
- Short Brushes
- High or Low Commutator Bar
- Open Circuit
- Low Battery Voltage
- Eccentricity of Commutator
- Overspeeding
Drive Motor1 topic
- Preparation of Drive Motor Commutator
Drive Motor Brush and Brush Holder2 topics
- Drive Motor Brush, Remove and Install (Motor Installed)
- Drive Motor Brush Holder, Remove and Install (Motor Installed)
Drive Motor Disassembly and Assembly2 topics
- Disassemble
- Assemble
Drive and Hydraulic Pump Motors9 topics
- Routine Preventive Maintenance
- Preventive Maintenance Checks
- Cleanliness
- Connections
- Discoloration and Burn Marks
- Brushes
- Short in Armature
- Commutator
- Bearings
Hoist Pump Motor4 topics
- Maintenance Instructions
- Remove
- Repair
- Install
Motor Tests4 topics
- Excessive Current Draw
- Measuring Current Draw
- Excessive Resistance
- Brush Springs
DC to DC Converter
Table 1. Fault Codes and Display Messages
Table 2. 1254 Hydraulic Pump Controller Parameter Settings
Table 3. Coil Resistance
Table 4. Potentiometer Specifications
Steering System
Description and Features
On-Demand Steering Circuit7 topics
- Steering Control Handle
- Remove
- Install
- Steering Sensor
- Test
- Remove
- Install
Steering Control Unit (SCU)1 topic
- Replace
Steering Pump and Motor Assembly2 topics
- Disassembly
- Assembly
Power Steering Pump2 topics
- Disassemble
- Assembly
Steer Unit Actuator-Kordel™3 topics
- Disassemble
- Clean
- Assemble
Checks and Adjustments3 topics
- Air in System
- Operation Check
- Steering Pressure
Electric Brake System
Description and Operation
Electric Brake Repair
Electric Brake Operational Check
Brake Pedal Assembly2 topics
- Bushings and Spring
- Brake Switch Assembly
Hydraulic System
Multifunction Control Handle
Manual Lowering1 topic
- How to lower mast manually
Main Hydraulic Control Valve6 topics
- Check and Adjust
- Manifold Pressures
- Counter Balance Valve
- Disassemble
- Clean
- Assemble
Lift Pump and Motor3 topics
- Motor
- Lift Pump
- Motor
Lift Pump1 topic
- Assembly
Hydraulic Tank3 topics
- Clean
- Steam Method
- Trisodium Phosphate Method
Table 1. Pressure Settings
Table 2. Main Hydraulic Control Valve Cartridges
Tilt Cylinders
Description
Tilt Cylinder Repair
Tilt Cylinder Leak Check
Mast Tilt Angle Adjustment
Mast2 topics
- Carriages
- Mast Mounts
Two-Stage Mast, Limited Free-Lift (LFL)1 topic
- Description and Operation
Two-Stage Mast, Full Free-Lift (FFL)
Three-Stage Mast, Full Free-Lift (FFL)
Cylinder Cushion During Lifting Sequence
Cylinder Cushion During Lowering Sequence
Fork Repair
Carriages Repair9 topics
- Standard Carriage
- Remove
- Repair
- Install
- Integral Sideshift Carriage
- Remove
- Clean and Inspect
- Repair
- Install
Mast Repair6 topics
- Two-Stage LFL and Two-Stage FFL Masts, Disassemble
- Three-Stage FFL Mast
- Disassemble
- Mast and Chains, Clean and Inspect
- Two-Stage LFL and Two-Stage FFL Mast, Assemble
- Three-Stage FFL Mast, Assemble
Lift Cylinders Repair5 topics
- Free-Lift Cylinder, Remove
- Lift Cylinders, Disassemble
- Lift Cylinders, Assemble
- Main Lift Cylinders, Install
- Free-Lift Cylinder, Install
Header Hose Arrangement6 topics
- Two-Stage LFL Mast, New Hose Install
- Two-Stage LFL Mast, Adjust Hoses after Installation
- Two-Stage FFL Mast, New Hose Install
- Two-Stage FFL Mast, Adjust Hoses after Installation
- Three-Stage FFL Mast, New Hose Install
- Three-Stage FFL Mast, Adjust Hoses after Install
Lift and Tilt System Leak Check2 topics
- Lift Cylinders Leak Check
- Tilt Cylinders Leak Check
Tilt Cylinders Adjustment
Lift Chains Adjustment
Mast Adjustment
Carriage Adjustment
Capacities and Specifications
Battery Size Specifications
Fuses
Mast Speeds2 topics
- 19cc Pump One-Speed Contactor
- 19cc Pump Transistor Control
Motors (Voltage 36)
Tire Sizes
Torque Specifications3 topics
- Frame
- Wheels
- Mast/Tilt/Attachment Systems
Hoist Control Settings
Inside this manual
Real pages from this service manual (362 pages). Open the sample pages (PDF, 212 KB)
- Diagram, page 107: Schematics
- Specifications, page 327: Header Hose Arrangement
- Troubleshooting, page 347: Troubleshooting
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 362 pages
Quantity one is the manual described above.
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