Hyster W20-25ZA (A495 A895) Forklift Service Manual

Format: PDF (Printable Document)

File Language: English

File Pages: 1024

File Size: 37.46 MB (Speed Download Link)

Brand: Hyster

Model: W20-25ZA (A495 A895) Forklift

Type of Document: Service Manual

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Categories: Hyster PDF, PDF

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Hyster W20-25ZA (A495 A895) Forklift Service Manual

Hyster W20-25ZA (A495 A895) Forklift Index:

General
Description
- ZAPI™ Transistor Motor Controller
- Principles of Operation
Controller Safety
Controller Adjustments
Modes of Operation
- User-Selectable Operating Modes
Programming
- Custom Performance Mode
- Controller Parameters
  - Setting Drive Modes
- Tester Menu
- Set Option Menu
- ZAPI™ Handset
Alarm Code Diagnostics
- Alarm Code Diagnostic Procedure
Troubleshooting
- Auxiliary Hydraulics (W30-40ZA, W20-30ZR, W25-30-40ZC)
Control Card Functional Test
Traction Motor Test
ZAPI™ PC Interface
- Connecting PC to ZAPI™ Controller
- File Menu
  - Open File
  - TX From File
  - Save File
  - Print Settings
  - Exit
- Connection Menu
- Function Menu
  - Parameter
  - Memory Menu
  - Set Options
  - Tester
  - Data Logger
  - Alarm Logbook
  - Alarms
- Programming Tilt and Sideshift on the ZAPI Controller (Laptop)
Repair
- Remove
- Brass Stud Replacement
  - Remove
  - Install
- Install
- Repair
- Sideshift Setup With Auxiliary (W20/30ZR)

General
Description
- ZAPI™ Transistor Motor Controller
- Principles of Operation
Controller Safety
Controller Adjustments
Modes of Operation
- User-Selectable Operating Modes
Programming
- Custom Performance Mode
- Controller Parameters
  - Setting Drive Modes
- Tester Menu
- Set Option Menu
- ZAPI™ Handset
Alarm Code Diagnostics
- Alarm Code Diagnostic Procedure
Troubleshooting
- Auxiliary Hydraulics (W30-40ZA, W20-30ZR, W25-30-40ZC)
Control Card Functional Test
Traction Motor Test
ZAPI™ PC Interface
- Connecting PC to ZAPI™ Controller
- File Menu
  - Open File
  - TX From File
  - Save File
  - Print Settings
  - Exit
- Connection Menu
- Function Menu
  - Parameter
  - Memory Menu
  - Set Options
  - Tester
  - Data Logger
  - Alarm Logbook
  - Alarms
- Programming Tilt and Sideshift on the ZAPI Controller (Laptop)
Repair
- Remove
- Brass Stud Replacement
  - Remove
  - Install
- Install
- Repair
- Sideshift Setup With Auxiliary (W20/30ZR)

General
Description of Operation
Special Precautions
Moving a Disabled Lift Truck
Electrical System Checks
- Safety Precautions
Repairs
- Controller, Replace
  - Remove
  - Install
- Contactor Coil, Check
- Contactor, Replace
  - Remove
  - Install
Key Switch Removal and Installation
- Remove
- Install
Battery Indicator/Hourmeter Display
- Remove
- Install
Fuses
- W40Z
- W45-50Z
- W20-25ZA
- W25-30ZA2
Control Handle Arm Proximity Switch
- Repair
  - Check and Adjust
  - Remove
  - Install
Control Handle
- Disassemble
- Control Handle Card (Old Style)
- Control Handle Card (New Style)
  - Configure
  - Calibrate
- Assemble
- Switches (ON/OFF and Proportional)
  - Remove
  - Install
Traction Motor
- Disassemble
- Assemble
Lift Pump Motor
- Repair (W20-25ZA and W25-30ZA2)
Lift Link Proximity Sensor (W50Z)
- Check
- Repair
  - Remove
  - Test
  - Install
  - Adjust
Battery Charger (Moran®)
- Description
- Operation
  - Charging
  - Equalize
  - Signals
  - Protections
- Troubleshooting
Battery Charger (Accusense by DPI®)
- Description
- Operation
  - LED Display
  - Charging
- Charger Mode/Battery Type Selection (DPI Gen II Models)
  - Changing Mode Setting (DPI Gen II Models)
- Charger Mode/Battery Type Selection (DPI Gen III Models)
  - Changing Mode Setting (DPI Accusense Gen III Models with Jumper Ports)
  - Accusense Gen III with Dip Switches
  - Changing Mode Setting
- Troubleshooting (DPI Chargers)
  - General
  - Error Modes
  - Battery Pack Troubleshooting
Battery Charger (Accusense® 20A)
- Description
- Operation
  - LED Display
  - Charging
- Charger Mode/Battery Type Selection (Accusense 20A)
  - Changing Mode Setting (Accusense 20A)
- Troubleshooting (Accusense 20A Chargers)
  - General
  - Error Modes
  - Battery Pack Troubleshooting
Troubleshooting

General
Description of Operation
Special Precautions
Moving a Disabled Lift Truck
Electrical System Checks
- Safety Precautions
Repairs
- Controller, Replace
  - Remove
  - Install
- Contactor Coil, Check
- Contactor, Replace
  - Remove
  - Install
Key Switch Removal and Installation
- Remove
- Install
Battery Indicator/Hourmeter Display
- Remove
- Install
Fuses
- W40Z
- W45-50Z
- W20-25ZA
- W25-30ZA2
Control Handle Arm Proximity Switch
- Repair
  - Check and Adjust
  - Remove
  - Install
Control Handle
- Disassemble
- Control Handle Card (Old Style)
- Control Handle Card (New Style)
  - Configure
  - Calibrate
- Assemble
- Switches (ON/OFF and Proportional)
  - Remove
  - Install
Traction Motor
- Disassemble
- Assemble
Lift Pump Motor
- Repair (W20-25ZA and W25-30ZA2)
Lift Link Proximity Sensor (W50Z)
- Check
- Repair
  - Remove
  - Test
  - Install
  - Adjust
Battery Charger (Moran®)
- Description
- Operation
  - Charging
  - Equalize
  - Signals
  - Protections
- Troubleshooting
Battery Charger (Accusense by DPI®)
- Description
- Operation
  - LED Display
  - Charging
- Charger Mode/Battery Type Selection (DPI Gen II Models)
  - Changing Mode Setting (DPI Gen II Models)
- Charger Mode/Battery Type Selection (DPI Gen III Models)
  - Changing Mode Setting (DPI Accusense Gen III Models with Jumper Ports)
  - Accusense Gen III with Dip Switches
  - Changing Mode Setting
- Troubleshooting (DPI Chargers)
  - General
  - Error Modes
  - Battery Pack Troubleshooting
Battery Charger (Accusense® 20A)
- Description
- Operation
  - LED Display
  - Charging
- Charger Mode/Battery Type Selection (Accusense 20A)
  - Changing Mode Setting (Accusense 20A)
- Troubleshooting (Accusense 20A Chargers)
  - General
  - Error Modes
  - Battery Pack Troubleshooting
Troubleshooting

General
Brush and Commutator Inspection
- Hydraulic Pump Motor and Traction Motor
- Steering Pump Motor
- Normal Commutator Surface
- Commutator Problems
Brush Replacement
Stoning the Commutator
Motors Repair
- 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 Armature
- Test for an Open Circuit in One Armature Winding
- 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