Hyster W25ZA2, W30ZA2 (B495 B895) Forklift Service Manual

Format: PDF (Printable Document)

File Language: English

File Pages: 1192

File Size: 42.32 MB (Speed Download Link)

Brand: Hyster

Model: W25ZA2-W30ZA2 (B495 B895) Forklift

Type of Document: Service Manual

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Hyster W25ZA2, W30ZA2 (B495 B895) Forklift Service Manual

Hyster W25ZA2-W30ZA2 (B495 B895) Forklift Service Manual

Hyster W25ZA2-W30ZA2 (B495 B895) 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
Safety Procedures When Working Near Mast
Load Backrest Extension, Carriage, Load Rollers, Side Rollers, and Forks
- Load Backrest Extension, Remove and Install
- Carriage Assembly, Remove and Install
- Carriage Load Rollers, Remove and Install
- Side Rollers, Disassemble and Assemble
- Fork, Replace
  - Hook-Type Forks
Two-Stage Mast Assembly
- Remove
- Clean and Inspect
- Lift Cylinders, Remove and Install Dual-Lift Cylinders
- Lift Cylinder, Remove and Install Single Main-Lift Cylinders
  - Remove
  - Install
- Inner Mast Assembly, Remove and Install
- Hoses, Replace
- Hose and Cable Sheaves, Replace
- Two-Stage Lift Chains
  - Remove and Install
  - Clean and Inspect
- Two-Stage Chain Sheave, Remove and Install
- Load Rollers and Wear Plugs, Remove and Install
- Two-Stage Mast Assembly, Install
Three-Stage Mast Assembly
- Three-Stage Mast Assembly, Remove
  - N30XHM, N30XMH (C210), and V30ZMD (D210/E210) Only2
- Clean and Inspect
- Free-Lift Cylinder, Remove and Install
- Main Cylinders (Standard), Remove and Install
- Main Cylinders N30XMH, N30XMH (C210) and V30ZMD (D210/E210), Remove and Install2
- Inner and Intermediate Mast Assemblies, Remove and Install
- Hoses, Replace
- Hose and Cable Sheaves, Replace
  - Free-Lift Hose Sheave
  - Carriage Sheaves
- Three-Stage Lift Chains, Remove and Install
  - General
  - Free-Lift Chains
  - Main-Lift Chains
- Three-Stage Chain Sheaves, Disassemble and Assemble
  - Free-Lift Chain Sheaves
  - Main-Lift Chain Sheaves
- Load Rollers and Wear Plugs, Remove and Install
- Three-Stage Mast Assemble, Install
Mast Operation Check
Hydraulic System Leaks Check
Lift Chains Check
- General
- Clean and Inspect
- Lubrication
Mast Adjustments
- General
- Adjust Wear Plugs – Mast
- Adjust Free-Lift Chain (Three-Stage Only)
- Adjust Main-Lift Chains
  - Two-Stage
  - Three-Stage
- Adjust Wear Strips
Carriage Adjustments
- Adjust Wear Plug – Carriage
- Adjust Side Rollers – Carriage
- Adjust Thrust Rollers – Carriage
Troubleshooting