Hyster W20ZR, W30ZR, W40Z (C455 D821) Forklift Service Manual

Format: PDF (Printable Document)

File Language: English

File Pages: 1400

File Size: 43.96 MB (Speed Download Link)

Brand: Hyster

Model: W20ZR, W30ZR, W40Z (C455 D821) Forklift

Type of Document: Service Manual

Categories: Hyster PDF, PDF

$ 45

Hyster W20ZR, W30ZR, W40Z (C455 D821) Forklift Service Manual

📘 Show Index

Hyster W20ZR, W30ZR, W40Z (C455 D821) 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
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