Hyster B495 (W25-30ZA) Service Manual – PDF DOWNLOAD
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Hyster B495 (W25-30ZA) Service Manual – PDF DOWNLOAD
Language : English
Pages : 367
Downloadable : Yes
File Type : PDF
Size: 15.4 MB
TABLE OF CONTENTS:
Hyster B495 (W25-30ZA) Service Manual – PDF DOWNLOAD
Brakes.......................................................................... 1 toc......................................................................... 1 Brakes.................................................................. 1 General................................................................. 3 Description............................................................. 3 Special Precautions..................................................... 4 Brake Assembly Repair................................................... 5 Brake Override...................................................... 5 Remove.............................................................. 6 Repair.............................................................. 8 Install............................................................. 9 Troubleshooting......................................................... 10 Capacities and Specifications................................................... 12 toc......................................................................... 12 Capacities and Specifications........................................... 12 Lubrication Specifications.............................................. 14 Hydraulic System........................................................ 14 Master Drive Unit Specifications........................................ 15 Tires and Wheels........................................................ 15 Torque Specifications................................................... 15 Frame............................................................... 15 Master Drive Unit................................................... 15 Brake............................................................... 16 Steering............................................................ 16 Hydraulic........................................................... 16 Mast................................................................ 16 Truck Weights........................................................... 16 Travel Speeds........................................................... 17 Battery Specifications.................................................. 17 DC Motor Maintenance............................................................ 19 toc......................................................................... 19 DC Motor Maintenance.................................................... 19 General................................................................. 21 Brush and Commutator Inspection......................................... 21 Hydraulic Pump Motor and Traction Motor............................. 21 Steering Pump Motor................................................. 24 Normal Commutator Surface........................................... 25 Commutator Problems................................................. 25 Brush Replacement....................................................... 28 Stoning the Commutator.................................................. 30 Motors Repair........................................................... 32 Disassemble......................................................... 32 Traction Motor and Hydraulic Pump Motor......................... 32 Steering Pump Motor............................................. 34 Assemble............................................................ 36 Traction Motor and Hydraulic Pump Motor......................... 36 Steering Pump Motor............................................. 37 Brush Alignment, Traction and Hydraulic Motors.......................... 39 Tests for Damaged Field and Armature.................................... 39 Test for an Open Circuit in One Armature Winding.................... 39 Test for Short Circuit in One Armature Winding...................... 40 Test for Short Circuit to Armature Shaft............................ 40 Test for Open Circuit in Field Coil................................. 40 Test for Short Circuit in Field Coil................................ 41 Test for Short Circuit Between Field and Motor Case................. 41 Brush Holder Test................................................... 41 Troubleshooting......................................................... 41 tables...................................................................... 19 Table 1. Normal Commutator Surfaces..................................... 24 Table 2. Commutator Problems............................................ 25 Table 3. Brush Wear Replacement Guide................................... 28 Diagrams........................................................................ 46 toc......................................................................... 46 Diagrams................................................................ 46 Electrical System............................................................... 63 toc......................................................................... 63 Electrical System....................................................... 63 General................................................................. 66 Description of Operation................................................ 67 Special Precautions..................................................... 69 Moving a Disabled Lift Truck............................................ 71 Electrical System Checks................................................ 72 Safety Precautions.................................................. 72 Repairs................................................................. 72 Controller, Replace................................................. 72 Remove.......................................................... 72 Install......................................................... 75 Contactor Coil, Check............................................... 75 Contactor, Replace.................................................. 75 Remove.......................................................... 75 Install......................................................... 76 Key Switch Removal and Installation..................................... 76 Remove.............................................................. 76 Install............................................................. 76 Battery Indicator/Hourmeter Display..................................... 76 Remove.............................................................. 77 Install............................................................. 77 Fuses................................................................... 77 W40Z................................................................ 77 W45-50Z............................................................. 77 W20-25ZA............................................................ 77 W25-30ZA 2.......................................................... 77 Control Handle Arm Proximity Switch..................................... 78 Repair.............................................................. 78 Check and Adjust................................................ 78 Remove.......................................................... 78 Install......................................................... 79 Control Handle.......................................................... 79 Disassemble......................................................... 79 Control Handle Card (Old Style)..................................... 80 Control Handle Card (New Style)..................................... 81 Configure....................................................... 81 Calibrate....................................................... 82 Assemble............................................................ 83 Switches (ON/OFF and Proportional).................................. 85 Remove.......................................................... 85 Install......................................................... 85 Traction Motor.......................................................... 86 Disassemble......................................................... 86 Assemble............................................................ 86 Lift Pump Motor......................................................... 88 Repair ( W20-25ZA and W25-30ZA 2 ).................................. 88 Lift Link Proximity Sensor (W50Z)....................................... 89 Check............................................................... 89 Repair.............................................................. 89 Remove.......................................................... 89 Test............................................................ 90 Install......................................................... 90 Adjust.......................................................... 90 Battery Charger (Early Models).......................................... 91 Description......................................................... 91 Operation........................................................... 91 Charging........................................................ 91 Equalize........................................................ 91 Signals......................................................... 91 Protections..................................................... 91 Troubleshooting..................................................... 91 Battery Charger (Late Models)........................................... 94 Description......................................................... 94 Operation........................................................... 94 LED Display..................................................... 94 Charging........................................................ 94 Troubleshooting..................................................... 94 Battery Mode Selection (DPI Early Models)........................... 95 Changing Mode Setting (DPI Early Models)........................ 96 Battery Mode Selection (DPI Late Models)............................ 96 Changing Mode Setting (DPI Late Models)......................... 96 Troubleshooting......................................................... 97 tables...................................................................... 63 Table 1. Contactor Coil Resistance Values............................... 75 Table 2. Charger LEDs................................................... 94 Table 3. LED Codes...................................................... 95 Table 4. Battery Modes.................................................. 95 Table 5. Battery Modes.................................................. 96 Frame........................................................................... 98 toc......................................................................... 98 Frame................................................................... 98 General.................................................................100 Description.........................................................100 Features............................................................101 Frame Repair............................................................101 Base Arms...............................................................101 Remove..............................................................102 Install.............................................................103 Adjust..............................................................103 Painting Instructions...................................................103 Label Replacement.......................................................103 Battery Compartment.....................................................105 tables...................................................................... 98 Table 1. Base Arm Width.................................................101 Industrial Battery..............................................................107 toc.........................................................................107 Industrial Battery......................................................107 General.................................................................109 Lead-Acid Batteries.....................................................109 Specific Gravity........................................................110 Chemical Reaction in a Cell.............................................110 Electrical Terms........................................................111 Battery Selection.......................................................112 Battery Voltage.........................................................113 Battery as a Counterweight..............................................113 Battery Ratings.........................................................114 Kilowatt-Hours......................................................114 Battery Maintenance.....................................................114 Safety Procedures...................................................114 Maintenance Records.................................................115 New Battery.........................................................115 Cleaning Battery....................................................115 Adding Water to Battery.............................................117 Hydrometer..........................................................118 Battery Temperature.................................................118 Charging Battery....................................................119 Types of Battery Charges........................................120 Methods of Charging.............................................121 Troubleshooting Charger.........................................122 Knowing When Battery Is Fully Charged...........................122 Where to Charge Batteries...........................................122 Equipment Needed................................................122 Battery Connectors..................................................123 Battery Care........................................................123 tables......................................................................107 Table 1. Battery Capacity Terms.........................................114 Lift Cylinders..................................................................126 toc.........................................................................126 Lift Cylinders..........................................................126 General.................................................................128 Description.............................................................128 Lowering Control Valve..............................................129 Main Cylinder Repair....................................................131 Disassemble.........................................................131 Assemble............................................................132 Free-Lift Cylinder Repair...............................................133 Disassemble.........................................................133 Assemble............................................................133 Troubleshooting.........................................................135 Mast Description................................................................137 toc.........................................................................137 Mast....................................................................137 General.................................................................139 Mast Weldments..........................................................141 Carriages...............................................................142 Two-Stage Mast..........................................................145 Description.........................................................145 Operation...........................................................150 Three-Stage Mast........................................................150 Description.........................................................150 Operation...........................................................153 Mast Repair.....................................................................156 toc.........................................................................156 Mast....................................................................156 General.................................................................159 Safety Procedures When Working Near Mast................................160 Load Backrest Extension, Carriage, Load Rollers, Side Rollers, a........161 Load Backrest Extension, Remove and Install.........................161 Carriage Assembly, Remove and Install...............................161 Carriage Load Rollers, Remove and Install...........................164 Side Rollers, Disassemble and Assemble..............................164 Fork, Replace.......................................................165 Hook-Type Forks.................................................165 Remove......................................................166 Install.....................................................166 Two-Stage Mast Assembly.................................................166 Remove..............................................................166 Clean and Inspect...................................................169 Lift Cylinders, Remove and Install Dual-Lift Cylinders..............171 Lift Cylinder, Remove and Install Single Main-Lift Cylinders........172 Remove..........................................................173 Install.........................................................173 Inner Mast Assembly, Remove and Install.............................174 Hoses, Replace......................................................174 Hose and Cable Sheaves, Replace.....................................176 Two-Stage Lift Chains...............................................176 Remove and Install..............................................177 Clean and Inspect...............................................177 Two-Stage Chain Sheave, Remove and Install..........................177 Load Rollers and Wear Plugs, Remove and Install.....................178 Two-Stage Mast Assembly, Install....................................179 Three-Stage Mast Assembly...............................................180 Three-Stage Mast Assembly, Remove...................................180 N30XHM, N30XMH 2 (C210), and V30ZMD (D210/E210) Only............183 Clean and Inspect...................................................183 Free-Lift Cylinder, Remove and Install..............................184 Main Cylinders (Standard), Remove and Install.......................186 Main Cylinders N30XMH, N30XMH 2 (C210) and V30ZMD (D210/E210), R....186 Inner and Intermediate Mast Assemblies, Remove and Install..........187 Hoses, Replace......................................................189 Hose and Cable Sheaves, Replace.....................................189 Free-Lift Hose Sheave...........................................189 Carriage Sheaves................................................190 Three-Stage Lift Chains, Remove and Install.........................190 General.........................................................190 Free-Lift Chains................................................190 Main-Lift Chains................................................191 Three-Stage Chain Sheaves, Disassemble and Assemble.................191 Free-Lift Chain Sheaves.........................................191 Main-Lift Chain Sheaves.........................................191 Load Rollers and Wear Plugs, Remove and Install.....................192 Three-Stage Mast Assemble, Install..................................193 Mast Operation Check....................................................194 Hydraulic System Leaks Check............................................194 Lift Chains Check.......................................................195 General.............................................................195 Clean and Inspect...................................................195 Lubrication.........................................................195 Mast Adjustments........................................................196 General.............................................................196 Adjust Wear Plugs - Mast............................................197 Adjust Free-Lift Chain (Three-Stage Only)...........................198 Adjust Main-Lift Chains.............................................199 Two-Stage.......................................................199 Three-Stage.....................................................200 Adjust Wear Strips..................................................200 Carriage Adjustments....................................................201 Adjust Wear Plug - Carriage.........................................201 Adjust Side Rollers - Carriage......................................201 Adjust Thrust Rollers - Carriage....................................202 Troubleshooting.........................................................203 Master Drive Unit...............................................................206 toc.........................................................................206 Master Drive Unit.......................................................206 General.................................................................208 Description.............................................................208 Special Precautions.....................................................208 Master Drive Unit Repair................................................210 Remove..............................................................210 Disassemble.........................................................212 Repair..............................................................213 Assemble............................................................213 Install.............................................................213 Troubleshooting.........................................................214 Metric and Inch (SAE) Fasteners.................................................217 toc.........................................................................217 Metric and Inch (SAE) Fasteners.........................................217 General.................................................................219 Threaded Fasteners..................................................219 Nomenclature, Threads...............................................219 Strength Identification.............................................220 Cotter (Split) Pins.................................................220 Fastener Torque Tables..............................................225 Conversion Table....................................................227 tables......................................................................217 Table 1. Bolts and Screws...............................................221 Table 2. Studs and Nuts.................................................222 Table 3. Torque Nuts....................................................223 Table 4. Torque Nuts With Nylon Insert..................................224 Table 5. Torque Values for Metric Fasteners*............................225 Table 6. Torque Values for Inch Fasteners*..............................226 Table 7. Conversion Table for Metric and English Units..................227 Table 8. Cotter Pin Dimensional Data....................................228 Table 9. Cotter Pin Dimensional Data....................................229 Table 10. Cotter Pin Dimensional Data...................................230 Table 11. Cotter Pin Dimensional Data...................................232 Periodic Maintenance............................................................236 toc.........................................................................236 Periodic Maintenance....................................................236 General.................................................................239 How to Move a Disabled Lift Truck...................................239 How to Tow a Lift Truck.........................................240 How to Put The Lift Truck on Blocks.................................241 How to Raise the Drive/Steer Tire...............................241 How to Raise the Load Wheels ...................................242 Special Precautions.....................................................242 Discharging the Capacitor...........................................242 Safety Procedures When Working Near Mast................................243 Maintenance Schedule....................................................244 Maintenance Procedures Every 8 Hours or Daily...........................249 Checks Before Operation.............................................249 How to Make Checks With Key Switch OFF..............................249 Safety Labels...................................................249 Battery.........................................................249 Brake...........................................................250 Tires and Wheels................................................250 Mast, Forks, and Lift Chains....................................250 Control Handle..................................................252 Hydraulic System................................................253 How to Make Checks With Key Switch ON...............................253 Check for Leaks in Lift System..................................253 Control Buttons.................................................254 Direction/Speed Control and Switches............................254 Gauges, Horn, Fuses.............................................254 Maintenance Procedures Every 350 Hours or Every 2 Months................255 Fittings Lubrication................................................255 Other Lubrication...................................................255 Base Arm Capscrews..................................................255 Battery.............................................................255 Brake...............................................................255 Lift Chain Adjustments..............................................255 Drive Wheel.........................................................257 Hydraulic System....................................................257 Master Drive Unit...................................................258 Traction and Pump Motor Brushes.....................................258 Contactor...........................................................260 Maintenance Procedures Every 2000 Hours or Yearly.......................260 Load Wheels.........................................................260 Hydraulic Oil Change................................................260 How to Change Drive Unit Oil........................................261 Welding Repairs.........................................................262 General Repairs.........................................................262 Load Wheels.........................................................262 Remove..........................................................262 Install.........................................................262 Lift Cylinder Leak Test.............................................263 Battery Maintenance.....................................................264 How to Charge the Battery...........................................264 Normal Charge...................................................264 Equalizing Charge...............................................265 Industrial Battery Charging.....................................265 Battery Pack Charging...........................................265 How to Change the Battery...........................................265 Standard Battery Spacer Adjustment..............................265 Changing the Battery With an Overhead Crane.....................266 Remove......................................................266 Install.....................................................266 tables......................................................................236 Table 1. Maintenance Schedule...........................................246 Steering Mechanism..............................................................270 toc.........................................................................270 Steering Mechanism......................................................270 General.................................................................272 Special Precautions.....................................................272 Control Handle Head.....................................................273 Control Handle..........................................................273 Remove..............................................................273 Install.............................................................274 Gas Spring..............................................................276 Discharging the Gas Spring..........................................276 Troubleshooting.........................................................277 Walkie High Lift Hydraulic System...............................................279 toc.........................................................................279 Walkie High Lift Hydraulic System.......................................279 General.................................................................281 Description of Operation................................................281 Hydraulic Oil.......................................................282 Clean...............................................................282 Sound Level.........................................................282 Special Precautions.....................................................283 Control Valve...........................................................283 Hydraulic Reservoir.....................................................284 Description.........................................................284 Manual Lowering.........................................................284 Lift Pump and Motor.....................................................287 General.............................................................287 Remove Lift Pump and Motor Assembly.................................287 Disassemble.........................................................289 Remove Reservoir................................................289 Remove Pump Motor...............................................289 Disassemble Pump................................................290 Assemble............................................................290 Assemble Pump...................................................290 Install Pump Motor..............................................290 Install Reservoir to Pump.......................................290 Install Lift Pump and Motor Assembly................................294 Valve Repair............................................................294 Proportional Valve (Lowering).......................................294 Remove..........................................................294 Install.........................................................294 Relief Valve and Check Valve........................................295 Remove..........................................................295 Install.........................................................295 Relief Valve Adjustment.................................................296 Bleed Hydraulic System..................................................297 Troubleshooting.........................................................297 Hydraulic Schematic.....................................................300 tables......................................................................279 Table 1. Reservoir Capacities...........................................284 Table 2. Reservoir Capacities...........................................290 ZAPI™ Controllers...............................................................302 toc.........................................................................302 ZAPI™ Controllers.......................................................302 General.................................................................305 Description.............................................................305 ZAPI™ Transistor Motor Controller...................................305 Principles of Operation.............................................306 Controller Safety.......................................................306 Controller Adjustments..................................................307 Modes of Operation......................................................307 User-Selectable Operating Modes.....................................307 Programming.............................................................308 Custom Performance Mode.............................................308 Controller Parameters...............................................308 Setting Drive Modes.............................................308 Tester Menu.........................................................310 Set Option Menu.....................................................310 ZAPI™ Handset.......................................................311 Alarm Code Diagnostics..................................................314 Alarm Code Diagnostic Procedure.....................................314 Troubleshooting.........................................................316 Auxiliary Hydraulics (W30-40ZA, W20-30ZR, W25-30-40ZC)..............337 Traction Motor Test.....................................................338 ZAPI™ PC Interface......................................................339 Connecting PC to ZAPI™ Controller...................................339 File Menu...........................................................343 Open File.......................................................343 TX From File....................................................344 Save File.......................................................345 Print Settings..................................................347 Exit............................................................348 Connection Menu.....................................................349 Function Menu.......................................................350 Parameter.......................................................350 Memory Menu.....................................................354 Set Options.....................................................355 Tester..........................................................357 Data Logger.....................................................359 Alarm Logbook...................................................362 Alarms..........................................................363 Programming Tilt and Sideshift on the ZAPI Controller (Laptop)......364 Repair..................................................................365 Remove..............................................................365 Brass Stud Replacement..............................................365 Remove..........................................................365 Install.........................................................365 Install.............................................................365 Repair..............................................................365 Sideshift Setup With Auxiliary (W20/30ZR)...........................365 tables......................................................................302 Table 1. Parameters.....................................................309 Table 2. Example Handset Software Versions..............................314 Table 3. Example Controller Software Versions...........................314 Table 4. Example Alarm Code.............................................314
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