Hyster W30-40ZA Manual
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Hyster W30-40ZA Manual

Walkie high lift hydraulic system
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WALKIE HIGH LIFT
HYDRAULIC SYSTEM
W30-40ZA [B453];
W20-30ZR [B455];
W25-30-40ZC [B454]
PART NO. 1524251
2000 SRM 1025

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Summary of Contents for Hyster W30-40ZA

  • Page 1 WALKIE HIGH LIFT HYDRAULIC SYSTEM W30-40ZA [B453]; W20-30ZR [B455]; W25-30-40ZC [B454] PART NO. 1524251 2000 SRM 1025...
  • Page 2 • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

  • Page 3: Table Of Contents

    Remove ..............................Install..............................Relief Valve and Check Valve........................Remove............................... Install ................................. Pilot Operated Check Valve .......................... W20/30ZR..............................Remove ..............................Install..............................Selector Valves: Reach, Tilt, and Sideshift ....................W20/30ZR and W25/30/40ZC ........................Remove ..............................Install..............................Relief Valve Adjustment ............................ ©2003 HYSTER COMPANY...
  • Page 4 Table of Contents Walkie High Lift Hydraulic System TABLE OF CONTENTS (Continued) Bleed Hydraulic System ............................ Troubleshooting..............................Hydraulic Diagrams and Schematics ....................... This section is for the following models: W30-40ZA [B453]; W20-30ZR [B455]; W25-30-40ZC [B454]...

  • Page 5: General

    2000 SRM 1025 Description of Operation General This section covers the troubleshooting and repair For troubleshooting and repairs of the electrical com- procedures for the hydraulic components on the W30/ ponents, see Electrical System 2200 SRM 1026 and 40ZA, W25/30/40ZC, and W20/30ZR lift trucks. ZAPI Controllers 2200 SRM 1064.

  • Page 6: Hydraulic Oil

    Special Precautions 2000 SRM 1025 The function of the auxiliary cylinder(s) varies based 3. Filter each change of oil to prevent the introduc- on the optional attachment. tion of contaminants into the system. 4. Provide continuous protection from airborne con- HYDRAULIC OIL tamination by keeping the breather cap clean The hydraulic oil in the system performs the dual...

  • Page 7: Control Valve

    2000 SRM 1025 Control Valve Legend for Figure 1 1. NEGATIVE CONNECTION 2. POSITIVE CONNECTION 3. 200-OHM, 2-WATT RESISTOR 4. INSULATED JUMPER WIRES Figure 1. Discharging the Capacitor Control Valve sent to the traction/lift controller, is processed, and CAUTION is sent to the pump assembly. Lifting speed is con- The hydraulic oil must be kept clean to prevent trolled by varying the pump motor speed.

  • Page 8: Hydraulic Reservoir

    N•m (36 lbf in). WARNING On the W30-40ZA models without sideshift, the man- Failure to return the manual lowering screw to ual override screw is located on the back of the low- the full clockwise position will cause the forks ering solenoid near the mounting wall.
  • Page 9 2000 SRM 1025 Manual Lowering Figure 2. Single Function - Manual Lowering Screw (Top View)

  • Page 10: Lift Pump And Motor Repair

    Lift Pump and Motor Repair 2000 SRM 1025 Figure 3. Auxiliary Function - Manual Lowering Screw (Side View) Lift Pump and Motor Repair GENERAL The lift pump and motor are connected by capscrews and are located on top of the hydraulic reservoir in- The hydraulic pump and motor assembly has differ- side the drive unit compartment or hydraulic unit ent parts working together to perform the functions...
  • Page 11 2000 SRM 1025 Lift Pump and Motor Repair 3. Turn key switch to OFF position and disconnect battery. 4. Block load wheels to prevent lift truck from mov- ing. Refer to Periodic Maintenance 8000 SRM 1027. 5. Remove drive unit compartment cover. On W25/ 30/40ZC lift trucks, also remove the hydraulic compartment cover.
  • Page 12 Lift Pump and Motor Repair 2000 SRM 1025 1. MOTOR 10. TUBE 2. COUPLING 11. PRESSURE RELIEF VALVE 3. HYDRAULIC RESERVOIR 12. CHECK VALVE 4. CLAMP 13. SCREW 5. DRAIN PLUG AND O-RING 14. RESERVOIR MOUNTING BRACKET 6. BREATHER/FILLER CAP 15.
  • Page 13 2000 SRM 1025 Lift Pump and Motor Repair 1. MOTOR 12. BREATHER/FILLER CAP 2. COUPLING 13. SCREW 3. PUMP HOUSING 14. AUXILIARY VALVE BLOCK 4. HYDRAULIC RESERVOIR 15. DIRECTIONAL VALVE 5. CLAMP 16. TUBES 6. DRAIN PLUG AND O-RING 17. PRESSURE RELIEF VALVE 7.
  • Page 14 Lift Pump and Motor Repair 2000 SRM 1025 1. MOTOR 11. BREATHER/FILLER CAP AND ELBOW 2. COUPLING 12. SCREW 3. PUMP HOUSING 13. PLUG 4. HYDRAULIC RESERVOIR 14. AUXILIARY VALVE BLOCK 5. SCREW 15. VALVE (TILT) 6. DRAIN PLUG AND O-RING 16.

  • Page 15: Disassemble

    2000 SRM 1025 Lift Pump and Motor Repair DISASSEMBLE Remove Pump Motor 1. If the lift pump and motor assembly has not been Remove Reservoir previously removed, perform steps 1 through 6 in For the following procedures, refer to Figure 5 for Remove Lift Pump and Motor Assembly.

  • Page 16: Assemble

    Lift Pump and Motor Repair 2000 SRM 1025 Install Pump Motor 6. Remove relief valve and check valve from pump. See Relief Valve and Check Valve, Remove. 1. Lubricate the motor output shaft and the pump 7. Remove the coupling. input shaft with a light coating of multi - purpose #2 grease with 2% to 4% molybdenum disulfide.

  • Page 17: Valve Repair

    2000 SRM 1025 Valve Repair 5. Connect the power wires to the lift pump motor 9. Check the top of the lift cylinder to determine if with the two nuts and washers. Torque the nuts a buttonhead bleed screw is present. If a bleed to 4.0 N•m (35 lbf in).

  • Page 18: Directional Valve

    Valve Repair 2000 SRM 1025 11. Operate each hydraulic function several times to 8. Tag and identify the control wiring plugs and purge the air from the hydraulic circuit. valve coils. 12. Check the top of the lift cylinder to determine if 9.

  • Page 19: Lift Valve

    2000 SRM 1025 Valve Repair 15. Test lift truck by lifting and lowering a load sev- 11. Remove the lower O-ring from the valve car- eral times. Check for leaks. tridge. 16. Install the drive unit compartment cover. If nec- 12.

  • Page 20: Counterbalance Valve

    Valve Repair 2000 SRM 1025 COUNTERBALANCE VALVE W20/30ZR Remove 1. Move the lift truck to a safe and level area. 2. Lower the forks completely and extend the forks completely. Tilt the forks down until they contact the floor. 3. Turn key switch to OFF position and disconnect battery.

  • Page 21: W25/30/40Zc

    2000 SRM 1025 Valve Repair WARNING Hydraulic oil hoses and lines may be under high pressure. Hydraulic oil can be injected into the body by pressure. To prevent possible injury, shield yourself from any escaping oil. Wrap a rag around the fitting and loosen the fitting and loosen the connection slowly.

  • Page 22: Relief Valve And Check Valve

    Valve Repair 2000 SRM 1025 5. Disconnect the overhead lifting device from the 9. Slowly loosen the relief valve cartridge to relieve mast. pressure. 6. Connect battery and turn key switch to ON posi- 10. Remove the relief valve cartridge. tion.

  • Page 23: Remove

    2000 SRM 1025 Valve Repair Remove 1. Move the lift truck to a safe and level area. 2. Lower the forks completely and extend the forks completely. 3. Turn key switch to OFF position and disconnect battery. 4. Block load wheels to prevent lift truck from mov- ing.

  • Page 24: Install

    Valve Repair 2000 SRM 1025 3. Turn key switch to OFF position and disconnect battery. 4. Block load wheels to prevent lift truck from mov- ing. Refer to Periodic Maintenance 8000 SRM 1027. 5. Remove the drive unit compartment cover. On W25/30/40ZC lift trucks, also remove the hy- draulic compartment cover.

  • Page 25: Relief Valve Adjustment

    2000 SRM 1025 Relief Valve Adjustment 12. Check the top of the lift cylinder to determine if 14. Test lift truck by lifting and lowering a load sev- a buttonhead bleed screw is present. If a bleed eral times. Check for leaks. screw is present, bleed the air from the hydraulic 15.

  • Page 26: Bleed Hydraulic System

    Troubleshooting 2000 SRM 1025 16. Disconnect the battery. 22. Check hydraulic oil level in reservoir and fill to proper level. See Table 1. 17. Discharge the capacitor. See Special Precau- tions. 23. Remove blocks from wheels. 18. Remove the pressure gauge and tee. 24.
  • Page 27 2000 SRM 1025 Troubleshooting PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION The pump noise is not nor- Inlet fitting or inlet hose clamp is Tighten fitting. Install new hoses. mal. (Cont.) loose. Remove air from system. The pump bearings or gears are Repair or install new pump.
  • Page 28 Troubleshooting 2000 SRM 1025 PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Lift pump and motor oper- Oil in the hydraulic reservoir is low. Fill reservoir to correct level. Check ates but the mast will not for leaks. raise. The button is in the raise position.

  • Page 29: Hydraulic Diagrams And Schematics

    2000 SRM 1025 Hydraulic Diagrams and Schematics Hydraulic Diagrams and Schematics 1. LIFT PUMP AND MOTOR ASSEMBLY 4. FITTING 2. PROPORTIONAL LOWERING VALVE 5. TUBE AND NUT ASSEMBLY 3. HOSE ASSEMBLY 6. RELIEF VALVE Figure 13. Hydraulic Diagram W30/40ZA (Without Side-shift)
  • Page 30 Hydraulic Diagrams and Schematics 2000 SRM 1025 1. LIFT PUMP AND MOTOR ASSEMBLY 6. FITTING 2. FITTING 7. HOSE ASSEMBLY 3. HOSE ASSEMBLY 8. FITTING 4. FITTING 9. LIFT VALVE 5. TUBE AND NUT ASSEMBLY 10. PROPORTIONAL LOWERING VALVE Figure 14. Hydraulic Diagram W30/40ZA (With Side-shift)
  • Page 31 2000 SRM 1025 Hydraulic Diagrams and Schematics 1. LIFT PUMP AND MOTOR 12. FITTING 23. O-RING ASSEMBLY 13. VALVE ASSEMBLY 24. FITTING 2. FITTING 14. FITTING 25. FITTING 3. HOSE ASSEMBLY 15. HOSE ASSEMBLY 26. TUBE ASSEMBLY 4. FITTING 16. HOSE ASSEMBLY 27.
  • Page 32 Hydraulic Diagrams and Schematics 2000 SRM 1025 1. LIFT PUMP AND MOTOR ASSEMBLY 13. C/B VALVE ASSEMBLY 2. FITTING 14. FITTING O-RING 3. HOSE ASSEMBLY 15. FITTING O-RING 4. ADAPTER O-RING 16. FITTING 5. FITTING 17. FITTING 6. FITTING 18. FITTING 7.
  • Page 33 NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________...
  • Page 34 Hydraulic Diagrams and Schematics 2000 SRM 1025...
  • Page 35 2000 SRM 1025 Hydraulic Diagrams and Schematics Figure 17. Hydraulic Schematic W30/40ZA (Without Side-shift)
  • Page 36 Hydraulic Diagrams and Schematics 2000 SRM 1025...
  • Page 37 2000 SRM 1025 Hydraulic Diagrams and Schematics Figure 18. Hydraulic Schematic W30/40ZA (With Side-shift)
  • Page 38 Hydraulic Diagrams and Schematics 2000 SRM 1025...
  • Page 39 2000 SRM 1025 Hydraulic Diagrams and Schematics Figure 19. Hydraulic Schematic W20/30ZR (Without Side-shift)
  • Page 40 Hydraulic Diagrams and Schematics 2000 SRM 1025...
  • Page 41 2000 SRM 1025 Hydraulic Diagrams and Schematics Figure 20. Hydraulic Schematic W20/30ZR (With Side-shift)
  • Page 42 Hydraulic Diagrams and Schematics 2000 SRM 1025...
  • Page 43 2000 SRM 1025 Hydraulic Diagrams and Schematics Figure 21. Hydraulic Schematic W25/30/40ZC (With Side-shift)
  • Page 44 Hydraulic Diagrams and Schematics 2000 SRM 1025...
  • Page 45 2000 SRM 1025 Hydraulic Diagrams and Schematics Figure 22. Hydraulic Schematic W25/30/40ZC (With Side-shift and Aux)
  • Page 46 NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________...
  • Page 48 TECHNICAL PUBLICATIONS 2000 SRM 1025 5/03 (4/03)(2/03) Printed in U.S.A.

This manual is also suitable for:

W20-30zrW25-30-40zc

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