Hyster W30-40ZA Service & Repair Manual
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Hyster W30-40ZA Service & Repair Manual

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Summary of Contents for Hyster W30-40ZA

  • Page 2 PERIODIC MAINTENANCE W30-40ZA [B453]; W20-30ZR [B455]; W25-30-40ZC [B454] PART NO. 1524253 8000 SRM 1027...
  • Page 3 • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex- ceed 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 4: Table Of Contents

    Load Wheel Bearings () W25/30/40ZC......................32 Remove ................................32 Install ................................34 Master Drive Unit .............................34 Drive Unit Gear Oil ............................34 Welding Repairs ..............................34 General Repairs ..............................35 Load Wheels (W30-40ZA and W20-30ZR)......................35 Remove ................................35 Install ................................36 ©2014 HYSTER COMPANY...
  • Page 5 Thanks very much for your reading, Want to get more information, Please click here, Then get the complete manual NOTE: If there is no response to click on the link above, please download the PDF document first, and then click on it. Have any questions please write to me: admin@servicemanualperfect.com...
  • Page 6 Standard Battery Spacer Adjustment ......................39 Changing the Battery With an Overhead Crane ..................40 Remove ..............................40 Install ................................41 Changing Battery With Rollers ........................41 Remove ..............................43 Install ................................43 This section is for the following models: (W30-40ZA) [B453]; (W20-30ZR) [B455]; (W25-30-40ZC) [B454]...

  • Page 7: General

    Hyster lift truck dealer to help users who do their own repairs. Your Hyster lift truck dealer has the trained personnel and equipment to do a complete program of inspection, lubrication, and maintenance. This complete program will help your lift truck operate...

  • Page 8: How To Tow A Lift Truck

    General 8000 SRM 1027 How to Tow a Lift Truck WARNING Prior to releasing the electric brake, make sure the lift truck is blocked correctly to prevent movement causing damage to personnel or equipment. Stay clear of the tow chain, towing vehicle, and lift truck during the towing operation to prevent injury.

  • Page 9: How To Put The Lift Truck On Blocks

    HOW TO PUT THE LIFT TRUCK ON BLOCKS NOTE: Perform Step 3 for lift truck models (W30-40ZA and W20-30ZR). WARNING 3. To raise drive end of lift truck, hook a lift strap DO NOT put the lift truck on blocks if the surface under the bumper on both sides or hook the lift is not solid, even, and level.
  • Page 10 1. DRIVE END 3. STRAP 2. FORK END Figure 2. Lifting Points (W30-40ZA, W20-30ZR) 4. Install additional blocks under the frame near the drive tire. See Figure 3 and Figure 4. Figure 3. Putting Lift Truck on Blocks (W30-40ZA and W20-30ZR)

  • Page 11: How To Raise The Load Wheels

    8000 SRM 1027 Safety Procedures When Working Near Mast Figure 4. Putting Lift Truck on Blocks (W25-30-40ZC) How to Raise the Load Wheels (W30-40ZA Raise the outriggers only enough to suspend the and W20-30ZR) wheels. Install blocks under the outriggers at the rear of the wheels to support the lift truck.

  • Page 12: Safety Procedures When Working Near Mast

    Safety Procedures When Working Near Mast 8000 SRM 1027 Safety Procedures When Working Near Mast The following procedures must be used when in- 2. If parts of the mast must be in raised position, specting or working near the mast. Additional pre- install a safety chain to restrain moving parts cautions and procedures can be required when re- of mast.
  • Page 13 8000 SRM 1027 Safety Procedures When Working Near Mast Legend for Figure 5 A. TWO-STAGE MAST B. THREE-STAGE MAST 1. OUTER WELDMENT 2. INNER WELDMENT 3. INTERMEDIATE WELDMENT 4. HOOK 5. FREE-LIFT CYLINDER 6. CARRIAGE Figure 5. Safety Chain the Mast...

  • Page 14: Maintenance Schedule

    Maintenance Schedule 8000 SRM 1027 Maintenance Schedule The Maintenance Schedule has time intervals for The maintenance schedules are made according to inspection, lubrication, and maintenance for your the maximum service intervals for average condi- lift truck. The service intervals are given in both tions.
  • Page 15 8000 SRM 1027 Maintenance Schedule Figure 6. Maintenance Points W30/40ZA...
  • Page 16 Maintenance Schedule 8000 SRM 1027 Figure 7. Maintenance Points W20/30ZA...
  • Page 17 8000 SRM 1027 Maintenance Schedule Figure 8. Maintenance Points W25/30/40ZC...
  • Page 18 Maintenance Schedule 8000 SRM 1027 Table 1. Maintenance Schedule Item 350 hr 8 hr 2000 hr Procedure or or 2 Specification or 1 day or 1 year Quantity Description month 20 Safety Labels and Replace if Necessary See Parts Manual Operating Manual 21 Battery Check Water Level...
  • Page 19 8000 SRM 1027 Maintenance Schedule Table 1. Maintenance Schedule (Continued) Item 350 hr 8 hr 2000 hr Procedure or or 2 Specification or 1 day or 1 year Quantity Description month Check Hoses for Adjust or Replace as Damage and Wear Required 17 Lift/Lower Control Check Operation...
  • Page 20 SAE 80W-90 EP Gear Oil Multipurpose #2 grease with 2 to 4% molybdenum disulfide for normal operations. Chain Scale-Hyster-0871796 Equalization Charge approximately each month but not more than each week. Visual check for damage and proper adjustment. ISO 46 or Equivalent...

  • Page 21: Maintenance Procedures Every 8 Hours Or Daily

    8000 SRM 1027 Maintenance Procedures Every 8 Hours or Daily Maintenance Procedures Every 8 Hours or Daily Inspect the lift truck every 8 hours or daily before WARNING use. Put the lift truck on a level surface. Lower the carriage and forks, and turn the key switch to the DO NOT operate a lift truck that needs repairs.

  • Page 22: How To Make Checks With Key Switch Off

    Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1027 HOW TO MAKE CHECKS WITH KEY SWITCH OFF Safety Labels WARNING If labels that have warnings or instructions are damaged, they must be replaced immediately. Check that all safety labels are installed in the correct locations on the lift truck.

  • Page 23: Battery

    8000 SRM 1027 Maintenance Procedures Every 8 Hours or Daily Battery Check that the vent caps are clear. Check the elec- trolyte level daily on a minimum of one cell. If one cell is low, check the rest of the cells. Check the WARNING level when the electrolyte has stabilized.

  • Page 24: Brake

    Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1027 Brake Fully raising or lowering the control handle will ap- ply an electrical brake that is mounted on the drive motor. See Figure 10. When the brake is applied, a switch disconnects the power to the traction circuit.
  • Page 25 8000 SRM 1027 Maintenance Procedures Every 8 Hours or Daily 1. FORK 3. LOAD BACKREST 2. CARRIAGE 4. LOCK PIN Figure 12. Hook-Type Fork 1. Inspect the welds on the mast and carriage for 3. Inspect the channel for excessive wear in the cracks.

  • Page 26: Reach Mechanism (W20/30Zr)

    Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1027 Fork Tip Alignment Length of Forks 3% Dimension 0914 mm (36 in.) 27.00 mm (1.10 in.) 1067 mm (42 in.) 32.00 mm (1.26 in.) 1220 mm (48 in.) 37.00 mm (1.46 in.) 1371 mm (54 in.) 40.00 mm (1.57 in.) 1524 mm (60 in.)

This manual is also suitable for:

W20-30zrW25-30-40zcB453B455B454

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