Hyster A495 Service & Repair Manual Download | Manualshive

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Hyster A495 (W20ZA W25ZA) Forklift

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Summary of Contents for A495

Page 1: ...Hyster A495 W20ZA W25ZA Forklift...

Page 2: ...ZAPI CONTROLLERS W20 25ZA A495 W25 30ZA2 B495 W30 40ZA B453 W20 30ZR B455 W25 30 40ZC B454 PART NO 1537482 2200 SRM 1064...

Page 3: ...dic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use HYSTER APPROVED parts when ma...

Page 4: ...12 Troubleshooting 14 Auxiliary Hydraulics W30 40ZA W20 30ZR W25 30 40ZC 39 Control Card Functional Test 44 Traction Motor Test 46 ZAPI PC Interface 48 Connecting PC to ZAPI Controller 48 File Menu 51...

Page 5: ...ore 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 pl...

Page 6: ...This section is for the following models W20 25ZA A495 W25 30ZA2 B495 W30 40ZA B453 W20 30ZR B455 W25 30 40ZC B454 Table of Contents ii...

Page 7: ...al This section describes the ZAPI transistor motor controller Procedures are outlined for controller safety adjustments troubleshooting and repairs See Figure 1 Figure 1 Controller 2200 SRM 1064 Gene...

Page 8: ...n trol handle serial communications controller tem perature and internal logic functions The control lers on standard trucks come equipped with a red LED fault indicator located at the bottom of the c...

Page 9: ...LED An LED light emitting diode can be in stalled in trucks that do not use a display The LED flashes error codes to the technician for di agnosis The LED would be installed on the bot tom of the ZAPI...

Page 10: ...ase The following procedure is used to access the user selectable operating modes 1 The controller drive modes parameter must be ON This is the factory setting NOTE You must use the handset or PC inte...

Page 11: ...to install the adapter harness NOTE Connect and disconnect the handset only with the key switch in the OFF position 4 Connect adapter harness to controller 5 Turn key switch ON 6 The handset will turn...

Page 12: ...7 INVERSE BRAKING Adjusts plugging rate 0 long or soft plugging 9 short or rapid plugging 9 CUTBACK SPEED Speed control for trucks in optional mode 0 slow 9 fast not used 9 MAX SPEED FORW Adjusts max...

Page 13: ...OFF 12 LIFTING SWITCH lifting function request from control handle card proportional lift switch ON OFF 13 LOWERING SWITCH lowering function re quest from control handle card proportional lowering sw...

Page 14: ...tore the new values in the EEPROM This section describes the ZAPI handset func tions Six buttons provide the capability of chang ing or reading the parameters NOTE After a modification save the new va...

Page 15: ...NOTES 9...

Page 16: ...Programming 2200 SRM 1064 10...

Page 17: ...Figure 4 ZAPI Handset Instructions 2200 SRM 1064 Programming 11...

Page 18: ...changing to the second screen Wait for the second screen to appear with the controller software version 2 Write down the controller software version in formation and hourmeter reading that is dis pla...

Page 19: ...ting plate to fill any air pock ets in the mating surfaces which will impede conductivity and prevent the heat from flowing from the controller heat sink into the mounting plate of the controllers The...

Page 20: ...CAUSES AND TEST PROCEDURES LOGIC Brief description of the reason behind truck exhibited malfunction NOTE General error code information is provided by the Dash Display and Red LED at the base of the...

Page 21: ...y between batteries negative at battery and B power wire connection at controller If no continuity check Power wiring between battery and controller Verify continuity between battery positive at batte...

Page 22: ...ve dash display Connect handset to controller and confirm communication to handset If handset operates correctly replace MDI Defective LED Disconnect LED and connect handset If handset works replace L...

Page 23: ...rn throttle to neutral Release all hydraulic function controls If fault remains attach handset and go to test menu Check brake switch it should be off If steer handle is in vertical position and readi...

Page 24: ...d traction controller TRUCK RESPONSE Traction and hoist functions disabled POSSIBLE CAUSES AND TEST PROCEDURES Control card throttle calibration is out of range Install handset Go to tester function o...

Page 25: ...EDURES A lift lower switch is damaged or defective Install handset Go to tester function Check lifting control and EVP voltage Check on off switches and proportional switches for smooth linear operati...

Page 26: ...ion error between control card and traction controller TRUCK RESPONSE Traction and hoist functions disabled POSSIBLE CAUSES AND TEST PROCEDURES Control card throttle device is damaged or defective Ins...

Page 27: ...aged electrical connection between control card and controller Verify connection at controller Verify wire harness connection at base of steer handle Verify connection at control card Damaged or defec...

Page 28: ...n controller TRUCK RESPONSE Traction and hoist functions disabled POSSIBLE CAUSES AND TEST PROCEDURES Traction reversing switch is not connected Install handset Go to tester function Check for operati...

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