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Hyster W20-30ZR, Manual

The Hyster W20-30ZR forklift is a versatile and reliable machine designed to handle heavy loads with ease. For free access to the user manual, download it from manualshive.com. Learn how to operate and maintain this top-of-the-line forklift with the comprehensive manual, ensuring optimal performance and safety.

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Walkie High Lift Hydraulic System

Table of Contents

TABLE OF CONTENTS

General ...............................................................................................................................................................

1

Description of Operation....................................................................................................................................

1

Hydraulic Oil .................................................................................................................................................

2

Clean ..............................................................................................................................................................

2

Sound Level....................................................................................................................................................

2

Special Precautions............................................................................................................................................

2

Control Valve ......................................................................................................................................................

3

Hydraulic Reservoir ...........................................................................................................................................

4

Description .....................................................................................................................................................

4

Manual Lowering ...............................................................................................................................................

4

Lift Pump and Motor Repair .............................................................................................................................

6

General ...........................................................................................................................................................

6

Remove Lift Pump and Motor Assembly ......................................................................................................

6

Disassemble ...................................................................................................................................................

11

Remove Reservoir......................................................................................................................................

11

Remove Pump Motor .................................................................................................................................

11

Disassemble Pump ....................................................................................................................................

11

Assemble ........................................................................................................................................................

12

Assemble Pump .........................................................................................................................................

12

Install Pump Motor ...................................................................................................................................

12

Install Reservoir to Pump .........................................................................................................................

12

Install Lift Pump and Motor Assembly ........................................................................................................

12

Valve Repair .......................................................................................................................................................

13

Proportional Valve (Lowering) ......................................................................................................................

13

Remove.......................................................................................................................................................

13

Install .........................................................................................................................................................

13

Directional Valve ...........................................................................................................................................

14

Remove.......................................................................................................................................................

14

Install .........................................................................................................................................................

14

Lift Valve ........................................................................................................................................................

15

Remove.......................................................................................................................................................

15

Install .........................................................................................................................................................

15

Counterbalance Valve....................................................................................................................................

16

W20/30ZR...................................................................................................................................................

16

Remove ..................................................................................................................................................

16

Install.....................................................................................................................................................

16

W25/30/40ZC .............................................................................................................................................

17

Remove ..................................................................................................................................................

17

Install.....................................................................................................................................................

17

Relief Valve and Check Valve........................................................................................................................

18

Remove.......................................................................................................................................................

18

Install .........................................................................................................................................................

18

Pilot Operated Check Valve ..........................................................................................................................

18

W20/30ZR...................................................................................................................................................

18

Remove ..................................................................................................................................................

19

Install.....................................................................................................................................................

19

Selector Valves: Reach, Tilt, and Sideshift ..................................................................................................

19

W20/30ZR and W25/30/40ZC ....................................................................................................................

19

Remove ..................................................................................................................................................

19

Install.....................................................................................................................................................

20

Relief Valve Adjustment ....................................................................................................................................

21

©2003 HYSTER COMPANY

i

Summary of Contents for W20-30ZR

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: ...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...

Page 3: ...ssemble Pump 12 Install Pump Motor 12 Install Reservoir to Pump 12 Install Lift Pump and Motor Assembly 12 Valve Repair 13 Proportional Valve Lowering 13 Remove 13 Install 13 Directional Valve 14 Remo...

Page 4: ...High Lift Hydraulic System TABLE OF CONTENTS Continued Bleed Hydraulic System 22 Troubleshooting 22 Hydraulic Diagrams and Schematics 25 This section is for the following models W30 40ZA B453 W20 30ZR...

Page 5: ...to return to the reservoir and the forks lower Rate of flow is regulated by how far the valve opens The lift cylinder s rod extends to raise the forks through a series of mast channels and chains The...

Page 6: ...es can cause pump noises due to cavitation Aerated hydraulic oil Results in system noise that is similar to cavitation Aerated oil is caused by the ingestion of air through the pipe joints of the inle...

Page 7: ...the lift pump and mo tor assembly and is replaceable but not adjustable When the operator selects a hydraulic function by pressing a button on the control handle a signal is sent to the traction lift...

Page 8: ...mechanism or load during the manual lowering procedure Verify that there are no obstructions beneath the lift mechanism or load If the mast does not lower when the man ual lowering valve is activated...

Page 9: ...2000 SRM 1025 Manual Lowering Figure 2 Single Function Manual Lowering Screw Top View 5...

Page 10: ...bling the hydraulic pump and mo tor assembly An electric motor drives the hydraulic pump It may be removed without removing the en tire assembly from the drive unit compartment or hy draulic unit comp...

Page 11: ...an 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 CAUTION...

Page 12: ...MP 5 DRAIN PLUG AND O RING 6 BREATHER FILLER CAP 7 VALVE BLOCK 8 PROPORTIONAL VALVE LOWERING 9 PUMP 10 TUBE 11 PRESSURE RELIEF VALVE 12 CHECK VALVE 13 SCREW 14 RESERVOIR MOUNTING BRACKET 15 SCREWS 16...

Page 13: ...RING 7 MAIN VALVE BLOCK 8 PLUG 9 PROPORTIONAL VALVE LOWERING 10 LIFT VALVE AND COIL 11 CAPSCREWS 12 BREATHER FILLER CAP 13 SCREW 14 AUXILIARY VALVE BLOCK 15 DIRECTIONAL VALVE 16 TUBES 17 PRESSURE REL...

Page 14: ...7 CLAMPS AND O RING 8 MAIN VALVE BLOCK 9 PROPORTIONAL VALVE LOWERING 10 LIFT VALVE AND COIL 11 BREATHER FILLER CAP AND ELBOW 12 SCREW 13 PLUG 14 AUXILIARY VALVE BLOCK 15 VALVE TILT 16 VALVE SIDESHIFT...

Page 15: ...contamination Clean and flush the hydraulic reservoir as necessary Remove Pump Motor 1 If the lift pump and motor assembly has not been previously removed perform steps 1 through 6 in Remove Lift Pump...

Page 16: ...ing and torque to 22 N m 16 lbf ft Install Pump Motor 1 Lubricate the motor output shaft and the pump input shaft with a light coating of multi purpose 2 grease with 2 to 4 molybdenum disulfide 2 Inst...

Page 17: ...aulic compartment cover 6 Discharge the capacitor See Special Precau tions WARNING Hydraulic oil hoses and lines may be under high pressure Hydraulic oil can be injected into the body by pressure To p...

Page 18: ...ways install caps on the hoses and ports of the pump 7 Tag and disconnect any power wires or hydraulic hoses blocking access to the valve 8 Tag and identify the control wiring plugs and valve coils 9...

Page 19: ...the coil 10 Remove the upper O ring and slide the coil off the valve cartridge 11 Remove the lower O ring from the valve car tridge 12 Remove the valve cartridge Install 1 Verify that the valve cartri...

Page 20: ...hield yourself from any escaping oil Wrap a rag around the fitting and loosen the fitting and loosen the connection slowly 8 Loosen both hydraulic hose fittings on the bottom of the valve block to rel...

Page 21: ...NG 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 t...

Page 22: ...ing the mounting bracket to the isolators and tilt the lift pump and motor assembly away from the frame 9 Slowly loosen the relief valve cartridge to relieve pressure 10 Remove the relief valve cartri...

Page 23: ...ure See Figure 11 Item 1 9 Remove the check valve cartridge Install 1 Verify that the valve cartridge O rings are not damaged Replace as needed 2 Verify that the valve cartridge and valve block are cl...

Page 24: ...jected 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 10 Loosen the se...

Page 25: ...r 5 Turn key switch to OFF position and disconnect battery 6 Block load wheels to prevent lift truck from mov ing Refer to Periodic Maintenance 8000 SRM 1027 7 Discharge the capacitor See Special Prec...

Page 26: ...Hydraulic System 1 Loosen buttonhead screw near top of cylinder 2 Connect battery and turn key switch to ON posi tion 3 Briefly press and release Lift button repeatedly until hydraulic oil flows from...

Page 27: ...lief valve is stuck open Clean adjust or replace the relief valve The pump has low output The pump is worn Check repair or install new parts as required Seals or gaskets are damaged and cause leaks In...

Page 28: ...ervoir is low Fill reservoir to correct level Check for leaks Lift lower coil is defective Measure the resistance on the coil and replace if not correct EV1 17 7 EV2 22 5 Lift lower cartridge is defec...

Page 29: ...and Schematics Hydraulic Diagrams and Schematics 1 LIFT PUMP AND MOTOR ASSEMBLY 2 PROPORTIONAL LOWERING VALVE 3 HOSE ASSEMBLY 4 FITTING 5 TUBE AND NUT ASSEMBLY 6 RELIEF VALVE Figure 13 Hydraulic Diagr...

Page 30: ...0 SRM 1025 1 LIFT PUMP AND MOTOR ASSEMBLY 2 FITTING 3 HOSE ASSEMBLY 4 FITTING 5 TUBE AND NUT ASSEMBLY 6 FITTING 7 HOSE ASSEMBLY 8 FITTING 9 LIFT VALVE 10 PROPORTIONAL LOWERING VALVE Figure 14 Hydrauli...

Page 31: ...SSEMBLY 12 FITTING 13 VALVE ASSEMBLY 14 FITTING 15 HOSE ASSEMBLY 16 HOSE ASSEMBLY 17 FITTING 18 EXTEND RETRACT CYLINDER 19 VALVE ASSEMBLY 20 FITTING 21 HOSE ASSEMBLY 22 HOSE ASSEMBLY 23 O RING 24 FITT...

Page 32: ...FITTING 6 FITTING 7 HOSE ASSEMBLY 8 HOSE ASSEMBLY 9 HOSE ASSEMBLY 10 FITTING 11 FITTING 12 HOSE ASSEMBLY 13 C B VALVE ASSEMBLY 14 FITTING O RING 15 FITTING O RING 16 FITTING 17 FITTING 18 FITTING 19...

Page 33: ...________________________________________ ____________________________________________________________ ____________________________________________________________ _____________________________________...

Page 34: ...Hydraulic Diagrams and Schematics 2000 SRM 1025 30...

Page 35: ...2000 SRM 1025 Hydraulic Diagrams and Schematics Figure 17 Hydraulic Schematic W30 40ZA Without Side shift 31...

Page 36: ...Hydraulic Diagrams and Schematics 2000 SRM 1025 32...

Page 37: ...2000 SRM 1025 Hydraulic Diagrams and Schematics Figure 18 Hydraulic Schematic W30 40ZA With Side shift 33...

Page 38: ...Hydraulic Diagrams and Schematics 2000 SRM 1025 34...

Page 39: ...2000 SRM 1025 Hydraulic Diagrams and Schematics Figure 19 Hydraulic Schematic W20 30ZR Without Side shift 35...

Page 40: ...Hydraulic Diagrams and Schematics 2000 SRM 1025 36...

Page 41: ...2000 SRM 1025 Hydraulic Diagrams and Schematics Figure 20 Hydraulic Schematic W20 30ZR With Side shift 37...

Page 42: ...Hydraulic Diagrams and Schematics 2000 SRM 1025 38...

Page 43: ...2000 SRM 1025 Hydraulic Diagrams and Schematics Figure 21 Hydraulic Schematic W25 30 40ZC With Side shift 39...

Page 44: ...Hydraulic Diagrams and Schematics 2000 SRM 1025 40...

Page 45: ...2000 SRM 1025 Hydraulic Diagrams and Schematics Figure 22 Hydraulic Schematic W25 30 40ZC With Side shift and Aux 41...

Page 46: ...________________________________________ ____________________________________________________________ ____________________________________________________________ _____________________________________...

Page 47: ......

Page 48: ...TECHNICAL PUBLICATIONS 2000 SRM 1025 5 03 4 03 2 03 Printed in U S A...

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