Hyster A455 (W20-30XTR) Forklift Service Manual

Name: Hyster A455 (W20-30XTR) Forklift Service Manual
Brand: MidWestTech
SKU: 897979-A455
Price: 69.93 USD
Availability: InStock

504 pages · Publication 897979-A455

$69.93

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Models: A455 (W20-30XTR)
Manual type: Service Manual
Pages: 504
Publication: 897979-A455
Condition: Brand new

Hyster A455 (W20-30XTR) Forklift Service Manual, publication 897979-A455

What's inside

From the manual's own table of contents: 73 sections, 254 entries. See sample pages (PDF, 67 KB)

Search the contents

INTRODUCTION2 topics

GENERAL
DESCRIPTION

REPAIR22 topics

FRAME REMOVAL AND DISASSEMBLY
CASTER REMOVAL AND DISASSEMBLY- W/B40CL AND W/B40-60XL
CASTER REMOVAL AND DISASSEMBLY-W40XT, W45XT, AND W/B/C60-80XT
CASTER INSTALLATION W40XT, W45XT AND W/B/C60-80XT
CASTER WHEEL REPLACEMENT- W40XT,W45XT, W/B/C60-80XT/XT2, B60Z, AND W60Z
FRAME AND ASSEMBLY AND INSTALLATION
CASTER ASSEMVBLY AND INSTALLATION-W/B40-60XL AND W/B40CL
CASTER ASSEMBLY AND INSTALLATION-W40XT,W45XT,W/B/C60-80XT AND CA60-80XT/XT2,B60Z AND W60Z
PAINTING INSTRUCTIONS
LABEL REPLACEMENT
LABEL INSTALLATION-W40XT ANDW45XT
LABEL INSTALLATION-W/B40-60XL
LABEL INSTALLATION -W/B40CL
LABEL INSTALLATION-B60-80XT
LABEL INSTALLATION- W60-80XT
LABEL INSTALLATION- B60Z
LABEL INSTALLATION-W60Z
LABEL INSTALLATION-CA60-80XT
LABEL INSTALLATION-T5XT
LABEL INSTALLATION-W20-40TA
LABEL INSTALLATION-W20-40XTC
LABEL INSTALLATION-W20-30XTR

DC Motor Maintenance

Safety Precautions Maintenance and Repair

General

Brush and Commutator Inspection4 topics

Hydraulic Pump Motor and Traction Motor
Steering Pump Motor
Normal Commutator Surface
Commutator Problems

Brush Replacement

Stoning the Commutator

Motors Repair6 topics

Disassemble
- Traction Motor and Hydraulic Pump Motor
- Steering Pump Motor
Assemble
- Traction Motor and Hydraulic Pump Motor
- Steering Pump Motor

Brush Alignment, Traction and Hydraulic Motors

Tests for Damaged Field and Armature7 topics

Test for an Open Circuit in One Armature Winding
Test for Short Circuit in One Armature Winding
Test for Short Circuit to Armature Shaft
Test for Open Circuit in Field Coil
Test for Short Circuit in Field Coil
Test for Short Circuit Between Field and Motor Case
Brush Holder Test

Troubleshooting

Table 1. Normal Commutator Surfaces

Table 2. Commutator Problems

Table 3. Brush Wear Replacement Guide

Curtis Transistor Motor Controller

Principles of Operation12 topics

Transistor Motor Controller
- Basic Controller Operation
- Field Effect Transistor (FET)
- Motor Circuit That Operates With Pulses
- Induction Current From Motor
- Plugging
- Control Circuit
- Static-Return-To-Off (SRO) Function
- Thermal Protection Function
- Low Voltage Protection Function
- Current Limit Protection Function
- Power Circuit

Sequence of Operation10 topics

Key Switch
Brake Switch
Control Circuit
FWD/REV Switch Closed
Forward Contactor Energized
Gate Pulse to FETs
FETs ON for Time of Gate Pulse
Gate Pulse Removed
Induction Current Flows Through Motor and Flyback Diode
Plugging

Checks5 topics

Checking Contactor Coil
Checking Transistor Controller
- Checks With Controller Installed
- Bench Checks
- Accelerator Potentiometer Checks and Adjustments

Adjustments3 topics

Plugging Adjustment
Acceleration Adjustment
Current Limit Adjustment

Repairs7 topics

Contactors
- Replace
Curtis Contactor Parts, Replace
GE Contactor Parts, Replace
Controller, Replace
Accelerator Potentiometer and Control Switches, Replace and Adju
General Procedures

Fault Procedures

Table 1. Inductance

Table 2. Fault Codes and Display Messages for R30XMS2 Only

Show all 73 sections

Mast

Mast Weldments

Carriages

Two-Stage Mast1 topic

Operation

Three-Stage Mast

Lift Cylinders

Description1 topic

Lowering Control Valve

Main Cylinder Repair

Free-Lift Cylinder Repair

Safety Procedures When Working Near Mast

Load Backrest Extension, Carriage, Load Rollers, Side Rollers, a6 topics

Load Backrest Extension, Remove and Install
Carriage Assembly, Remove and Install
Carriage Load Rollers, Remove and Install
Side Rollers, Disassemble and Assemble
Fork, Replace
- Hook-Type Forks

Two-Stage Mast Assembly15 topics

Remove
Clean and Inspect
Lift Cylinders, Remove and Install Dual-Lift Cylinders
Lift Cylinder, Remove and Install Single Main-Lift Cylinders
- Remove
- Install
Inner Mast Assembly, Remove and Install
Hoses, Replace
Hose and Cable Sheaves, Replace
Two-Stage Lift Chains
- Remove and Install
- Clean and Inspect
Two-Stage Chain Sheave, Remove and Install
Load Rollers and Wear Plugs, Remove and Install
Two-Stage Mast Assembly, Install

Three-Stage Mast Assembly14 topics

Three-Stage Mast Assembly, Remove
Free-Lift Cylinder, Remove and Install
Main Cylinders (Standard), Remove and Install
Inner and Intermediate Mast Assemblies, Remove and Install
- Free-Lift Hose Sheave
- Carriage Sheaves
Three-Stage Lift Chains, Remove and Install
- General
- Free-Lift Chains
- Main-Lift Chains
Three-Stage Chain Sheaves, Disassemble and Assemble
- Free-Lift Chain Sheaves
- Main-Lift Chain Sheaves
Three-Stage Mast Assemble, Install

Mast Operation Check

Hydraulic System Leaks Check

Lift Chains Check1 topic

Lubrication

Mast Adjustments6 topics

Adjust Wear Plugs - Mast
Adjust Free-Lift Chain (Three-Stage Only)
Adjust Main-Lift Chains
- Two-Stage
- Three-Stage
Adjust Wear Strips

Carriage Adjustments8 topics

Adjust Wear Plug - Carriage
Adjust Side Rollers - Carriage
Adjust Thrust Rollers - Carriage
DESCRIPTION (FIGURE 1 AND FIGURE 2 )
REMOVAL AND DISASSEMBLY
- MDU-Removal
- Upper Housing-Removal And Diasassembly
- Lower Housing- Diasassembly

ASSEMBLY AND INSTALLATION4 topics

UPPER HOUSING-ASSEMBLY
UPPER HOUSING-INSTALLATION
LOWER HOUSING-ASSEMBLY
MDU-ASSEMBLY AND INSTALLATION

CHECKS AND ADJUSTMENTS10 topics

Bevel Pinion And Gear Adjustment
- Removal
- Installation
- Removal
- Installation
B60Z (NEW MODEL)
- Removal
- Installation
- Removal
- Installation

W60Z (NEW MODEL)2 topics

Removal
Installation

Brakes

Repairs - General

Brake Shoe Removal

Brake Shoe Installation

Brake Linkage Removal

Brake Linkage and Cable Installation

Brake Adjustment

Brake Linkage Adjustment

Battery Indicators8 topics

Indicators With Meter Movements
Battery Indicators With LCD or LED Displays
- Liquid Crystal Displays
- SEM Display Panels Description
- Light Emitting Diode Displays
- Description LX Series
- ZX Series Display Panels Description
- SEVCON POWERGAUGE™ Battery Display Panel Description

Battery Indicators Without Lift Interrupt Adjustment (Early Mode

Battery Indicators With Lift Interrupt Adjustment (Early Models)2 topics

Reset Potentiometer
Specific Gravity Alarm

Battery Indicators Without Lift Interrupt Check (Later Models)

Battery Indicators With Lift Interrupt Adjustment (Later Models)1 topic

Discharge Potentiometer

LED Display With Lift Interrupt

Curtis 933-1 Meter Check and Adjustment8 topics

Check
- Reset Check
- Discharge Check
- Lockout Check
- LEDs Do Not Illuminate
- Hourmeter Check
- Hourglass Icon
Adjust

SEVCON POWERGAUGE™ Adjustment

Curtis Dash Display Assembly15 topics

Description/Features
Testing
- Inoperative Dash Display Assembly
- Inoperative Drive Mode Selection
- Troubleshooting With a Programmer Handset
- Troubleshooting Without a Programmer Handset
- No Warnings or Faults Displayed
- MIB/Dash Display Communication
- Lift Interrupt
- Lost MIB Signal Displayed
- Lift Pump Hourmeter Input
- Forward/Reverse Hourmeter Inputs
Install
Adjust (Setup, Early Models)
Adjust (Setup, Later Model)

Battery Indicators Replacement

Battery Indicator Controller Replacement

Display Panel Components Replacement

SEM Display Panel Replacement1 topic

Remove and Replace

Table 1. Battery Indicator (Later Models)

Table 2. SEVCON Discharge Curve Selector Positions

Table 3. Dash Display Drive Mode Inputs

Table 4. Dash Display Drive Mode Test Voltages

Table 5. Dash Display Status/Warning/Fault Test Voltages

Table 6. Testing Dash Display Status/Warning/Fault Inputs

Table 7. Battery Indicator Reset Adjustment

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 504 pages

Quantity one is the manual described above.

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Ships in 1 business day.

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Binder not included

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Other editions and similar models

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).