Hyster B454 (W25-40ZC) Walkie High Lift Stacker Service Manual

Name: Hyster B454 (W25-40ZC) Walkie High Lift Stacker Service Manual
Brand: MidWestTech
SKU: 1524247-B454
Price: 69.75 USD
Availability: InStock

585 pages · Publication 1524247-B454

$69.75

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Models: B454 (W25-40ZC)
Manual type: Service Manual
Pages: 585
Publication: 1524247-B454
Condition: Brand new

Hyster B454 (W25-40ZC) Walkie High Lift Stacker Service Manual, publication 1524247-B454

What's inside

From the manual's own table of contents: 119 sections, 263 entries. See sample pages (PDF, 240 KB)

Search the contents

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

Mast

Mast Weldments

Carriages

Two-Stage Mast2 topics

Description
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

Show all 119 sections

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 Check2 topics

General
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 Adjustments3 topics

Adjust Wear Plug - Carriage
Adjust Side Rollers - Carriage
Adjust Thrust Rollers - Carriage

Steering Mechanism

Special Precautions

Control Handle Head1 topic

Install

Control Handle ( B60/80Z )6 topics

Remove (Handle)
Steer Bearings and Support
- Disassemble
- Repair
- Assemble
Install (Handle)

Gas Spring1 topic

Discharging the Gas Spring

Steering and Dash Assembly (Complete)

Brakes

Brake Check1 topic

Hold On Grade Test

Brake Coil Check

Brake Assembly Repair4 topics

Remove
- Install
- Remove
- Install

Brake Assembly Adjustment3 topics

Air Gap, Adjust
Torque Nut, Adjust
- Adjust

Table 1. Brake Coil Resistance

Table 2. Adjustment Specifications

Reach Carriages1 topic

Reach Assemblies

Repair - General

Load Backrest Removal and Installation

Fork Replacement1 topic

Hook Forks

Reach Assembly Removal and Installation

Carriage Load Rollers Removal and Installation

Side Rollers Disassembly and Assembly

Reach Assembly Repair

Reach Assembly Outer Frame4 topics

Remove Without Sideshifter
Disassemble Without Sideshifter
Assemble Without Sideshifter
Install Without Sideshifter

Single-Reach Scissor Arms2 topics

Remove and Disassemble
Assemble and Install

Double-Reach Scissor Arms

Inner Frame Assembly

Reach Cylinders

Tilt Cylinder1 topic

Clean, Inspect, and Repair

Sideshift Cylinder

Reach/Tilt Selector Valve

Carriage or Reach Assembly Adjustments4 topics

Adjust Wear Plug
Adjust Side Rollers
Adjust Thrust Rollers
Adjust Reach Cylinders

Specifications

Table 1. General Specifications

Table 2. Operating Times N30XMXDR3, N45XMXR3, N30/40XMR2, N25XMD

Table 3. Operating Times W20/30ZR

Tilt Cylinders

Tilt Cylinder Repair1 topic

Clean

Tilt Cylinder Leak Check

Mast Tilt Angle Adjustment

Frame

Frame Repair

Painting Instructions

Label Replacement

Battery Compartment3 topics

Battery Roller Option
- Remove
- Install

Walkie High Lift Hydraulic System

Description of Operation2 topics

Hydraulic Oil
Sound Level

Control Valve

Hydraulic Reservoir

Manual Lowering

Lift Pump and Motor Repair8 topics

Remove Lift Pump and Motor Assembly
- Remove Reservoir
- Remove Pump Motor
- Disassemble Pump
- Assemble Pump
- Install Pump Motor
- Install Reservoir to Pump
Install Lift Pump and Motor Assembly

Valve Repair15 topics

Proportional Valve (Lowering)
- Remove
- Install
Directional Valve
- Remove
- Install
Lift Valve
- Remove
- Install
Counterbalance Valve
Relief Valve and Check Valve
- Remove
- Install
Pilot Operated Check Valve
Selector Valves: Reach, Tilt, and Sideshift

Relief Valve Adjustment

Bleed Hydraulic System

Hydraulic Diagrams and Schematics

Table 1. Hydraulic Reservoir

Electrical System

Moving a Disabled Lift Truck

Electrical System Checks1 topic

Safety Precautions

Repairs7 topics

Controller, Replace
- Remove
- Install
Contactor Coil, Check
Contactor, Replace
- Remove
- Install

Key Switch

Battery Indicator/Hourmeter Display

Fuses

Brake Switch

Control Handle4 topics

Control Handle Card (Old Style)
Control Handle Card (New Style)
- Configure
- Calibrate

Drive Motor

Lift Pump Motor3 topics

General Troubleshooting
Hydraulic Troubleshooting
Sideshift and Tilt Function Setup (W20/30ZR and W25/30/40ZC)

Table 1. Sideshift - Aux Board Output

Table 2. Sideshift - Motor Controller Outputs

Table 3. Sideshift - Aux Board Inputs

Table 4. Tilt - Aux Board Output

Table 5. Tilt - Motor Controller Outputs

Table 6. Tilt - Aux Board Inputs

Table 7. Tilt - Controller Inputs (Handset or PC Tester Menu)

Table 8. Reach - Aux Board Output

Table 9. Reach - Motor Controller Outputs

Table 10. Reach - Aux Board Inputs

Table 11. Reach - Controller Inputs (Handset or PC Tester Menu)

Capacities and Specifications

Lift and Hydraulic System Specifications1 topic

Hydraulic Tank Capacity

Hydraulic Oils

Master Drive Unit Specifications

Gear Oils

Grease

Tire Specifications

Torque Specifications4 topics

Master Drive Unit
Brake
Steering
Mast

Truck Weight

Travel Speeds

Battery Specifications

Diagrams

Inside this manual

Real pages from this service manual (585 pages). Open the sample pages (PDF, 240 KB)

Sample pages from the Hyster B454 (W25-40ZC) Walkie High Lift Stacker Service Manual: Diagram, Specifications, Troubleshooting

Diagram, page 350: Hydraulic Diagrams and Schematics
Specifications, page 404: 12. If another lift truck that has the drive wheels
Troubleshooting, page 521: Troubleshooting

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, 585 pages

Quantity one is the manual described above.

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Ships in 1 business day.

60-day returns

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Binder not included

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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).