Hyster C454 Operating instructions

Hyster C454 (W25ZC, W30ZC, W40ZC) Forklift
Service Repair Manual

DIAGRAMS
W30-40ZA [B453, C453];
W20-30ZR [B455, C455];
W25-30-40ZC [B454, C454]
PART NO. 1524256 8000 SRM 1029

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
•When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
•DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
•Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic 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 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.
•Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
•Be sure to follow the WARNING and CAUTION notes in the instructions.
•Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
•Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

©2016 HYSTER COMPANY
TABLE OF CONTENTS
Diagrams, Schematics or Arrangements................................................................................................................1
Figure 1. Wiring Schematic.................................................................................................................................2
Figure 2. Wiring Diagram...................................................................................................................................4
Figure 3. Wiring Schematic.................................................................................................................................6
Figure 4. Wiring Diagram...................................................................................................................................8
Figure 5. Wiring Schematic...............................................................................................................................10
Figure 6. Wiring Diagram.................................................................................................................................12
Figure 7. Wiring Schematic...............................................................................................................................14
Figure 8. Wiring Diagram.................................................................................................................................16
Figure 9. Wiring Schematic...............................................................................................................................18
Figure 10. Wiring Diagram...............................................................................................................................20
Figure 11. Wiring Schematic.............................................................................................................................22
Figure 12. Wiring Diagram...............................................................................................................................24
Figure 13. Without Sideshift.............................................................................................................................26
Figure 14. With Sideshift.................................................................................................................................. 28
Figure 15. Without Sideshift.............................................................................................................................30
Figure 16. With SideShift..................................................................................................................................32
Figure 17. With or Without Sideshift...............................................................................................................34
Figure 18. With Sideshift and Auxiliary.......................................................................................................... 36
This section is for the following models:
(W30-40ZA) [B453, C453];
(W20-30ZR) [B455, C455];
(W25-30-40ZC) [B454, C454]
Table of Contents
i

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS

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8000 SRM 1029 Diagrams, Schematics or Arrangements
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W30-40ZA WITHOUT SIDESHIFT
Diagrams, Schematics or Arrangements 8000 SRM 1029
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Figure 1. Wiring Schematic
8000 SRM 1029 Diagrams, Schematics or Arrangements
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Diagrams, Schematics or Arrangements 8000 SRM 1029
4

Figure 2. Wiring Diagram
8000 SRM 1029 Diagrams, Schematics or Arrangements
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W30-40ZA WITH SIDESHIFT
Diagrams, Schematics or Arrangements 8000 SRM 1029
6

Figure 3. Wiring Schematic
8000 SRM 1029 Diagrams, Schematics or Arrangements
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Diagrams, Schematics or Arrangements 8000 SRM 1029
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Figure 4. Wiring Diagram
8000 SRM 1029 Diagrams, Schematics or Arrangements
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W20-30ZR WITHOUT SIDESHIFT
Diagrams, Schematics or Arrangements 8000 SRM 1029
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Figure 5. Wiring Schematic
8000 SRM 1029 Diagrams, Schematics or Arrangements
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Diagrams, Schematics or Arrangements 8000 SRM 1029
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Figure 6. Wiring Diagram
8000 SRM 1029 Diagrams, Schematics or Arrangements
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W20-30ZR WITH SIDESHIFT
Diagrams, Schematics or Arrangements 8000 SRM 1029
14