When a Hyster AP20Z logs a diagnostic trouble code, this 390-page service manual for the aerial work platform, OEM ID 4131885, gives you the factory diagnostics behind it. As a Hyster AP20Z service manual PDF, it pairs electrical schematics with controller pinouts and a trouble code list, so a code leads straight to the circuit it points at. Hydraulic schematics map the power unit and lift assemblies, while the hydraulic troubleshooting, relief valve pressure check and lift cylinder seal kit installation are written out in full. Read the brake coil against 18.5 to 21.3 ohms at 20°C (68°F). Pump pressure peaks at 21.03 MPa (3050 psi) continuous. Your job might be removing the lower controls panel mounting bracket, or discharging the capacitors before welding. Bookmarks sort the file by section, and the pages print cleanly when you want a working copy of the schematics.
What's Inside This Hyster AP20Z Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 7-8 | Description, Features, Working Near Power Lines |
| Special Precautions | 9-10 | Discharging the Capacitors, Welding |
| Service Doors, Covers, and Mounting Brackets | 11-17 | Service Doors (Remove, Install), Service Door Handles (Remove, Battery Cover (Remove, Mast Cylinder Cover (Remove |
| Caster Wheels | 18 | Remove, Install |
| Battery Compartment | 19 | |
| Painting Instructions | 20 | |
| Label Replacement | 21-23 | Warning Labels, Caution Labels, Nameplate, Label Locations |
| Operator Compartment | 27-46 | Operator Compartment Removal, Operator Door Disassembly, Mid-Mount Tray, Operator Compartment Installation |
| Master Drive Unit | 47-68 | Master Drive Unit Removal, Master Drive Unit Installation, Brake System, Steering System |
| Hydraulic System | 69-90 | Hydraulic Power Unit, Relief Valve Pressure Check, Hydraulic Troubleshooting, Lift Assemblies |
| Lift Cylinders | 91-108 | Lift Cylinder Removal, Lift Cylinder Disassembly, Seal Kit Installation, Torque Specifications |
| Electrical System and Diagnostics | 109-154 | Electrical System Features, Controller Pinouts, Diagnostic Trouble Codes, Electrical Schematics |
| Aerial Work Platform Battery | 155-180 | Chemical Reaction in a Cell, Battery Ratings, Where to Charge Batteries |
| Mast Repair | 181-212 | Clean and Inspect, Lateral Mast Adjustment, Vertical Mast Adjustment |
| Metric and Inch (SAE) Fasteners | 213-232 | Threaded Fasteners, Fastener Torque Tables, Conversion Table |
| Capacities and Specifications | 233-246 | Truck Weight, Electrical Specifications, Mast Speeds |
| Periodic Maintenance | 247-284 | How to Tow the Lift, Maintenance Schedule, Hydraulic Oil Analysis |
| Diagrams | 285-308 | Electrical Schematic, Hydraulic Schematic |
| Controller Diagnostics | 309-390 | General Maintenance and Diagnostic Data, Warning Codes, Diagnostic Trouble Codes |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Master drive unit weight | 23 kg (51 lb) | p. 58 |
| Gear box capscrew torque | 90 N·m (66 lbf ft) | p. 59 |
| Brake coil resistance at 20°C (68°F) | 18.5 to 21.3 ohms | p. 65 |
| Hydraulic Pump Displacement | 1.6 cc/rev | p. 240 |
| Hydraulic Pump Max Continuous Pressure | 21.03 MPa (3050 psi) | p. 240 |
| Excess Flow Protector Fitting | 85 to 94 N•m (63 to 69 lbf ft) | p. 105 |
| Fitting (Hydraulic Tube Fitting to Excess Flow Protector Fitting) | 55 to 60 N•m (40 to 44 lbf ft) | p. 105 |
| Gland | 340 to 410 N•m (251 to 302 lbf ft) | p. 105 |
| Mast Proximity switch gap | 8 mm (0.315 in.) | p. 122 |
| Operator Gate Proximity switch gap | 5 mm (0.197 in.) | p. 16 |
| Traction Controller mounting capscrews torque | 7 to 8 N·m (62 to 71 lbf in) | p. 144 |
| Traction Motor Controller Mounting Screws Torque | 7 to 8 N•m (62 to 71 lbf in) | p. 244 |
Hyster AP20Z Common Problems This Manual Covers
Hyster AP20Z lift assemblies troubleshooting: work platform fails to raise when lift function is selected
Check the needle valve first; an open manual lowering valve is a listed cause on page 86, so make sure it is fully closed. Check reservoir oil at room temperature and fill to the correct level, but do not overfill (page 84). Check for leaks, never with hands on pressurized lines (page 77). Inspect lifting components for deformation and replace damaged parts.
Manual Section: Hydraulic System Troubleshooting p. 86Slow lifting speed and insufficient handling capacity when raising the work platform under load
Test relief valve pressure with a tee fitting and a gauge rated to at least 3500 psi, oil at 25 to 35°C (77 to 95°F), following page 85. Target is 19.0 to 22.1 MPa (2800 to 3200 psi) per page 240. If incorrect, replace the relief valve; never open or adjust it (page 81). If the power unit is overheated, stop all hydraulic functions and let it cool. Check oil level and mast lubrication.
Manual Section: Hydraulic System Troubleshooting p. 86Work platform fails to lower from an elevated position after loss of electrical control
Open the manual lowering valve to bring the platform down safely, as page 87 directs for loss of electrical control. If it ran into an obstacle, lower using the lower controls panel and move away. Remove any blocks from under the mast channels. Inspect for deformed lifting components or a bent lift cylinder piston rod, then repair or replace.
Manual Section: Hydraulic System Troubleshooting p. 87DTC xx100 CANBus communications fault on the Combination controller with code still present after re-keying
Check battery state of charge, then inspect all connectors and wiring for the code (page 326). Key ON, disconnect CRS003 and measure CAN HI at socket 5 and CAN LO at socket 10 to B(-), about 2.5 Vdc each. Disconnect the battery, then measure socket 5 to 10: 60 ± 6 ohms; 120 ohms means an open or missing termination resistor (page 327). Never probe through the back of sealed plugs (page 315).
Manual Section: CANBus Communications - Combi p. 327DTC 30035 traction LH brake coil circuit fault shown as a status code on the display
Disconnect the battery, block the drive wheel, and discharge the controller capacitors with a 200-ohm, 2-watt resistor across B(+) and B(-), per page 316. Inspect the brake coil wiring for damage. Measure brake coil resistance against 18.5 to 21.3 ohms at 20°C (68°F) on page 65. If the wiring and coil check good, replace the traction controller.
Manual Section: Traction - LH Brake Coil - Circuit p. 65DTC 32033 or 32034 main contactor coil circuit or short fault shown as a status code
Disconnect the battery, block the drive wheel, and discharge the capacitors through a 200-ohm, 2-watt resistor across the controller B(+) and B(-) terminals (page 316). Inspect the contactor coil wiring for damage or shorts. Measure main contactor coil resistance against 32 ± 4 ohms on page 126. If the wiring and coil check good, replace the controller.
Manual Section: Main Contactor Coil - Circuit/Short p. 126Frequently Asked Questions
How do I reset the Hyster AP20Z battery discharge indicator (BDI)?
The BDI algorithm can be reset by adjusting the BDI ADJ STARTUP parameter. This parameter adjusts the difference in voltage level between key-off and key-on that will cause the BDI algorithm to reset, with a default value of 7 VDC (range 0-9 VDC). p. 132
How do I clear Hyster AP20Z power-timeout faults?
The power timeout is a configurable parameter that determines the time after all operation of the lift ceases until the lift enters an energy-saving state. You can adjust this value in the parameter configuration settings; a value of 0 disables the timeout entirely, while the default is 60 seconds (range 0-255 seconds). p. 134
What are the replacement specifications for the main lift cylinder gland on the Hyster AP20Z?
When installing the gland onto the rod in the tube, you must tighten the gland to a torque specification of 340 to 410 N•m (251 to 302 lbf ft). p. 103
What is the correct torque for the drive motor to frame capscrews on the Hyster AP20Z?
The drive motor to frame capscrews must be tightened to a torque of 120 N•m (88.5 lbf ft). p. 244
What is the correct resistance for the main contactor coil?
The main contactor coil resistance should read 32 ±4 ohms at room temperature. If the resistance is not within this specification, the coil must be replaced. p. 126
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