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Hyster B218 (W40Z W45Z W50Z) Service Manual – PDF DOWNLOAD
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Hyster B218 (W40Z W45Z W50Z) Service Manual – PDF DOWNLOAD
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Description
Hyster B218 (W40Z W45Z W50Z) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster B218 (W40Z W45Z W50Z) Service Manual – PDF DOWNLOAD
Language : English
Pages : 668
Downloadable : Yes
File Type : PDF
Size: 16.9 MB
TABLE OF CONTENTS:
Hyster B218 (W40Z W45Z W50Z) Service Manual – PDF DOWNLOAD
Binder1................................................................ 1 Brakes............................................................. 1 toc............................................................ 1 Brakes..................................................... 1 General.................................................... 3 Description................................................ 3 Special Precautions........................................ 4 Brake Assembly Repair...................................... 5 Brake Override......................................... 5 Remove................................................. 6 Repair................................................. 8 Install................................................ 9 Troubleshooting............................................ 10 Capacities and Specifications...................................... 12 toc............................................................ 12 Capacities and Specifications.............................. 12 Hydraulic Oils............................................. 14 Gear Oils.................................................. 15 Grease..................................................... 16 Hydraulic System........................................... 17 Weight..................................................... 17 Basic Truck Without Battery............................ 17 Tires...................................................... 18 Torque Specifications...................................... 18 Caster Assembly........................................ 18 Master Drive Unit...................................... 18 Steering............................................... 18 Brake.................................................. 18 Lift Mechanism......................................... 18 Battery Specifications and Adjustments..................... 18 4000 LB - 24 Volt...................................... 18 4500 - 12 Volt......................................... 19 4500 and 5000 LB - 24 Volt............................. 20 DC Motor Maintenance............................................... 23 toc............................................................ 23 DC Motor Maintenance....................................... 23 General.................................................... 25 Brush and Commutator Inspection............................ 25 Hydraulic Pump Motor and Traction Motor................ 25 Steering Pump Motor.................................... 28 Normal Commutator Surface.............................. 29 Commutator Problems.................................... 29 Brush Replacement.......................................... 32 Stoning the Commutator..................................... 34 Motors Repair.............................................. 36 Disassemble............................................ 36 Traction Motor and Hydraulic Pump Motor............ 36 Steering Pump Motor................................ 38 Assemble............................................... 40 Traction Motor and Hydraulic Pump Motor............ 40 Steering Pump Motor................................ 41 Brush Alignment, Traction and Hydraulic Motors............. 43 Tests for Damaged Field and Armature....................... 43 Test for an Open Circuit in One Armature Winding....... 43 Test for Short Circuit in One Armature Winding......... 44 Test for Short Circuit to Armature Shaft............... 44 Test for Open Circuit in Field Coil.................... 44 Test for Short Circuit in Field Coil................... 45 Test for Short Circuit Between Field and Motor Case.... 45 Brush Holder Test...................................... 45 Troubleshooting............................................ 45 tables......................................................... 23 Table 1. Normal Commutator Surfaces........................ 28 Table 2. Commutator Problems............................... 29 Table 3. Brush Wear Replacement Guide...................... 32 Diagrams........................................................... 50 toc............................................................ 50 Diagrams................................................... 50 General Notes.............................................. 52 Electrical System.................................................. 67 toc............................................................ 67 Electrical System.......................................... 67 General.................................................... 70 Description of Operation................................... 71 Special Precautions........................................ 73 Moving a Disabled Lift Truck............................... 75 Electrical System Checks................................... 76 Safety Precautions..................................... 76 Repairs.................................................... 76 Controller, Replace.................................... 76 Remove............................................. 76 Install............................................ 79 Contactor Coil, Check.................................. 79 Contactor, Replace..................................... 79 Remove............................................. 79 Install............................................ 80 Key Switch Removal and Installation........................ 80 Remove................................................. 80 Install................................................ 80 Battery Indicator/Hourmeter Display........................ 80 Remove................................................. 81 Install................................................ 81 Fuses...................................................... 81 W40Z................................................... 81 W45-50Z................................................ 81 W20-25ZA............................................... 81 W25-30ZA 2............................................. 81 Control Handle Arm Proximity Switch........................ 82 Repair................................................. 82 Check and Adjust................................... 82 Remove............................................. 82 Install............................................ 83 Control Handle............................................. 83 Disassemble............................................ 83 Control Handle Card (Old Style)........................ 84 Control Handle Card (New Style)........................ 85 Configure.......................................... 85 Calibrate.......................................... 86 Assemble............................................... 87 Switches (ON/OFF and Proportional)..................... 89 Remove............................................. 89 Install............................................ 89 Traction Motor............................................. 90 Disassemble............................................ 90 Assemble............................................... 90 Lift Pump Motor............................................ 92 Repair ( W20-25ZA and W25-30ZA 2 )..................... 92 Lift Link Proximity Sensor (W50Z).......................... 93 Check.................................................. 93 Repair................................................. 93 Remove............................................. 93 Test............................................... 94 Install............................................ 94 Adjust............................................. 94 Battery Charger (Early Models)............................. 95 Description............................................ 95 Operation.............................................. 95 Charging........................................... 95 Equalize........................................... 95 Signals............................................ 95 Protections........................................ 95 Troubleshooting........................................ 95 Battery Charger (Late Models).............................. 98 Description............................................ 98 Operation.............................................. 98 LED Display........................................ 98 Charging........................................... 98 Troubleshooting........................................ 98 Battery Mode Selection (DPI Early Models).............. 99 Changing Mode Setting (DPI Early Models)...........100 Battery Mode Selection (DPI Late Models)...............100 Changing Mode Setting (DPI Late Models)............100 Troubleshooting............................................101 tables......................................................... 67 Table 1. Contactor Coil Resistance Values.................. 79 Table 2. Charger LEDs...................................... 98 Table 3. LED Codes......................................... 99 Table 4. Battery Modes..................................... 99 Table 5. Battery Modes.....................................100 Frame..............................................................103 toc............................................................103 Frame......................................................103 General....................................................105 Description............................................105 Frame Repair...............................................106 Features...............................................106 Frame Separation and Assembly..............................106 Separation.............................................106 Assembly...............................................106 Battery Compartment........................................107 Battery Compartment Specifications.....................107 Changing the Battery...................................107 Remove.............................................108 Install............................................108 Battery Spacer Adjustment..........................108 Label Replacement..........................................108 Painting Instructions......................................110 Load Wheels................................................110 Remove.................................................110 Install................................................110 Industrial Battery.................................................114 toc............................................................114 Industrial Battery.........................................114 General....................................................116 Lead-Acid Batteries........................................116 Specific Gravity...........................................117 Chemical Reaction in a Cell................................117 Electrical Terms...........................................118 Battery Selection..........................................119 Battery Voltage............................................120 Battery as a Counterweight.................................120 Battery Ratings............................................121 Kilowatt-Hours.........................................121 Battery Maintenance........................................121 Safety Procedures......................................121 Maintenance Records....................................122 New Battery............................................122 Cleaning Battery.......................................122 Adding Water to Battery................................124 Hydrometer.............................................125 Battery Temperature....................................125 Charging Battery.......................................126 Types of Battery Charges...........................127 Methods of Charging................................128 Troubleshooting Charger............................129 Knowing When Battery Is Fully Charged..............129 Where to Charge Batteries..............................129 Equipment Needed...................................129 Battery Connectors.....................................130 Battery Care...........................................130 tables.........................................................114 Table 1. Battery Capacity Terms............................121 Lifting Mechanism..................................................133 toc............................................................133 Lifting Mechanism..........................................133 General....................................................135 Lift Linkage...........................................135 Load Wheel.................................................136 Remove.................................................136 Install................................................136 Rear Link and Load Wheel...................................137 Remove.................................................137 Install................................................138 Compression Rod............................................138 Remove.................................................138 Install................................................139 Lower Link.................................................139 Remove.................................................139 Install................................................139 Upper Link.................................................140 Remove.................................................140 Install................................................141 Caster Wheels (Optional)...................................142 Remove.................................................142 Install................................................142 Replace................................................142 Master Drive Unit..................................................144 toc............................................................144 Master Drive Unit..........................................144 General....................................................146 Description................................................146 Special Precautions........................................146 Master Drive Unit Repair...................................148 Remove.................................................148 Disassemble............................................150 Repair.................................................151 Assemble...............................................151 Install................................................151 Troubleshooting............................................152 Metric and Inch (SAE) Fasteners....................................155 toc............................................................155 Metric and Inch (SAE) Fasteners............................155 General....................................................157 Threaded Fasteners.....................................157 Nomenclature, Threads..................................157 Strength Identification................................158 Cotter (Split) Pins....................................158 Fastener Torque Tables.................................163 Conversion Table.......................................165 tables.........................................................155 Table 1. Bolts and Screws..................................159 Table 2. Studs and Nuts....................................160 Table 3. Torque Nuts.......................................161 Table 4. Torque Nuts With Nylon Insert.....................162 Table 5. Torque Values for Metric Fasteners*...............163 Table 6. Torque Values for Inch Fasteners*.................164 Table 7. Conversion Table for Metric and English Units.....165 Table 8. Cotter Pin Dimensional Data.......................166 Table 9. Cotter Pin Dimensional Data.......................167 Table 10. Cotter Pin Dimensional Data......................168 Table 11. Cotter Pin Dimensional Data......................170 Periodic Maintenance...............................................174 toc............................................................174 Periodic Maintenance.......................................174 General....................................................176 How to Move a Disabled Truck...........................176 How to Tow the Lift Truck..........................176 How to Put a Lift Truck on Blocks......................177 How to Raise Drive/Steer Tire......................178 How to Raise Load Wheels...........................178 Welding Repairs........................................178 Battery Maintenance........................................179 How to Charge the Battery..............................179 Equalizing Charge..................................179 Normal Charge......................................179 Maintenance-Free Battery Charger...................180 Battery Charger ( W40Z Only).......................180 How to Change the Battery..............................180 Maintenance Schedule.......................................181 Checks and Inspection Procedures.......................181 Hydraulic System...................................182 Lifting Mechanism..................................183 Controls...........................................183 Electrical and Battery.............................184 Wheels and Tires...................................185 Casters................................................185 Recommended Schedule of Maintenance........................186 Lubrication Instructions...................................191 Every 8 Hours or Daily.................................191 Every 350 Hours or 6 Months............................191 Check Hydraulic Oil Level..........................191 Every 2000 Hours or 2 Years............................192 To Fill Hydraulic Reservoir........................192 tables.........................................................174 Table 1. Specific Gravity Corrections......................179 Steering Mechanism.................................................197 toc............................................................197 Steering Mechanism.........................................197 General....................................................199 Special Precautions........................................199 Control Handle Head........................................200 Control Handle.............................................200 Remove.................................................200 Install................................................201 Gas Spring.................................................203 Discharging the Gas Spring.............................203 Troubleshooting............................................204 Walkie Hydraulic Systems...........................................206 toc............................................................206 Walkie Hydraulic Systems...................................206 General....................................................208 Operation..................................................208 Lifting a Load.........................................208 Lowering a Load........................................208 Hydraulic Lines........................................208 Hydraulic Oil..........................................209 Cleanliness............................................209 Sound Level............................................210 Hydraulic Unit.............................................211 Remove.................................................211 Special Precautions....................................211 Install................................................212 Hydraulic Pump.............................................212 Remove.................................................212 Install................................................212 Hydraulic Pump Reservoir...................................214 Remove.................................................214 Install................................................214 Hydraulic Cylinder.........................................215 Remove.................................................215 Repacking..............................................215 Install................................................216 Relief Valve Adjustment....................................217 Relief Valve Pressure Check............................217 Relief Valve Adjust....................................218 Troubleshooting............................................219 Lift Assemblies........................................219 Hydraulic Cylinders....................................220 Hydraulic Pump.........................................221 tables.........................................................206 Table 1. Relief Valve Settings.............................218 ZAPI™ Controllers (2)..............................................225 toc............................................................225 ZAPI™ Controllers..........................................225 General....................................................227 Description................................................228 ZAPI™ Transistor Motor Controller......................228 Principles of Operation................................229 Controller Safety..........................................229 Controller Adjustments.....................................230 Modes of Operation.........................................230 User-Selectable Operating Modes........................230 Programming................................................231 Custom Performance Mode................................231 Controller Parameters..................................231 Tester Menu............................................232 Set Option Menu........................................232 ZAPI™ Handset..........................................233 Troubleshooting............................................236 ZAPI™ PC Interface.........................................259 Connecting PC to ZAPI™ Controller......................259 File Menu..............................................262 Open File..........................................262 TX From File.......................................263 Save File..........................................265 Print Settings.....................................267 Exit...............................................268 Connection Menu........................................269 Function Menu..........................................269 Parameter..........................................270 Memory Menu........................................274 Set Options........................................275 Tester.............................................277 Data Logger........................................279 Alarm Logbook......................................282 Alarms.............................................283 Repair.....................................................284 Remove.................................................284 Brass Stud Replacement.................................284 Remove.............................................284 Install............................................284 Install................................................284 Repair.................................................284 tables.........................................................225 Table 1. Parameters........................................231 ZAPI™ Controllers..................................................286 toc............................................................286 ZAPI™ Controllers..........................................286 General....................................................288 Description................................................289 ZAPI™ Transistor Motor Controller......................289 Principles of Operation................................289 Controller Safety..........................................290 Controller Adjustments.....................................290 Modes of Operation.........................................291 User-Selectable Operating Modes........................291 Programming................................................291 Custom Performance Mode................................291 Controller Parameters..................................291 Tester Menu............................................292 Set Option Menu........................................293 ZAPI™ Handset..........................................293 Troubleshooting............................................297 ZAPI™ PC Interface.........................................317 Connecting PC to ZAPI™ Controller......................317 File Menu..............................................320 Open File..........................................320 TX From File.......................................321 Save File..........................................323 Print Settings.....................................325 Exit...............................................326 Connection Menu........................................327 Function Menu..........................................327 Parameter..........................................328 Memory Menu........................................332 Set Options........................................333 Tester.............................................335 Data Logger........................................337 Alarm Logbook......................................340 Alarms.............................................341 Repair.....................................................342 Remove.................................................342 Brass Stud Replacement.................................342 Remove.............................................342 Install............................................342 Install................................................342 Repair.................................................342 tables.........................................................286 Table 1. Parameters........................................292 Binder1`...............................................................345 BATTERY 899648-2240SRM0001-(02-2008)-US-EN.........................345 toc............................................................345 Industrial Battery.........................................345 Safety Precautions Maintenance and Repair..................346 General....................................................349 Lead-Acid Batteries........................................349 Specific Gravity...........................................350 Chemical Reaction in a Cell................................350 Electrical Terms...........................................351 Battery Selection..........................................352 Battery Voltage............................................353 Battery as a Counterweight.................................353 Battery Ratings............................................354 Kilowatt-Hours.........................................354 Battery Maintenance........................................354 Safety Procedures......................................354 Maintenance Records....................................355 New Battery............................................355 Cleaning Battery.......................................355 Adding Water to Battery................................357 Hydrometer.............................................358 Battery Temperature....................................358 Charging Battery.......................................359 Types of Battery Charges...........................360 Methods of Charging................................361 Troubleshooting Charger............................362 Knowing When Battery Is Fully Charged..............362 Where to Charge Batteries..............................362 Equipment Needed...................................362 Battery Connectors.....................................363 Battery Care...........................................363 tables.........................................................345 Table 1. Battery Capacity Terms............................354 BRAKES 1511565-1800SRM1005-(03-2008)-US-EN.........................367 toc............................................................367 Brakes.....................................................367 Safety Precautions Maintenance and Repair..................368 General....................................................371 Description................................................371 Special Precautions........................................372 Brake Assembly Repair......................................373 Brake Override.........................................373 Remove.................................................374 Repair.................................................376 Install................................................377 Troubleshooting............................................378 CAP & SPEC 1499833-8000SRM1010-(10-2006)-US-EN.....................381 toc............................................................381 Capacities and Specifications..............................381 Safety Precautions Maintenance and Repair..................382 Hydraulic Oils.............................................385 Gear Oils..................................................386 Grease.....................................................387 Hydraulic System...........................................388 Weight.....................................................388 Basic Truck Without Battery............................388 Tires......................................................389 Torque Specifications......................................389 Caster Assembly........................................389 Master Drive Unit......................................389 Steering...............................................389 Brake..................................................389 Lift Mechanism.........................................389 Battery Specifications and Adjustments.....................389 4000 LB - 24 Volt......................................389 4500 - 12 Volt.........................................390 4500 and 5000 LB - 24 Volt.............................391 DC MOTOR MAINTENANCE 897076-0620SRM0294-(03-2008)-US-EN............395 toc............................................................395 DC Motor Maintenance.......................................395 Safety Precautions Maintenance and Repair..................396 General....................................................399 Brush and Commutator Inspection............................399 Hydraulic Pump Motor and Traction Motor................399 Steering Pump Motor....................................402 Normal Commutator Surface..............................403 Commutator Problems....................................403 Brush Replacement..........................................406 Stoning the Commutator.....................................408 Motors Repair..............................................410 Disassemble............................................410 Traction Motor and Hydraulic Pump Motor............410 Steering Pump Motor................................412 Assemble...............................................414 Traction Motor and Hydraulic Pump Motor............414 Steering Pump Motor................................415 Brush Alignment, Traction and Hydraulic Motors.............417 Tests for Damaged Field and Armature.......................417 Test for an Open Circuit in One Armature Winding.......417 Test for Short Circuit in One Armature Winding.........418 Test for Short Circuit to Armature Shaft...............418 Test for Open Circuit in Field Coil....................418 Test for Short Circuit in Field Coil...................419 Test for Short Circuit Between Field and Motor Case....419 Brush Holder Test......................................419 Troubleshooting............................................419 tables.........................................................395 Table 1. Normal Commutator Surfaces........................402 Table 2. Commutator Problems...............................403 Table 3. Brush Wear Replacement Guide......................406 DIAGRAMS 1499812-8000SRM1011-(02-2007)-US-EN.......................425 toc............................................................425 Diagrams...................................................425 Safety Precautions Maintenance and Repair..................426 General Notes..............................................429 ELECTRICAL SYSTEM 1511566-2200SRM1007-(09-2008)-US-EN..............445 toc............................................................445 Electrical System..........................................445 Safety Precautions Maintenance and Repair..................446 General....................................................449 Description of Operation...................................450 Special Precautions........................................452 Moving a Disabled Lift Truck...............................454 Electrical System Checks...................................455 Safety Precautions.....................................455 Repairs....................................................455 Controller, Replace....................................455 Remove.............................................455 Install............................................458 Contactor Coil, Check..................................458 Contactor, Replace.....................................458 Remove.............................................458 Install............................................459 Key Switch Removal and Installation........................459 Remove.................................................459 Install................................................459 Battery Indicator/Hourmeter Display........................459 Remove.................................................460 Install................................................460 Fuses......................................................460 W40Z...................................................460 W45-50Z................................................460 W20-25ZA...............................................460 W25-30ZA 2.............................................460 Control Handle Arm Proximity Switch........................461 Repair.................................................461 Check and Adjust...................................461 Remove.............................................461 Install............................................462 Control Handle.............................................462 Disassemble............................................462 Control Handle Card (Old Style)........................463 Control Handle Card (New Style)........................464 Configure..........................................464 Calibrate..........................................465 Assemble...............................................466 Switches (ON/OFF and Proportional).....................468 Remove.............................................468 Install............................................468 Traction Motor.............................................469 Disassemble............................................469 Assemble...............................................469 Lift Pump Motor............................................471 Repair ( W20-25ZA and W25-30ZA 2 ).....................471 Lift Link Proximity Sensor (W50Z)..........................472 Check..................................................472 Repair.................................................472 Remove.............................................472 Test...............................................473 Install............................................473 Adjust.............................................473 Battery Charger (Early Models).............................474 Description............................................474 Operation..............................................474 Charging...........................................474 Equalize...........................................474 Signals............................................474 Protections........................................474 Troubleshooting........................................474 Battery Charger (Late Models)..............................477 Description............................................477 Operation..............................................477 LED Display........................................477 Charging...........................................477 Troubleshooting........................................477 Battery Mode Selection (DPI Early Models)..............478 Changing Mode Setting (DPI Early Models)...........479 Battery Mode Selection (DPI Late Models)...............479 Changing Mode Setting (DPI Late Models)............479 Troubleshooting............................................480 tables.........................................................445 Table 1. Contactor Coil Resistance Values..................458 Table 2. Charger LEDs......................................477 Table 3. LED Codes.........................................478 Table 4. Battery Modes.....................................478 Table 5. Battery Modes.....................................479 FASTENERS 910442-8000SRM0231-(12-2004)-US-EN.......................483 toc............................................................483 Metric and Inch (SAE) Fasteners............................483 Safety Precautions Maintenance and Repair..................484 General....................................................487 Threaded Fasteners.....................................487 Nomenclature, Threads..................................487 Strength Identification................................488 Cotter (Split) Pins....................................488 Fastener Torque Tables.................................493 Conversion Table.......................................495 tables.........................................................483 Table 1. Bolts and Screws..................................489 Table 2. Studs and Nuts....................................490 Table 3. Torque Nuts.......................................491 Table 4. Torque Nuts With Nylon Insert.....................492 Table 5. Torque Values for Metric Fasteners*...............493 Table 6. Torque Values for Inch Fasteners*.................494 Table 7. Conversion Table for Metric and English Units.....495 Table 8. Cotter Pin Dimensional Data.......................496 Table 9. Cotter Pin Dimensional Data.......................497 Table 10. Cotter Pin Dimensional Data......................498 Table 11. Cotter Pin Dimensional Data......................500 FRAME 1518993-0100SRM1015-(08-2005)-US-EN..........................505 toc............................................................505 Frame......................................................505 Safety Precautions Maintenance and Repair..................506 General....................................................509 Description............................................509 Frame Repair...............................................510 Features...............................................510 Frame Separation and Assembly..............................510 Separation.............................................510 Assembly...............................................510 Battery Compartment........................................511 Battery Compartment Specifications.....................511 Changing the Battery...................................511 Remove.............................................512 Install............................................512 Battery Spacer Adjustment..........................512 Label Replacement..........................................512 Painting Instructions......................................514 Load Wheels................................................514 Remove.................................................514 Install................................................514 LIFTING SYSTEM 1511567-4000SRM1008-(09-2005)-US-EN.................519 toc............................................................519 Lifting Mechanism..........................................519 Safety Precautions Maintenance and Repair..................520 General....................................................523 Lift Linkage...........................................523 Load Wheel.................................................524 Remove.................................................524 Install................................................524 Rear Link and Load Wheel...................................525 Remove.................................................525 Install................................................526 Compression Rod............................................526 Remove.................................................526 Install................................................527 Lower Link.................................................527 Remove.................................................527 Install................................................527 Upper Link.................................................528 Remove.................................................528 Install................................................529 Caster Wheels (Optional)...................................530 Remove.................................................530 Install................................................530 Replace................................................530 MDU 1511563-0630SRM1003-(03-2008)-US-EN............................533 toc............................................................533 Master Drive Unit..........................................533 Safety Precautions Maintenance and Repair..................534 General....................................................537 Description................................................537 Special Precautions........................................537 Master Drive Unit Repair...................................539 Remove.................................................539 Disassemble............................................541 Repair.................................................542 Assemble...............................................542 Install................................................542 Troubleshooting............................................543 PERIODIC MAINTENANCE 1499808-8000SRM1009-(02-2007)-US-EN...........547 toc............................................................547 Periodic Maintenance.......................................547 Safety Precautions Maintenance and Repair..................548 General....................................................551 How to Move a Disabled Truck...........................551 How to Tow the Lift Truck..........................551 How to Put a Lift Truck on Blocks......................552 How to Raise Drive/Steer Tire......................553 How to Raise Load Wheels...........................553 Welding Repairs........................................553 Battery Maintenance........................................554 How to Charge the Battery..............................554 Equalizing Charge..................................554 Normal Charge......................................554 Maintenance-Free Battery Charger...................555 Battery Charger ( W40Z Only).......................555 How to Change the Battery..............................555 Maintenance Schedule.......................................556 Checks and Inspection Procedures.......................556 Hydraulic System...................................557 Lifting Mechanism..................................558 Controls...........................................558 Electrical and Battery.............................559 Wheels and Tires...................................560 Casters................................................560 Recommended Schedule of Maintenance........................561 Lubrication Instructions...................................566 Every 8 Hours or Daily.................................566 Every 350 Hours or 6 Months............................566 Check Hydraulic Oil Level..........................566 Every 2000 Hours or 2 Years............................567 To Fill Hydraulic Reservoir........................567 tables.........................................................547 Table 1. Specific Gravity Corrections......................554 STEERING 1511564-1600SRM1004-(03-2008)-US-EN.......................573 toc............................................................573 Steering Mechanism.........................................573 Safety Precautions Maintenance and Repair..................574 General....................................................577 Special Precautions........................................577 Control Handle Head........................................578 Control Handle.............................................578 Remove.................................................578 Install................................................579 Gas Spring.................................................581 Discharging the Gas Spring.............................581 Troubleshooting............................................582 WALKIE LIFTING SYSTEMS 1518954-1900SRM1018-(04-2007)-US-EN.........585 toc............................................................585 Walkie Hydraulic Systems...................................585 Safety Precautions Maintenance and Repair..................586 General....................................................589 Operation..................................................589 Lifting a Load.........................................589 Lowering a Load........................................589 Hydraulic Lines........................................589 Hydraulic Oil..........................................590 Cleanliness............................................590 Sound Level............................................591 Hydraulic Unit.............................................592 Remove.................................................592 Special Precautions....................................592 Install................................................593 Hydraulic Pump.............................................593 Remove.................................................593 Install................................................593 Hydraulic Pump Reservoir...................................595 Remove.................................................595 Install................................................595 Hydraulic Cylinder.........................................596 Remove.................................................596 Repacking..............................................596 Install................................................597 Relief Valve Adjustment....................................598 Relief Valve Pressure Check............................598 Relief Valve Adjust....................................599 Troubleshooting............................................600 Lift Assemblies........................................600 Hydraulic Cylinders....................................601 Hydraulic Pump.........................................602 tables.........................................................585 Table 1. Relief Valve Settings.............................599 ZAPI CONTROLLERS 1511612-2200SRM1006-(11-2007)-US-EN...............607 toc............................................................607 ZAPI™ Controllers..........................................607 Safety Precautions Maintenance and Repair..................608 General....................................................611 Description................................................612 ZAPI™ Transistor Motor Controller......................612 Principles of Operation................................612 Controller Safety..........................................613 Controller Adjustments.....................................613 Modes of Operation.........................................614 User-Selectable Operating Modes........................614 Programming................................................614 Custom Performance Mode................................614 Controller Parameters..................................614 Tester Menu............................................615 Set Option Menu........................................616 ZAPI™ Handset..........................................616 Troubleshooting............................................620 ZAPI™ PC Interface.........................................640 Connecting PC to ZAPI™ Controller......................640 File Menu..............................................643 Open File..........................................643 TX From File.......................................644 Save File..........................................646 Print Settings.....................................648 Exit...............................................649 Connection Menu........................................650 Function Menu..........................................650 Parameter..........................................651 Memory Menu........................................655 Set Options........................................656 Tester.............................................658 Data Logger........................................660 Alarm Logbook......................................663 Alarms.............................................664 Repair.....................................................665 Remove.................................................665 Brass Stud Replacement.................................665 Remove.............................................665 Install............................................665 Install................................................665 Repair.................................................665 tables.........................................................607 Table 1. Parameters........................................615
HYSTER B218 (W40Z W45Z W50Z) SERVICE MANUAL – PDF DOWNLOAD:
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