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Hyster B230 B233 (B60Z AC B80Z AC) Service Manual – PDF DOWNLOAD
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Hyster B230 B233 (B60Z AC B80Z AC) Service Manual – PDF DOWNLOAD
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Description
Hyster B230 B233 (B60Z AC B80Z AC) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster B230 B233 (B60Z AC B80Z AC) Service Manual – PDF DOWNLOAD
Language : English
Pages : 963
Downloadable : Yes
File Type : PDF
Size: 43.2 MB
TABLE OF CONTENTS:
Hyster B230 B233 (B60Z AC B80Z AC) Service Manual – PDF DOWNLOAD
Binder1............................................................................. 1 AC Motor Controller............................................................. 1 toc......................................................................... 1 AC Motor Controller..................................................... 1 General................................................................. 3 Discharging the Capacitors.......................................... 3 Description............................................................. 4 Electrical System................................................... 4 AC Traction Motor............................................... 5 Controller...................................................... 5 Service PC Connection........................................... 5 Parameters.............................................................. 5 General............................................................. 5 Parameter Description................................................... 6 Parameters.......................................................... 6 Extended Shift.................................................. 6 Walk Speed (Both Directions).................................... 6 Hi Speed (FWD).................................................. 7 Hi Speed (REV).................................................. 7 Minimum Acceleration............................................ 7 Maximum Acceleration............................................ 7 Plugging........................................................ 7 ADS-Throttle.................................................... 7 ADS-Neutral..................................................... 7 Pick Acceleration............................................... 7 Pick Deceleration............................................... 7 Battery Full Voltage............................................ 7 Battery Empty Voltage........................................... 7 Min Steering Assist (High Speed FWD)............................ 7 Min Steering Assist (High Speed REV)............................ 7 Maximum Steering Assist ........................................ 8 Troubleshooting......................................................... 8 General............................................................. 8 Status Codes........................................................ 8 Dash Display............................................................ 54 General............................................................. 54 Startup............................................................. 54 Status LED.......................................................... 54 Performance Mode Indicator.......................................... 54 Hourmeter........................................................... 55 Battery Charge Indicator............................................ 55 Fault Log........................................................... 55 Connector Pin-Outs...................................................... 56 System Logic Diagram.................................................... 57 tables...................................................................... 1 Table 1. Parameter Default Values....................................... 6 Table 2. Fault Codes.................................................... 9 AC Motor Repair................................................................. 60 toc......................................................................... 60 AC Motor Repair......................................................... 60 General................................................................. 62 Accessing the Drive Unit Compartment................................ 62 B60-80Z AC...................................................... 62 C60-80Z AC and T5-7Z AC......................................... 62 Special Precautions..................................................... 64 Discharging the Capacitors.......................................... 64 Description............................................................. 65 AC Motor Repair......................................................... 65 Remove.............................................................. 65 Disassemble......................................................... 65 Inspect............................................................. 67 Assemble............................................................ 67 Install............................................................. 67 Troubleshooting......................................................... 68 Brakes.......................................................................... 71 toc......................................................................... 71 Brakes.................................................................. 71 General................................................................. 73 Accessing the Drive Unit Compartment................................ 73 B60-80Z AC...................................................... 73 C60-80Z AC and T5-7Z AC......................................... 74 Description............................................................. 75 Special Precautions..................................................... 76 Brake Check............................................................. 77 Brake Release....................................................... 77 Brake Apply......................................................... 77 Air Gap............................................................. 77 Hold On Grade Test.................................................. 79 Brake Assembly Repair................................................... 79 B60Z AC, C60Z AC, and T5Z AC ....................................... 79 Remove.......................................................... 79 Repair.......................................................... 80 Install......................................................... 81 B80Z AC, C80Z AC, and T7Z AC ....................................... 81 Remove.......................................................... 81 Repair.......................................................... 82 Install......................................................... 83 Troubleshooting......................................................... 84 tables...................................................................... 71 Table 1. Stator Resistance.............................................. 77 Table 2. Adjustment Specifications...................................... 78 Capacities and Specifications................................................... 86 toc......................................................................... 86 Capacities and Specifications........................................... 86 Hydraulic System........................................................ 88 Hydraulic Oils.......................................................... 89 Gear Oils............................................................... 89 Grease.................................................................. 89 Truck Weight............................................................ 90 Tire Sizes.............................................................. 90 Torque Specifications................................................... 91 Caster Assembly..................................................... 91 Drive Wheel Assembly................................................ 91 Master Drive Unit................................................... 91 Standard Steering................................................... 91 Power Assist Steering............................................... 91 Brake............................................................... 91 Electrical.......................................................... 91 Lift Mechanism...................................................... 91 Hydraulics.......................................................... 91 Battery Specifications.................................................. 92 tables...................................................................... 86 Table 1. B60Z AC........................................................ 92 Table 2. B80Z AC........................................................ 93 Diagrams........................................................................ 95 toc......................................................................... 95 Diagrams................................................................ 95 Electrical System...............................................................106 toc.........................................................................106 Electrical System.......................................................106 General.................................................................108 Accessing the Drive Unit Compartment................................109 Special Precautions.....................................................110 Discharging the Capacitors..........................................110 Electrical System Checks................................................111 Safety Precautions..................................................111 Calibration.............................................................114 Calibration Mode....................................................114 Repairs.................................................................114 Controller, Replace.................................................114 Remove..........................................................114 Install.........................................................115 Contactor Coil, Check...............................................116 Contactor, Replace..................................................116 Fuses...................................................................116 Horn....................................................................117 Replace.............................................................117 Brake Switch Operation..................................................117 Brake and Interlock Switches - (Manual Steering)........................118 Disassemble.........................................................118 Assemble............................................................118 Brake Switch and Handle Position Sensor - (Power Assist Steering........119 Brake Switch........................................................119 Handle Potentiometer Sensor.........................................120 Disassemble.....................................................120 Assemble........................................................122 Height Limit............................................................124 Control Handle..........................................................124 Disassemble.........................................................124 Assemble............................................................124 Remote Control Box Switches.............................................126 Remove..............................................................126 Install.............................................................126 Motor Tests.............................................................127 Excessive Current Draw..............................................127 Measuring Current Draw..............................................128 Excessive Resistance................................................128 Troubleshooting.........................................................128 tables......................................................................106 Table 1. Voltage Checks.................................................113 Frame (2).......................................................................131 toc.........................................................................131 Frame...................................................................131 General.................................................................133 Features (W30/40ZA and W20/30ZR)....................................133 Features (W25/30/40ZC)..............................................133 Frame Repair............................................................136 Painting Instructions...................................................136 Label Replacement.......................................................136 Battery Compartment.....................................................139 Battery Roller Option...............................................139 Remove..........................................................139 Install.........................................................139 Frame...........................................................................142 toc.........................................................................142 Frame...................................................................142 General.................................................................144 Frame Separation and Assembly...........................................144 Frame Separation....................................................144 Frame Assembly......................................................144 Painting Instructions...................................................146 Label Replacement.......................................................146 Industrial Battery..............................................................151 toc.........................................................................151 Industrial Battery......................................................151 General.................................................................153 Lead-Acid Batteries.....................................................153 Specific Gravity........................................................154 Chemical Reaction in a Cell.............................................154 Electrical Terms........................................................155 Battery Selection.......................................................156 Battery Voltage.........................................................157 Battery as a Counterweight..............................................157 Battery Ratings.........................................................158 Kilowatt-Hours......................................................158 Battery Maintenance.....................................................158 Safety Procedures...................................................158 Maintenance Records.................................................159 New Battery.........................................................159 Cleaning Battery....................................................159 Adding Water to Battery.............................................161 Hydrometer..........................................................162 Battery Temperature.................................................162 Charging Battery....................................................163 Types of Battery Charges........................................164 Methods of Charging.............................................165 Troubleshooting Charger.........................................166 Knowing When Battery Is Fully Charged...........................166 Where to Charge Batteries...........................................166 Equipment Needed................................................166 Battery Connectors..................................................167 Battery Care........................................................167 tables......................................................................151 Table 1. Battery Capacity Terms.........................................158 Lifting Mechanism...............................................................170 toc.........................................................................170 Lifting Mechanism.......................................................170 General.................................................................172 Description of Operation................................................172 Load Wheel..............................................................172 Remove..............................................................172 Install.............................................................173 Caster Wheels...........................................................174 Caster Shim Adjustment..............................................174 Caster Replacement..................................................176 Disassemble.........................................................177 Assemble............................................................177 Caster Lubrication..................................................178 Rear Link and Load Wheel Assembly.......................................179 Remove..............................................................179 Install.............................................................181 Pull Rod................................................................183 Remove..............................................................183 End Replacement.....................................................183 Install.............................................................183 Adjust..............................................................184 Rear Fork Adjustment................................................185 Rocker Arm..............................................................186 Remove..............................................................186 Install.............................................................187 Upper Link..............................................................188 Remove..............................................................188 Install.............................................................189 Troubleshooting.........................................................189 Master Drive Unit...............................................................193 toc.........................................................................193 Master Drive Unit.......................................................193 General.................................................................195 Check Oil Level.....................................................195 Change Gear Oil ( T5-7Z AC, B60-80Z AC, and C60-80Z AC )............196 Safety Precautions......................................................196 Drive Tire..............................................................199 Remove..............................................................199 Install.............................................................199 Master Drive Unit.......................................................199 Remove..............................................................199 Install.............................................................207 Troubleshooting.........................................................209 tables......................................................................193 Table 1. Drive Unit Specifications......................................195 Metric and Inch (SAE) Fasteners.................................................212 toc.........................................................................212 Metric and Inch (SAE) Fasteners.........................................212 General.................................................................214 Threaded Fasteners..................................................214 Nomenclature, Threads...............................................214 Strength Identification.............................................215 Cotter (Split) Pins.................................................215 Fastener Torque Tables..............................................220 Conversion Table....................................................222 tables......................................................................212 Table 1. Bolts and Screws...............................................216 Table 2. Studs and Nuts.................................................217 Table 3. Torque Nuts....................................................218 Table 4. Torque Nuts With Nylon Insert..................................219 Table 5. Torque Values for Metric Fasteners*............................220 Table 6. Torque Values for Inch Fasteners*..............................221 Table 7. Conversion Table for Metric and English Units..................222 Table 8. Cotter Pin Dimensional Data....................................223 Table 9. Cotter Pin Dimensional Data....................................224 Table 10. Cotter Pin Dimensional Data...................................225 Table 11. Cotter Pin Dimensional Data...................................227 Periodic Maintenance............................................................231 toc.........................................................................231 Periodic Maintenance....................................................231 General.................................................................234 How to Move a Disabled Truck........................................234 How to Tow the Lift Truck.......................................235 How to Put a Lift Truck on Blocks...................................235 How to Raise Drive/Steer Tire...................................235 How to Raise Load Wheels........................................236 Accessing the Drive Unit Compartment................................236 Special Precautions.....................................................237 Discharging the Capacitors..........................................237 Welding Repairs.........................................................239 Maintenance Schedule....................................................239 Maintenance Procedures Every 8 Hours or Daily...........................243 Checks With Key Switch Turned OFF...................................243 Battery.........................................................243 Hydraulic Leaks.................................................243 Drive Tire, Load Wheels, Casters, and Frame.....................244 Checks With Key Switch Turned ON....................................245 Operation.......................................................245 Maintenance Procedures Every 250 Hours or Every 6 Weeks.................247 Caster Lubrication..................................................247 Maintenance Procedures Every 500 Hours or Every 3 Months ...............248 Hydraulic System....................................................248 Hydraulic Oil...................................................248 Hydraulic Reservoir Breather....................................248 Steering System.....................................................248 Power Assist Steering...........................................248 Lift Linkage and Load Wheels........................................249 Casters.............................................................249 Caster Shim Check...............................................249 Caster Shim Adjust..............................................250 Master Drive Unit...................................................251 Change Gear Oil.................................................251 Check Oil Level.................................................251 Drive Tire Check....................................................252 Maintenance Procedures Every 2000 Hours or Yearly.......................252 Lubrication.........................................................252 Repack Load Wheel Bearings......................................252 Repack Steer Bearings (Manual Steer Only) ......................252 Hydraulic System....................................................252 Oil Change......................................................252 Brake...............................................................253 Electrical..........................................................253 MDU.................................................................253 Oil Change......................................................253 Battery Maintenance.....................................................254 How to Charge the Battery...........................................254 Equalizing Charge...............................................254 Normal Charge...................................................254 How to Change the Battery...........................................255 Transporting............................................................256 Loading.............................................................256 Unloading...........................................................256 Preparation for Storage.................................................257 Short-Term Storage (1 to 6 months)..................................257 Long-Term Storage (6 months or longer)..............................257 Preparation for Use.....................................................257 Preparation After Shipment..........................................257 Preparation After Storage...........................................257 tables......................................................................231 Table 1. Maintenance Schedule...........................................240 Table 2. Specific Gravity Corrections...................................254 Steering Mechanism..............................................................259 toc.........................................................................259 Steering Mechanism......................................................259 General.................................................................262 Accessing the Drive Unit Compartment................................262 Special Precautions.....................................................263 Discharging the Capacitors..........................................263 Calibration.............................................................264 Power Assist Steering Sensor........................................264 Control Handle..........................................................264 Control Handle Head.................................................264 Control Handle......................................................264 Standard Steering...............................................264 Remove......................................................265 Install.....................................................265 Power Assist Steering...........................................267 Remove......................................................267 Install.....................................................268 Gas Spring..............................................................272 Discharging the Gas Spring..........................................272 Remove .............................................................273 Install ............................................................273 Articulating Shaft and Pinions (Power Assist Models)....................274 Remove..............................................................274 Pinion Repair.......................................................275 Upper Pinion....................................................275 Lower Pinion....................................................276 Install.............................................................277 Steer Motor Assembly....................................................278 Repair..............................................................278 Steer Motor, Replace............................................278 Steer Motor Gear, Replace.......................................279 Gearbox/Complete Assembly, Replace..............................279 Steer Support Assembly..................................................280 Standard Steering...................................................280 Remove (Complete Unit)..........................................280 Disassemble.....................................................280 Assemble........................................................282 Install (Complete Unit).........................................282 Power Assist Steering...............................................284 Remove (Complete Unit)..........................................284 Disassemble.....................................................284 Support Base................................................284 Steer Swivel................................................285 Assemble........................................................285 Steer Swivel................................................285 Support Base................................................286 Install (Complete Unit).........................................287 Coast Control Option....................................................288 Disassemble.........................................................288 Assemble............................................................290 Checks..............................................................290 Troubleshooting.........................................................291 Troubleshooting and Adjustments Using the AC Controls Program (ETACC)...........293 toc.........................................................................293 Troubleshooting and Adjustments Using the AC Controls Program (E........293 General.................................................................296 Computer Requirements...............................................296 Software, Install...................................................296 Language Selection..................................................296 Demo Mode...........................................................297 Connect PC to Lift Truck............................................301 Starting AC Controls Program........................................303 Lift Truck Control Setup................................................307 Change Lift Truck Serial Number or Hourmeter........................307 Setting Factory Default Values or Changing Lift Truck Parameters....309 Create New Custom Lift Truck Configuration..........................315 Lift Truck Configuration Properties.................................318 Import New Lift Truck Configuration From Disk.......................321 Delete Custom Lift Truck Configuration or Password File.............323 Dash Display............................................................326 Custom Display Languages............................................326 Download Display Language...........................................328 Clear Operator Log..................................................328 Password Functions......................................................331 Enable/Disable Password and Lift Truck Inspection Functions.........331 Truck Inspection Checklist......................................331 Password........................................................331 Password Properties.................................................331 Create New Password File............................................336 Download Passwords..................................................338 Upload Passwords....................................................338 Reports Menu............................................................342 Devices Report......................................................342 Custom Report.......................................................342 Password Report.....................................................342 Operator Report.....................................................349 Current Settings Report.............................................352 Status Code Report..................................................355 Status Codes Log....................................................358 Troubleshooting.........................................................360 Diagnostics.........................................................360 Help Menu...............................................................363 General.............................................................363 Contents............................................................363 Technical Support...................................................363 About Electric Truck AC Controls Program............................363 User Interface (2)..............................................................369 toc.........................................................................369 User Interface..........................................................369 General.................................................................372 Description.........................................................372 Dash Display Menu Access............................................372 Menu Navigation.........................................................373 Dash Display Versions...................................................375 Technician Menu.........................................................376 View Versions.......................................................377 Hourmeters..........................................................377 Diagnostics.........................................................377 Fault Log.......................................................378 Controller Inputs...............................................378 Steer Handle Inputs.............................................379 Run Diagnostics.................................................379 Traction Motor..............................................381 Pump Motor and Valve........................................381 Control Handle..............................................382 Temperatures................................................382 Power Steering..............................................383 Service Reminder....................................................383 Change Supervisor Password..........................................384 Operator Modes......................................................384 Set Performance.....................................................385 Extended Shift..................................................386 Walk Speed......................................................386 High Speed (FWD)................................................387 High Speed (REV)................................................387 Minimum Acceleration............................................387 Maximum Acceleration............................................388 Plugging........................................................388 ADS-Neutral.....................................................388 ADS-Throttle....................................................389 Pick Acceleration...............................................389 Pick Deceleration...............................................389 Battery Full....................................................390 Lift Interrupt..................................................390 Min Steer Assist FWD (Power Steering Assist Only)...............390 Min Steer Assist REV (Power Steering Assist Only)...............391 Max Steer Assist (Power Steering Assist Only)...................391 Defaults........................................................391 Save and Exit...................................................392 Exit Without Saving.............................................392 Set General Items...................................................392 A/V Alarm (Audible/Visual)......................................393 Clear Fault Log.....................................................393 Calibrations........................................................394 Throttle........................................................394 Steer Handle (Power Steering Assist Only).......................395 Change Service Technician Password..................................395 Exit to Run Mode....................................................396 tables......................................................................369 Table 1. Technician Menu................................................376 Table 2. Diagnostics Menu...............................................378 Table 3. Controller Inputs..............................................378 Table 4. Steer Handle Inputs............................................379 Table 5. Run Diagnostics Menu...........................................380 Table 6. Performance Parameters.........................................385 Table 7. Set Performance Menu...........................................385 Table 8. Set General Items Menu.........................................392 Table 9. Calibrations Menu..............................................394 User Interface..................................................................399 toc.........................................................................399 User Interface..........................................................399 General.................................................................401 Description.........................................................401 Dash Display Menu Access............................................401 Menu Navigation.........................................................402 Dash Display Versions...................................................404 Supervisor Menu.........................................................405 View Versions.......................................................405 Hourmeters..........................................................406 Diagnostics.........................................................406 Fault Log.......................................................407 Controller Inputs...............................................407 Control Handle Inputs...........................................408 Run Diagnostics.................................................408 Traction Motor..............................................410 Pump Motor and Valve........................................410 Control Handle..............................................411 Temperatures................................................411 Power Steering..............................................412 Service Reminder....................................................412 Change Supervisor Password..........................................412 Operator Modes......................................................413 Exit to Run Mode....................................................413 tables......................................................................399 Table 1. Supervisor Menu................................................405 Table 2. Diagnostics Menu...............................................406 Table 3. Controller Inputs..............................................407 Table 4. Control Handle Inputs..........................................408 Table 5. Run Diagnostics Menu...........................................409 Walkie Hydraulic Systems........................................................416 toc.........................................................................416 Walkie Hydraulic Systems................................................416 General.................................................................419 Description of Operation................................................419 Lifting a Load......................................................420 Lowering a Load.....................................................420 Hydraulic Lines.....................................................420 Hydraulic Oil.......................................................420 Clean...............................................................423 Sound Level.........................................................423 Special Precautions.....................................................423 Hydraulic Reservoir.....................................................425 Description.........................................................425 Drive Unit Compartment Covers...........................................425 C60Z, C80Z, C60Z AC, and C80Z AC....................................425 Remove..........................................................425 Install.........................................................425 B60Z, B80Z, B60Z AC, B80Z AC, W60Z, W65Z, and W80Z..................426 Remove..........................................................426 Install.........................................................427 Lift Pump and Motor.....................................................428 General.............................................................428 Remove..............................................................428 Lift Pump and Motor Assembly....................................428 Disassemble.........................................................429 Remove Reservoir................................................429 Remove Pump Motor...............................................431 B60Z, B60Z AC, C60Z, C60Z AC, and W60Z......................431 B80Z, B80Z AC, C80Z, C80Z AC, W65Z, and W80Z................431 Disassemble Pump................................................431 B60Z, B60Z AC, C60Z, C60Z AC, and W60Z......................431 B80Z, B80Z AC, C80Z, C80Z AC, W65Z, and W80Z................431 Assemble............................................................433 Assemble Pump...................................................433 B60Z, B60Z AC, C60Z, C60Z AC, and W60Z......................433 B80Z, B80Z AC, C80Z, C80Z AC, W65Z, and W80Z................433 Install Pump Motor..............................................433 Install Reservoir to Pump.......................................434 Install.............................................................434 Lift Pump and Motor Assembly....................................434 Valve Repair............................................................435 Lowering Valve......................................................435 Remove..........................................................435 Install.........................................................435 Relief Valve........................................................436 B60Z, B60Z AC, C60Z, C60Z AC, and W60Z..........................436 Remove......................................................436 Install.....................................................436 B80Z, B80Z AC, C80Z, C80Z AC, W65Z, and W80Z....................437 Remove......................................................437 Install.....................................................437 Check Valve.........................................................437 B80Z, B80Z AC, C80Z, C80Z AC, W65Z, and W80Z....................437 Remove......................................................437 Install.....................................................438 Lift Cylinder...........................................................438 Remove..............................................................438 Disassemble.........................................................440 Assemble............................................................440 Install.............................................................440 Relief Valve Adjustment.................................................441 Relief Valve Pressure Check.........................................441 Adjust Relief Valve Pressure........................................442 B60Z, B60Z AC, C60Z, C60Z AC, and W60Z..........................442 B80Z, B80Z AC, C80Z, C80Z AC, W65Z, and W80Z....................443 Troubleshooting.........................................................444 Lift Assemblies.....................................................444 Lift Cylinders......................................................445 Lift Pump and Motor Assembly........................................446 tables......................................................................416 Table 1. Hydraulic Reservoir............................................425 Table 2. Relief Valve Settings..........................................441 Binder1`............................................................................450 899648-2240SRM0001-(06-2007)-US-EN..............................................450 toc.........................................................................450 Industrial Battery......................................................450 Safety Precautions Maintenance and Repair...............................451 General.................................................................454 Lead-Acid Batteries.....................................................454 Specific Gravity........................................................455 Chemical Reaction in a Cell.............................................455 Electrical Terms........................................................456 Battery Selection.......................................................457 Battery Voltage.........................................................458 Battery as a Counterweight..............................................458 Battery Ratings.........................................................459 Kilowatt-Hours......................................................459 Battery Maintenance.....................................................459 Safety Procedures...................................................459 Maintenance Records.................................................460 New Battery.........................................................460 Cleaning Battery....................................................460 Adding Water to Battery.............................................462 Hydrometer..........................................................463 Battery Temperature.................................................463 Charging Battery....................................................464 Types of Battery Charges........................................465 Methods of Charging.............................................466 Troubleshooting Charger.........................................467 Knowing When Battery Is Fully Charged...........................467 Where to Charge Batteries...........................................467 Equipment Needed................................................467 Battery Connectors..................................................468 Battery Care........................................................468 tables......................................................................450 Table 1. Battery Capacity Terms.........................................459 910442-8000SRM0231-(12-2004)-US-EN..............................................472 toc.........................................................................472 Metric and Inch (SAE) Fasteners.........................................472 Safety Precautions Maintenance and Repair...............................473 General.................................................................476 Threaded Fasteners..................................................476 Nomenclature, Threads...............................................476 Strength Identification.............................................477 Cotter (Split) Pins.................................................477 Fastener Torque Tables..............................................482 Conversion Table....................................................484 tables......................................................................472 Table 1. Bolts and Screws...............................................478 Table 2. Studs and Nuts.................................................479 Table 3. Torque Nuts....................................................480 Table 4. Torque Nuts With Nylon Insert..................................481 Table 5. Torque Values for Metric Fasteners*............................482 Table 6. Torque Values for Inch Fasteners*..............................483 Table 7. Conversion Table for Metric and English Units..................484 Table 8. Cotter Pin Dimensional Data....................................485 Table 9. Cotter Pin Dimensional Data....................................486 Table 10. Cotter Pin Dimensional Data...................................487 Table 11. Cotter Pin Dimensional Data...................................489 1500193-0100SRM0960-(11-2006)-US-EN.............................................494 toc.........................................................................494 Frame...................................................................494 Safety Precautions Maintenance and Repair...............................495 General.................................................................498 Frame Separation and Assembly...........................................498 Frame Separation....................................................498 Frame Assembly......................................................498 Painting Instructions...................................................500 Label Replacement.......................................................500 1500198-0630SRM0961-(11-2006)-US-EN.............................................506 toc.........................................................................506 Master Drive Unit.......................................................506 Safety Precautions Maintenance and Repair...............................507 General.................................................................510 Check Oil Level.....................................................510 Change Gear Oil ( B60Z AC and B80Z AC ).............................511 Safety Precautions......................................................511 Drive Tire..............................................................514 Remove..............................................................514 Install.............................................................514 Master Drive Unit.......................................................514 Remove..............................................................514 Install.............................................................519 Troubleshooting.........................................................521 tables......................................................................506 Table 1. Drive Unit Specifications......................................510 1500201-1900SRM0964-(11-2006)-US-EN.............................................524 toc.........................................................................524 Walkie Hydraulic Systems................................................524 Safety Precautions Maintenance and Repair...............................525 General.................................................................528 Description of Operation................................................528 Lifting a Load......................................................528 Lowering a Load.....................................................531 Hydraulic Lines.....................................................531 Hydraulic Oil.......................................................531 Clean...............................................................531 Sound Level.........................................................532 Special Precautions.....................................................532 Hydraulic Reservoir.....................................................533 Description.........................................................533 Drive Unit Compartment Covers...........................................533 B60Z, W60Z, W65Z, B80Z, W80Z, C60Z, and C80Z........................533 Remove..........................................................533 Install.........................................................533 B60Z AC and B80Z AC.................................................533 Remove..........................................................533 Install.........................................................534 Lift Pump and Motor.....................................................534 General.............................................................534 Remove..............................................................535 Lift Pump and Motor Assembly....................................535 Disassemble.........................................................536 Remove Reservoir................................................536 Remove Pump Motor...............................................540 B60Z, C60Z, W60Z, and B60Z AC...............................540 B80Z, C80Z, W65Z, W80Z, and B80Z AC.........................540 Disassemble Pump................................................540 B60Z, C60Z, W60Z, and B60Z AC...............................540 B80Z, C80Z, W65Z, W80Z, and B80Z AC.........................540 Assemble............................................................540 Assemble Pump...................................................540 B60Z, C60Z, W60Z, and B60Z AC...............................540 B80Z, C80Z, W65Z, W80Z, and B80Z AC.........................540 Install Pump Motor..............................................541 Install Reservoir to Pump.......................................541 Install.............................................................541 Lift Pump and Motor Assembly....................................541 Valve Repair............................................................543 Lowering Valve......................................................543 Remove..........................................................543 Install.........................................................543 Relief Valve........................................................543 B80Z, C80Z, W65Z, W80Z, and B80Z AC.............................543 Remove......................................................543 Install.....................................................544 B60Z, C60Z, W60Z, and B60Z AC...................................544 Remove......................................................544 Install.....................................................544 Check Valve.........................................................545 B80Z, C80Z, W65Z, W80Z, and B80Z AC.............................545 Remove......................................................545 Install.....................................................545 Lift Cylinder...........................................................545 Remove..............................................................545 Disassemble.........................................................547 Assemble............................................................547 Install.............................................................547 Relief Valve Adjustment.................................................547 Relief Valve Pressure Check.........................................547 Adjust Relief Valve Pressure........................................548 B60Z, C60Z, W60Z, and B60Z AC...................................548 B80Z, C80Z, W65Z, W80Z, and B80Z AC.............................549 Troubleshooting.........................................................549 Lift Assemblies.....................................................549 Lift Cylinders......................................................550 Lift Pump and Motor Assembly........................................551 tables......................................................................524 Table 1. Hydraulic Reservoir............................................533 Table 2. Relief Valve Settings..........................................548 1500202-4000SRM0965-(11-2006)-US-EN.............................................556 toc.........................................................................556 Lifting Mechanism.......................................................556 Safety Precautions Maintenance and Repair...............................557 General.................................................................560 Description of Operation................................................560 Load Wheel..............................................................560 Remove..............................................................560 Install.............................................................561 Caster Wheels...........................................................562 Caster Shim Check...................................................562 Caster Shim Adjustment..............................................563 Caster Replacement..................................................564 Disassemble.........................................................564 Assemble............................................................565 Caster Lubrication..................................................565 Rear Link and Load Wheel Assembly.......................................567 Remove..............................................................567 Install.............................................................569 Pull Rod................................................................571 Remove..............................................................571 End Replacement.....................................................571 Install.............................................................571 Adjust..............................................................572 Rear Fork Adjustment................................................573 Rocker Arm..............................................................574 Remove..............................................................574 Install.............................................................575 Upper Link..............................................................576 Remove..............................................................576 Install.............................................................576 Troubleshooting.........................................................577 1534737-2200SRM1058-(11-2006)-US-EN.............................................582 toc.........................................................................582 Troubleshooting and Adjustments Using the AC Controls Program (E........582 Safety Precautions Maintenance and Repair...............................583 General.................................................................586 Computer Requirements...............................................586 Software, Install...................................................586 Language Selection..................................................586 Demo Mode...........................................................587 Connect PC to Lift Truck............................................591 Starting AC Controls Program........................................592 Lift Truck Control Setup................................................597 Change Lift Truck Serial Number or Hourmeter........................597 Setting Factory Default Values or Changing Lift Truck Parameters....599 Create New Custom Lift Truck Configuration..........................604 Lift Truck Configuration Properties.................................607 Import New Lift Truck Configuration From Disk.......................611 Delete Custom Lift Truck Configuration or Password File.............613 Dash Display............................................................616 Custom Display Languages............................................616 Download Display Language...........................................619 Clear Operator Log..................................................621 Password Functions......................................................623 Enable/Disable Password and Lift Truck Inspection Functions.........623 Truck Inspection Checklist......................................623 Password........................................................623 Password Properties.................................................625 Create New Password File............................................628 Download Passwords..................................................630 Upload Passwords....................................................632 Reports Menu............................................................634 Devices Report......................................................634 Custom Report.......................................................636 Password Report.....................................................637 Operator Report.....................................................642 Current Settings Report.............................................645 Status Code Report..................................................647 Status Codes Log....................................................651 Troubleshooting.........................................................653 Diagnostics.........................................................653 Help Menu...............................................................656 General.............................................................656 Contents............................................................656 Technical Support...................................................659 About Electric Truck AC Controls Program............................661 1640802-0620SRM1283-(11-2006)-US-EN.............................................666 toc.........................................................................666 AC Motor Repair.........................................................666 Safety Precautions Maintenance and Repair...............................667 General.................................................................670 Accessing the Drive Unit Compartment................................670 Special Precautions.....................................................671 Discharging the Capacitors..........................................671 Description.............................................................672 AC Motor Repair.........................................................672 Remove..............................................................672 Disassemble.........................................................672 Inspect.............................................................674 Assemble............................................................674 Install.............................................................674 Troubleshooting.........................................................675 1640803-1600SRM1284-(07-2008)-US-EN.............................................680 toc.........................................................................680 Steering Mechanism......................................................680 Safety Precautions Maintenance and Repair...............................681 General.................................................................684 Accessing the Drive Unit Compartment................................684 Special Precautions.....................................................685 Discharging the Capacitors..........................................685 Calibration.............................................................686 Power Assist Steering Sensor........................................686 Control Handle..........................................................686 Control Handle Head.................................................686 Control Handle......................................................686 Standard Steering...............................................686 Remove......................................................687 Install.....................................................687 Power Assist Steering...........................................689 Remove......................................................689 Install.....................................................690 Gas Spring..............................................................694 Discharging the Gas Spring..........................................694 Remove .............................................................695 Install ............................................................695 Articulating Shaft and Pinions (Power Assist Models)....................696 Remove..............................................................696 Pinion Repair.......................................................697 Upper Pinion....................................................697 Lower Pinion....................................................698 Install.............................................................699 Steer Motor Assembly....................................................700 Repair..............................................................700 Steer Motor, Replace............................................700 Steer Motor Gear, Replace.......................................701 Gearbox/Complete Assembly, Replace..............................701 Steer Support Assembly..................................................702 Standard Steering...................................................702 Remove (Complete Unit)..........................................702 Disassemble.....................................................702 Assemble........................................................704 Install (Complete Unit).........................................704 Power Assist Steering...............................................706 Remove (Complete Unit)..........................................706 Disassemble.....................................................706 Support Base................................................706 Steer Swivel................................................707 Assemble........................................................707 Steer Swivel................................................707 Support Base................................................708 Install (Complete Unit).........................................709 Coast Control Option....................................................710 Disassemble.........................................................710 Assemble............................................................712 Checks..............................................................712 Troubleshooting.........................................................713 1640803-1600SRM1284-(12-2006)-US-EN.............................................716 toc.........................................................................716 Steering Mechanism......................................................716 Safety Precautions Maintenance and Repair...............................717 General.................................................................720 Accessing the Drive Unit Compartment................................720 Special Precautions.....................................................721 Discharging the Capacitors..........................................721 Calibration.............................................................722 Power Assist Steering Sensor........................................722 Control Handle..........................................................722 Control Handle Head.................................................722 Control Handle......................................................722 Standard Steering...............................................722 Remove......................................................723 Install.....................................................723 Power Assist Steering...........................................725 Remove......................................................725 Install.....................................................726 Gas Spring..............................................................730 Discharging the Gas Spring..........................................730 Remove..............................................................730 Install.............................................................731 Articulating Shaft and Pinions (Power Assist Models)....................732 Remove..............................................................732 Pinion Repair.......................................................733 Upper Pinion....................................................733 Lower Pinion....................................................734 Install.............................................................735 Steer Motor Assembly....................................................735 Repair..............................................................735 Steer Motor, Replace............................................735 Steer Motor Gear, Replace.......................................736 Gearbox/Complete Assembly, Replace..............................737 Steer Support Assembly..................................................737 Standard Steering...................................................737 Remove (Complete Unit)..........................................737 Disassemble.....................................................738 Assemble........................................................738 Install (Complete Unit).........................................739 Power Assist Steering...............................................741 Remove (Complete Unit)..........................................741 Disassemble.....................................................741 Support Base................................................741 Steer Swivel................................................742 Assemble........................................................743 Steer Swivel................................................743 Support Base................................................743 Install (Complete Unit).........................................744 Troubleshooting.........................................................745 1640804-1800SRM1285-(01-2007)-US-EN.............................................748 toc.........................................................................748 Brakes..................................................................748 Safety Precautions Maintenance and Repair...............................749 General.................................................................752 Accessing the Drive Unit Compartment................................752 Description.............................................................753 Special Precautions.....................................................754 Brake Check.............................................................755 Brake Release.......................................................755 Brake Apply.........................................................755 Air Gap.............................................................755 Hold On Grade Test..................................................757 Brake Assembly Repair...................................................757 B60Z AC.............................................................757 Remove..........................................................757 Repair..........................................................758 Install.........................................................758 B80Z AC.............................................................759 Remove..........................................................759 Repair..........................................................759 Install.........................................................760 Troubleshooting.........................................................761 tables......................................................................748 Table 1. Stator Resistance..............................................755 Table 2. Adjustment Specifications......................................756 1640805-2200SRM1286-(05-2007)-US-EN.............................................766 toc.........................................................................766 AC Motor Controller.....................................................766 Safety Precautions Maintenance and Repair...............................767 General.................................................................770 Discharging the Capacitors..........................................770 Description.............................................................771 Electrical System...................................................771 AC Traction Motor...............................................772 Controller......................................................772 Service PC Connection...........................................772 Parameters..............................................................772 General.............................................................772 Parameter Description...................................................773 Parameters..........................................................773 Extended Shift..................................................773 Walk Speed (Both Directions)....................................773 Hi Speed (FWD)..................................................774 Hi Speed (REV)..................................................774 Minimum Acceleration............................................774 Maximum Acceleration............................................774 Plugging........................................................774 ADS-Throttle....................................................774 ADS-Neutral.....................................................774 Pick Acceleration...............................................774 Pick Deceleration...............................................774 Battery Full Voltage............................................774 Battery Empty Voltage...........................................774 Min Steering Assist (High Speed FWD)............................774 Min Steering Assist (High Speed REV)............................774 Maximum Steering Assist ........................................775 Troubleshooting.........................................................775 General.............................................................775 Status Codes........................................................775 Dash Display............................................................821 General.............................................................821 Startup.............................................................821 Status LED..........................................................821 Performance Mode Indicator..........................................821 Hourmeter...........................................................822 Battery Charge Indicator............................................822 Fault Log...........................................................822 Connector Pin-Outs......................................................823 System Logic Diagram....................................................824 tables......................................................................766 Table 1. Parameter Default Values.......................................773 Table 2. Fault Codes....................................................776 1640806-2200SRM1287-(11-2006)-US-EN.............................................828 toc.........................................................................828 Electrical System.......................................................828 Safety Precautions Maintenance and Repair...............................829 General.................................................................832 Accessing the Drive Unit Compartment................................833 Special Precautions.....................................................834 Discharging the Capacitors..........................................834 Electrical System Checks................................................835 Safety Precautions..................................................835 Calibration.............................................................838 Calibration Mode....................................................838 Repairs.................................................................838 Controller, Replace.................................................838 Remove..........................................................838 Install.........................................................839 Contactor Coil, Check...............................................840 Contactor, Replace..................................................840 Fuses...................................................................840 Horn....................................................................841 Replace.............................................................841 Brake Switch Operation..................................................841 Brake and Interlock Switches - (Manual Steering)........................842 Disassemble.........................................................842 Assemble............................................................842 Brake Switch and Handle Position Sensor - (Power Assist Steering........843 Brake Switch........................................................843 Handle Potentiometer Sensor.........................................844 Disassemble.....................................................844 Assemble........................................................846 Height Limit............................................................848 Control Handle..........................................................848 Disassemble.........................................................848 Assemble............................................................848 Remote Control Box Switches.............................................850 Remove..............................................................850 Install.............................................................850 Motor Tests.............................................................851 Excessive Current Draw..............................................851 Measuring Current Draw..............................................852 Excessive Resistance................................................852 Troubleshooting.........................................................852 tables......................................................................828 Table 1. Voltage Checks.................................................837 1640808-8000SRM1288-(02-2007)-US-EN.............................................856 toc.........................................................................856 Diagrams................................................................856 Safety Precautions Maintenance and Repair...............................857 1644779-8000SRM1298-(11-2006)-US-EN.............................................870 toc.........................................................................870 Periodic Maintenance....................................................870 Safety Precautions Maintenance and Repair...............................871 General.................................................................874 How to Move a Disabled Truck........................................874 How to Tow the Lift Truck.......................................875 How to Put a Lift Truck on Blocks...................................875 How to Raise Drive/Steer Tire...................................875 How to Raise Load Wheels........................................876 Accessing the Drive Unit Compartment................................876 Special Precautions.....................................................877 Discharging the Capacitors..........................................877 Welding Repairs.........................................................879 Maintenance Schedule....................................................879 Maintenance Procedures Every 8 Hours or Daily...........................883 Checks With Key Switch Turned OFF...................................883 Battery.........................................................883 Hydraulic Leaks.................................................883 Drive Tire, Load Wheels, Casters, and Frame.....................884 Checks With Key Switch Turned ON....................................885 Operation.......................................................885 Maintenance Procedures Every 250 Hours or Every 6 Weeks.................887 Caster Lubrication..................................................887 Maintenance Procedures Every 500 Hours or Every 3 Months ...............888 Hydraulic System....................................................888 Hydraulic Oil...................................................888 Hydraulic Reservoir Breather....................................888 Steering System.....................................................888 Power Assist Steering...........................................888 Lift Linkage and Load Wheels........................................889 Casters.............................................................889 Caster Shim Check...............................................889 Caster Shim Adjust..............................................890 Master Drive Unit...................................................891 Change Gear Oil.................................................891 Check Oil Level.................................................891 Drive Tire Check....................................................892 Maintenance Procedures Every 2000 Hours or Yearly.......................892 Lubrication.........................................................892 Repack Load Wheel Bearings......................................892 Repack Steer Bearings (Manual Steer Only) ......................892 Hydraulic System....................................................892 Oil Change......................................................892 Brake...............................................................893 Electrical..........................................................893 MDU.................................................................893 Oil Change......................................................893 Battery Maintenance.....................................................894 How to Charge the Battery...........................................894 Equalizing Charge...............................................894 Normal Charge...................................................894 How to Change the Battery...........................................895 Transporting............................................................896 Loading.............................................................896 Unloading...........................................................896 Preparation for Storage.................................................897 Short-Term Storage (1 to 6 months)..................................897 Long-Term Storage (6 months or longer)..............................897 Preparation for Use.....................................................897 Preparation After Shipment..........................................897 Preparation After Storage...........................................897 tables......................................................................870 Table 1. Maintenance Schedule...........................................880 Table 2. Specific Gravity Corrections...................................894 1644780-8000SRM1299-(11-2006)-US-EN.............................................900 toc.........................................................................900 Capacities and Specifications...........................................900 Safety Precautions Maintenance and Repair...............................901 Hydraulic System........................................................904 Hydraulic Oils..........................................................905 Gear Oils...............................................................905 Grease..................................................................905 Truck Weight............................................................906 Tire Sizes..............................................................906 Torque Specifications...................................................907 Caster Assembly.....................................................907 Drive Wheel Assembly................................................907 Master Drive Unit...................................................907 Standard Steering...................................................907 Power Assist Steering...............................................907 Brake...............................................................907 Electrical..........................................................907 Lift Mechanism......................................................907 Hydraulics..........................................................907 Battery Specifications..................................................908 tables......................................................................900 Table 1. B60Z AC........................................................908 Table 2. B80Z AC........................................................909 1654668-2200SRM1323-(05-2007)-US-EN.............................................912 toc.........................................................................912 User Interface..........................................................912 Safety Precautions Maintenance and Repair...............................913 General.................................................................916 Description.........................................................916 Dash Display Menu Access............................................916 Menu Navigation.........................................................917 Dash Display Versions...................................................919 Supervisor Menu.........................................................920 View Versions.......................................................920 Hourmeters..........................................................921 Diagnostics.........................................................921 Fault Log.......................................................922 Controller Inputs...............................................922 Control Handle Inputs...........................................923 Run Diagnostics.................................................923 Traction Motor..............................................925 Pump Motor and Valve........................................925 Control Handle..............................................926 Temperatures................................................926 Power Steering..............................................927 Service Reminder....................................................927 Change Supervisor Password..........................................927 Operator Modes......................................................928 Exit to Run Mode....................................................928 tables......................................................................912 Table 1. Supervisor Menu................................................920 Table 2. Diagnostics Menu...............................................921 Table 3. Controller Inputs..............................................922 Table 4. Control Handle Inputs..........................................923 Table 5. Run Diagnostics Menu...........................................924 1654669-2200SRM1324-(05-2007)-US-EN.............................................932 toc.........................................................................932 User Interface..........................................................932 Safety Precautions Maintenance and Repair...............................933 General.................................................................936 Description.........................................................936 Dash Display Menu Access............................................936 Menu Navigation.........................................................937 Dash Display Versions...................................................939 Technician Menu.........................................................940 View Versions.......................................................941 Hourmeters..........................................................941 Diagnostics.........................................................941 Fault Log.......................................................942 Controller Inputs...............................................942 Steer Handle Inputs.............................................943 Run Diagnostics.................................................943 Traction Motor..............................................945 Pump Motor and Valve........................................945 Control Handle..............................................946 Temperatures................................................946 Power Steering..............................................947 Service Reminder....................................................947 Change Supervisor Password..........................................948 Operator Modes......................................................948 Set Performance.....................................................949 Extended Shift..................................................950 Walk Speed......................................................950 High Speed (FWD)................................................951 High Speed (REV)................................................951 Minimum Acceleration............................................951 Maximum Acceleration............................................952 Plugging........................................................952 ADS-Neutral.....................................................952 ADS-Throttle....................................................953 Pick Acceleration...............................................953 Pick Deceleration...............................................953 Battery Full....................................................954 Lift Interrupt..................................................954 Min Steer Assist FWD (Power Steering Assist Only)...............954 Min Steer Assist REV (Power Steering Assist Only)...............955 Max Steer Assist (Power Steering Assist Only)...................955 Defaults........................................................955 Save and Exit...................................................956 Exit Without Saving.............................................956 Set General Items...................................................956 A/V Alarm (Audible/Visual)......................................957 Clear Fault Log.....................................................957 Calibrations........................................................958 Throttle........................................................958 Steer Handle (Power Steering Assist Only).......................959 Change Service Technician Password..................................959 Exit to Run Mode....................................................960 tables......................................................................932 Table 1. Technician Menu................................................940 Table 2. Diagnostics Menu...............................................942 Table 3. Controller Inputs..............................................942 Table 4. Steer Handle Inputs............................................943 Table 5. Run Diagnostics Menu...........................................944 Table 6. Performance Parameters.........................................949 Table 7. Set Performance Menu...........................................949 Table 8. Set General Items Menu.........................................956 Table 9. Calibrations Menu..............................................958
HYSTER B230 B233 (B60Z AC B80Z AC) SERVICE MANUAL – PDF DOWNLOAD:
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