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Hyster B60Z ACB230 B80Z ACB233 service manual – PDF DOWNLOAD
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Description
Hyster B60Z ACB230 B80Z ACB233 service manual
File Details:
Hyster B60Z ACB230 B80Z ACB233 service manual
Language : English
Pages : 449
Size : 43.5 MB
Downloadable : Yes
Format : PDF
HYSTER B60Z ACB230 B80Z ACB233 SERVICE MANUAL – PDF DOWNLOAD:
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Description:
Hyster B60Z ACB230 B80Z ACB233 service manual
- This section describes the Iskra® motor controller and dash display used in B60ZAC and B80ZAC lift trucks. Procedures are outlined for controller programming and troubleshooting.
- DISCHARGING THE CAPACITORS WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. DO NOT use a screwdriver to discharge the traction motor controller.
- WARNING To avoid personal injury and prevent electrical shock, perform the following steps before performing any troubleshooting or adjustments, and connecting or disconnecting a handset or PC
- . CAUTION To avoid controller damage, always disconnect the battery. Discharge the capacitor and never put power to the controller with any power wire disconnected. Never short any controller terminal or motor terminal to battery. Make sure to use proper procedures when servicing the controller. 1. Move the truck to a safe, level area. Turn the key switch to the OFF position and disconnect the battery.
Table of Contents:
Hyster B60Z ACB230 B80Z ACB233 service manual
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 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 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 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 toc......................................................................... 95 Diagrams................................................................ 95 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 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 toc.........................................................................142 Frame...................................................................142 General.................................................................144 Frame Separation and Assembly...........................................144 Frame Separation....................................................144 Frame Assembly......................................................144 Painting Instructions...................................................146 Label Replacement.......................................................146 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 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 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 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 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 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 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 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 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 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
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
