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Hyster C215 (W40Z W45Z W50Z) Service Manual – PDF DOWNLOAD
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Hyster C215 (W40Z W45Z W50Z) Service Manual – PDF DOWNLOAD
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Description
Hyster C215 (W40Z W45Z W50Z) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster C215 (W40Z W45Z W50Z) Service Manual – PDF DOWNLOAD
Language : English
Pages : 344
Downloadable : Yes
File Type : PDF
Size: 15.7 MB
TABLE OF CONTENTS:
Hyster C215 (W40Z W45Z W50Z) Service Manual – PDF DOWNLOAD
Brakes............................................................. 1 toc............................................................ 1 Brakes..................................................... 1 General.................................................... 3 Description................................................ 3 Special Precautions........................................ 4 Brake Assembly Repair...................................... 5 Brake Override......................................... 5 Remove................................................. 6 Repair................................................. 8 Install................................................ 9 Troubleshooting............................................ 10 Capacities and Specifications...................................... 12 toc............................................................ 12 Capacities and Specifications.............................. 12 Hydraulic Oils............................................. 14 Gear Oils.................................................. 15 Grease..................................................... 16 Hydraulic System........................................... 17 Weight..................................................... 17 Basic Truck Without Battery............................ 17 Tires...................................................... 18 Torque Specifications...................................... 18 Caster Assembly........................................ 18 Master Drive Unit...................................... 18 Steering............................................... 18 Brake.................................................. 18 Lift Mechanism......................................... 18 Battery Specifications and Adjustments..................... 18 4000 LB - 24 Volt...................................... 18 4500 - 12 Volt......................................... 19 4500 and 5000 LB - 24 Volt............................. 20 DC Motor Maintenance............................................... 23 toc............................................................ 23 DC Motor Maintenance....................................... 23 General.................................................... 25 Brush and Commutator Inspection............................ 25 Hydraulic Pump Motor and Traction Motor................ 25 Steering Pump Motor.................................... 28 Normal Commutator Surface.............................. 29 Commutator Problems.................................... 29 Brush Replacement.......................................... 32 Stoning the Commutator..................................... 34 Motors Repair.............................................. 36 Disassemble............................................ 36 Traction Motor and Hydraulic Pump Motor............ 36 Steering Pump Motor................................ 38 Assemble............................................... 40 Traction Motor and Hydraulic Pump Motor............ 40 Steering Pump Motor................................ 41 Brush Alignment, Traction and Hydraulic Motors............. 43 Tests for Damaged Field and Armature....................... 43 Test for an Open Circuit in One Armature Winding....... 43 Test for Short Circuit in One Armature Winding......... 44 Test for Short Circuit to Armature Shaft............... 44 Test for Open Circuit in Field Coil.................... 44 Test for Short Circuit in Field Coil................... 45 Test for Short Circuit Between Field and Motor Case.... 45 Brush Holder Test...................................... 45 Troubleshooting............................................ 45 tables......................................................... 23 Table 1. Normal Commutator Surfaces........................ 28 Table 2. Commutator Problems............................... 29 Table 3. Brush Wear Replacement Guide...................... 32 Diagrams........................................................... 50 toc............................................................ 50 Diagrams................................................... 50 General Notes.............................................. 52 Electrical System.................................................. 67 toc............................................................ 67 Electrical System.......................................... 67 General.................................................... 70 Description of Operation................................... 71 Special Precautions........................................ 73 Moving a Disabled Lift Truck............................... 75 Electrical System Checks................................... 76 Safety Precautions..................................... 76 Repairs.................................................... 76 Controller, Replace.................................... 76 Remove............................................. 76 Install............................................ 79 Contactor Coil, Check.................................. 79 Contactor, Replace..................................... 79 Remove............................................. 79 Install............................................ 80 Key Switch Removal and Installation........................ 80 Remove................................................. 80 Install................................................ 80 Battery Indicator/Hourmeter Display........................ 80 Remove................................................. 81 Install................................................ 81 Fuses...................................................... 81 W40Z................................................... 81 W45-50Z................................................ 81 W20-25ZA............................................... 81 W25-30ZA 2............................................. 81 Control Handle Arm Proximity Switch........................ 82 Repair................................................. 82 Check and Adjust................................... 82 Remove............................................. 82 Install............................................ 83 Control Handle............................................. 83 Disassemble............................................ 83 Control Handle Card (Old Style)........................ 84 Control Handle Card (New Style)........................ 85 Configure.......................................... 85 Calibrate.......................................... 86 Assemble............................................... 87 Switches (ON/OFF and Proportional)..................... 89 Remove............................................. 89 Install............................................ 89 Traction Motor............................................. 90 Disassemble............................................ 90 Assemble............................................... 90 Lift Pump Motor............................................ 92 Repair ( W20-25ZA and W25-30ZA 2 )..................... 92 Lift Link Proximity Sensor (W50Z).......................... 93 Check.................................................. 93 Repair................................................. 93 Remove............................................. 93 Test............................................... 94 Install............................................ 94 Adjust............................................. 94 Battery Charger (Early Models)............................. 95 Description............................................ 95 Operation.............................................. 95 Charging........................................... 95 Equalize........................................... 95 Signals............................................ 95 Protections........................................ 95 Troubleshooting........................................ 95 Battery Charger (Late Models).............................. 98 Description............................................ 98 Operation.............................................. 98 LED Display........................................ 98 Charging........................................... 98 Troubleshooting........................................ 98 Battery Mode Selection (DPI Early Models).............. 99 Changing Mode Setting (DPI Early Models)...........100 Battery Mode Selection (DPI Late Models)...............100 Changing Mode Setting (DPI Late Models)............100 Troubleshooting............................................101 tables......................................................... 67 Table 1. Contactor Coil Resistance Values.................. 79 Table 2. Charger LEDs...................................... 98 Table 3. LED Codes......................................... 99 Table 4. Battery Modes..................................... 99 Table 5. Battery Modes.....................................100 Frame..............................................................103 toc............................................................103 Frame......................................................103 General....................................................105 Description............................................105 Frame Repair...............................................106 Features...............................................106 Frame Separation and Assembly..............................106 Separation.............................................106 Assembly...............................................106 Battery Compartment........................................107 Battery Compartment Specifications.....................107 Changing the Battery...................................107 Remove.............................................108 Install............................................108 Battery Spacer Adjustment..........................108 Label Replacement..........................................108 Painting Instructions......................................110 Load Wheels................................................110 Remove.................................................110 Install................................................110 Industrial Battery.................................................114 toc............................................................114 Industrial Battery.........................................114 General....................................................116 Lead-Acid Batteries........................................116 Specific Gravity...........................................117 Chemical Reaction in a Cell................................117 Electrical Terms...........................................118 Battery Selection..........................................119 Battery Voltage............................................120 Battery as a Counterweight.................................120 Battery Ratings............................................121 Kilowatt-Hours.........................................121 Battery Maintenance........................................121 Safety Procedures......................................121 Maintenance Records....................................122 New Battery............................................122 Cleaning Battery.......................................122 Adding Water to Battery................................124 Hydrometer.............................................125 Battery Temperature....................................125 Charging Battery.......................................126 Types of Battery Charges...........................127 Methods of Charging................................128 Troubleshooting Charger............................129 Knowing When Battery Is Fully Charged..............129 Where to Charge Batteries..............................129 Equipment Needed...................................129 Battery Connectors.....................................130 Battery Care...........................................130 tables.........................................................114 Table 1. Battery Capacity Terms............................121 Lifting Mechanism..................................................133 toc............................................................133 Lifting Mechanism..........................................133 General....................................................135 Lift Linkage...........................................135 Load Wheel.................................................136 Remove.................................................136 Install................................................136 Rear Link and Load Wheel...................................137 Remove.................................................137 Install................................................138 Compression Rod............................................138 Remove.................................................138 Install................................................139 Lower Link.................................................139 Remove.................................................139 Install................................................139 Upper Link.................................................140 Remove.................................................140 Install................................................141 Caster Wheels (Optional)...................................142 Remove.................................................142 Install................................................142 Replace................................................142 Master Drive Unit..................................................144 toc............................................................144 Master Drive Unit..........................................144 General....................................................146 Description................................................146 Special Precautions........................................146 Master Drive Unit Repair...................................148 Remove.................................................148 Disassemble............................................150 Repair.................................................151 Assemble...............................................151 Install................................................151 Troubleshooting............................................152 Metric and Inch (SAE) Fasteners....................................155 toc............................................................155 Metric and Inch (SAE) Fasteners............................155 General....................................................157 Threaded Fasteners.....................................157 Nomenclature, Threads..................................157 Strength Identification................................158 Cotter (Split) Pins....................................158 Fastener Torque Tables.................................163 Conversion Table.......................................165 tables.........................................................155 Table 1. Bolts and Screws..................................159 Table 2. Studs and Nuts....................................160 Table 3. Torque Nuts.......................................161 Table 4. Torque Nuts With Nylon Insert.....................162 Table 5. Torque Values for Metric Fasteners*...............163 Table 6. Torque Values for Inch Fasteners*.................164 Table 7. Conversion Table for Metric and English Units.....165 Table 8. Cotter Pin Dimensional Data.......................166 Table 9. Cotter Pin Dimensional Data.......................167 Table 10. Cotter Pin Dimensional Data......................168 Table 11. Cotter Pin Dimensional Data......................170 Periodic Maintenance...............................................174 toc............................................................174 Periodic Maintenance.......................................174 General....................................................176 How to Move a Disabled Truck...........................176 How to Tow the Lift Truck..........................176 How to Put a Lift Truck on Blocks......................177 How to Raise Drive/Steer Tire......................178 How to Raise Load Wheels...........................178 Welding Repairs........................................178 Battery Maintenance........................................179 How to Charge the Battery..............................179 Equalizing Charge..................................179 Normal Charge......................................179 Maintenance-Free Battery Charger...................180 Battery Charger ( W40Z Only).......................180 How to Change the Battery..............................180 Maintenance Schedule.......................................181 Checks and Inspection Procedures.......................181 Hydraulic System...................................182 Lifting Mechanism..................................183 Controls...........................................183 Electrical and Battery.............................184 Wheels and Tires...................................185 Casters................................................185 Recommended Schedule of Maintenance........................186 Lubrication Instructions...................................191 Every 8 Hours or Daily.................................191 Every 350 Hours or 6 Months............................191 Check Hydraulic Oil Level..........................191 Every 2000 Hours or 2 Years............................192 To Fill Hydraulic Reservoir........................192 tables.........................................................174 Table 1. Specific Gravity Corrections......................179 Steering Mechanism.................................................197 toc............................................................197 Steering Mechanism.........................................197 General....................................................199 Special Precautions........................................199 Control Handle Head........................................200 Control Handle.............................................200 Remove.................................................200 Install................................................201 Gas Spring.................................................203 Discharging the Gas Spring.............................203 Troubleshooting............................................204 Walkie Hydraulic Systems...........................................206 toc............................................................206 Walkie Hydraulic Systems...................................206 General....................................................208 Operation..................................................208 Lifting a Load.........................................208 Lowering a Load........................................208 Hydraulic Lines........................................208 Hydraulic Oil..........................................209 Cleanliness............................................209 Sound Level............................................210 Hydraulic Unit.............................................211 Remove.................................................211 Special Precautions....................................211 Install................................................212 Hydraulic Pump.............................................212 Remove.................................................212 Install................................................212 Hydraulic Pump Reservoir...................................214 Remove.................................................214 Install................................................214 Hydraulic Cylinder.........................................215 Remove.................................................215 Repacking..............................................215 Install................................................216 Relief Valve Adjustment....................................217 Relief Valve Pressure Check............................217 Relief Valve Adjust....................................218 Troubleshooting............................................219 Lift Assemblies........................................219 Hydraulic Cylinders....................................220 Hydraulic Pump.........................................221 tables.........................................................206 Table 1. Relief Valve Settings.............................218 ZAPI™ Controllers (2)..............................................225 toc............................................................225 ZAPI™ Controllers..........................................225 General....................................................227 Description................................................228 ZAPI™ Transistor Motor Controller......................228 Principles of Operation................................229 Controller Safety..........................................229 Controller Adjustments.....................................230 Modes of Operation.........................................230 User-Selectable Operating Modes........................230 Programming................................................231 Custom Performance Mode................................231 Controller Parameters..................................231 Tester Menu............................................232 Set Option Menu........................................232 ZAPI™ Handset..........................................233 Troubleshooting............................................236 ZAPI™ PC Interface.........................................259 Connecting PC to ZAPI™ Controller......................259 File Menu..............................................262 Open File..........................................262 TX From File.......................................263 Save File..........................................265 Print Settings.....................................267 Exit...............................................268 Connection Menu........................................269 Function Menu..........................................269 Parameter..........................................270 Memory Menu........................................274 Set Options........................................275 Tester.............................................277 Data Logger........................................279 Alarm Logbook......................................282 Alarms.............................................283 Repair.....................................................284 Remove.................................................284 Brass Stud Replacement.................................284 Remove.............................................284 Install............................................284 Install................................................284 Repair.................................................284 tables.........................................................225 Table 1. Parameters........................................231 ZAPI™ Controllers..................................................286 toc............................................................286 ZAPI™ Controllers..........................................286 General....................................................288 Description................................................289 ZAPI™ Transistor Motor Controller......................289 Principles of Operation................................289 Controller Safety..........................................290 Controller Adjustments.....................................290 Modes of Operation.........................................291 User-Selectable Operating Modes........................291 Programming................................................291 Custom Performance Mode................................291 Controller Parameters..................................291 Tester Menu............................................292 Set Option Menu........................................293 ZAPI™ Handset..........................................293 Troubleshooting............................................297 ZAPI™ PC Interface.........................................317 Connecting PC to ZAPI™ Controller......................317 File Menu..............................................320 Open File..........................................320 TX From File.......................................321 Save File..........................................323 Print Settings.....................................325 Exit...............................................326 Connection Menu........................................327 Function Menu..........................................327 Parameter..........................................328 Memory Menu........................................332 Set Options........................................333 Tester.............................................335 Data Logger........................................337 Alarm Logbook......................................340 Alarms.............................................341 Repair.....................................................342 Remove.................................................342 Brass Stud Replacement.................................342 Remove.............................................342 Install............................................342 Install................................................342 Repair.................................................342 tables.........................................................286 Table 1. Parameters........................................292
HYSTER C215 (W40Z W45Z W50Z) SERVICE MANUAL – PDF DOWNLOAD:
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