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Hyster D233 (E80ZAC) Service Manual – PDF DOWNLOAD
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Hyster D233 (E80ZAC) Service Manual – PDF DOWNLOAD
PART NO. 1640805
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Description
Hyster D233 (E80ZAC) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster D233 (E80ZAC) Service Manual – PDF DOWNLOAD
PART NO. 1640805
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies,make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOWTO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster D233 (E80ZAC) Service Manual – PDF DOWNLOAD
AC Motor Controller (1)................................................................. 1 toc................................................................................. 1 AC Motor Controller............................................................. 1 Safety Precautions Maintenance and Repair....................................... 2 General......................................................................... 5 Discharging the Capacitors.................................................. 5 Description..................................................................... 6 Electrical System........................................................... 6 AC Traction Motor....................................................... 7 Controller.............................................................. 7 Service PC Connection................................................... 7 Parameters...................................................................... 7 General..................................................................... 7 Parameter Description........................................................... 9 Parameters.................................................................. 9 Extended Shift.......................................................... 9 Walk Speed (Both Directions)............................................ 9 Hi Speed (FWD).......................................................... 9 Hi Speed (REV).......................................................... 9 Minimum Acceleration.................................................... 9 Maximum Acceleration.................................................... 9 Plugging................................................................ 9 ADS-Neutral............................................................. 9 ADS-Throttle............................................................ 9 Pick Acceleration....................................................... 9 Pick Deceleration....................................................... 10 Battery Full Voltage.................................................... 10 Lift Interrupt.......................................................... 10 Troubleshooting................................................................. 10 General..................................................................... 10 Non-Status Code Errors...................................................... 11 Powered Black Screen.................................................... 11 Tiller Oscillation and Bias (EPAS Option)............................... 12 Status Codes................................................................ 12 Electrical Checks...............................................................105 General Electrical System Checks............................................105 Static Checks on Power and Ground Connections...............................105 Static Checks on CAN Connections............................................106 Tiller Harness Shorts and Continuity Checks.................................107 Control Card Functional Test....................................................108 Dash Display....................................................................111 General.....................................................................111 Startup.....................................................................111 Status LED..................................................................111 Performance Mode Indicator..................................................111 Hourmeter...................................................................112 Battery Charge Indicator....................................................112 Fault Log...................................................................112 Connector Pin-Outs..............................................................113 System Logic Diagram............................................................114 tables.............................................................................. 1 Table 1. Parameter Default Values............................................... 8 Table 2. Fault Codes............................................................ 13 AC Motor Controller.....................................................................117 toc.................................................................................117 AC Motor Controller.............................................................117 Safety Precautions Maintenance and Repair.......................................118 General.........................................................................121 Discharging the Capacitors..................................................121 Description.....................................................................122 Electrical System...........................................................122 AC Traction Motor.......................................................123 Controller..............................................................123 Service PC Connection...................................................123 Parameters......................................................................123 General.....................................................................123 Parameter Description...........................................................125 Parameters..................................................................125 Extended Shift..........................................................125 Walk Speed (Both Directions)............................................125 Hi Speed (FWD)..........................................................125 Hi Speed (REV)..........................................................125 Minimum Acceleration....................................................125 Maximum Acceleration....................................................125 Plugging................................................................125 ADS-Neutral.............................................................125 ADS-Throttle............................................................125 Pick Acceleration.......................................................125 Pick Deceleration.......................................................126 Battery Full Voltage....................................................126 Lift Interrupt..........................................................126 Troubleshooting.................................................................126 General.....................................................................126 Non-Status Code Errors......................................................127 Powered Black Screen....................................................127 Tiller Oscillation and Bias (EPAS Option)...............................128 Status Codes................................................................128 Electrical Checks...............................................................221 General Electrical System Checks............................................221 Static Checks on Power and Ground Connections...............................221 Static Checks on CAN Connections............................................222 Tiller Harness Shorts and Continuity Checks.................................223 Control Card Functional Test....................................................224 Dash Display....................................................................227 General.....................................................................227 Startup.....................................................................227 Status LED..................................................................227 Performance Mode Indicator..................................................227 Hourmeter...................................................................228 Battery Charge Indicator....................................................228 Fault Log...................................................................228 Connector Pin-Outs..............................................................229 System Logic Diagram............................................................230 tables..............................................................................117 Table 1. Parameter Default Values...............................................124 Table 2. Fault Codes............................................................129 Brakes (1)..............................................................................233 toc.................................................................................233 Brakes..........................................................................233 Safety Precautions Maintenance and Repair.......................................234 General.........................................................................237 Accessing the Drive Unit Compartment........................................237 B60-80Z AC and B60-80Z HD...............................................237 C60-80Z AC and T5-7Z AC.................................................238 Description.....................................................................239 Special Precautions.............................................................241 Brake Check.....................................................................242 Brake Release...............................................................242 Brake Apply.................................................................242 Air Gap.....................................................................242 Hold On Grade Test..........................................................244 Brake Assembly Repair...........................................................244 B60Z AC, C60Z AC, T5Z AC, and B60Z HD.......................................244 Remove..................................................................244 Repair..................................................................245 Install.................................................................245 B80Z AC, C80Z AC, T7Z AC, B80Z HD...........................................246 Remove..................................................................246 Repair..................................................................246 Install.................................................................247 Troubleshooting.................................................................248 tables..............................................................................233 Table 1. Stator Resistance......................................................242 Table 2. Adjustment Specifications..............................................243 Brakes..................................................................................253 toc.................................................................................253 Brakes..........................................................................253 Safety Precautions Maintenance and Repair.......................................254 General.........................................................................257 Accessing the Drive Unit Compartment........................................257 B60-80Z AC and B60-80Z HD...............................................257 C60-80Z AC and T5-7Z AC.................................................258 Description.....................................................................259 Special Precautions.............................................................261 Brake Check.....................................................................262 Brake Release...............................................................262 Brake Apply.................................................................262 Air Gap.....................................................................262 Hold On Grade Test..........................................................264 Brake Assembly Repair...........................................................264 B60Z AC, C60Z AC, T5Z AC, and B60Z HD.......................................264 Remove..................................................................264 Repair..................................................................265 Install.................................................................265 B80Z AC, C80Z AC, T7Z AC, B80Z HD...........................................266 Remove..................................................................266 Repair..................................................................266 Install.................................................................267 Troubleshooting.................................................................268 tables..............................................................................253 Table 1. Stator Resistance......................................................262 Table 2. Adjustment Specifications..............................................263 Diagrams (1)............................................................................273 toc.................................................................................273 Diagrams........................................................................273 Safety Precautions Maintenance and Repair.......................................274 Diagrams................................................................................293 toc.................................................................................293 Diagrams........................................................................293 Safety Precautions Maintenance and Repair.......................................294 Elect. System (1).......................................................................313 toc.................................................................................313 Electrical System...............................................................313 Safety Precautions Maintenance and Repair.......................................314 General.........................................................................317 Accessing the Drive Unit Compartment........................................318 Special Precautions.............................................................319 Discharging the Capacitors..................................................319 Electromagnetic Shield (Power Assist Steering 6/2009⇒)......................320 Electrical System Checks........................................................320 Safety Precautions..........................................................320 Calibration.....................................................................323 Calibration Mode............................................................323 Power Assist Steering Sensor................................................323 Repairs.........................................................................324 Controller, Replace.........................................................324 Remove..................................................................324 Install.................................................................325 Contactor Coil, Check.......................................................325 Contactor, Replace..........................................................326 Fuses...........................................................................326 Horn............................................................................326 Replace.....................................................................326 Brake Switch Operation..........................................................327 Brake and Interlock Switches - (Manual Steering)................................327 Disassemble.................................................................327 Assemble....................................................................327 Brake Switch and Handle Position Sensor - (Power Assist Steering................328 Brake Switch(es)............................................................328 Handle Potentiometer Sensor (Power Assist Steering ⇒5/2009).................329 Disassemble.............................................................329 Assemble................................................................330 Height Limit....................................................................333 Control Handle (Standard).......................................................334 Disassemble.................................................................334 Assemble....................................................................334 Proximity Switch (Power Assist Steering 6/2009⇒)................................336 Remove......................................................................336 Install.....................................................................336 Remote Control Box Switches.....................................................336 Remove......................................................................336 Install.....................................................................337 Motor Tests.....................................................................338 Excessive Current Draw......................................................338 Measuring Current Draw......................................................339 Excessive Resistance........................................................339 Troubleshooting.................................................................339 tables..............................................................................313 Table 1. Voltage Checks.........................................................322 Elect. System...........................................................................343 toc.................................................................................343 Electrical System...............................................................343 Safety Precautions Maintenance and Repair.......................................344 General.........................................................................347 Accessing the Drive Unit Compartment........................................348 Special Precautions.............................................................349 Discharging the Capacitors..................................................349 Electromagnetic Shield (Power Assist Steering 6/2009⇒)......................350 Electrical System Checks........................................................350 Safety Precautions..........................................................350 Calibration.....................................................................353 Calibration Mode............................................................353 Power Assist Steering Sensor................................................353 Repairs.........................................................................354 Controller, Replace.........................................................354 Remove..................................................................354 Install.................................................................355 Contactor Coil, Check.......................................................355 Contactor, Replace..........................................................356 Fuses...........................................................................356 Horn............................................................................356 Replace.....................................................................356 Brake Switch Operation..........................................................357 Brake and Interlock Switches - (Manual Steering)................................357 Disassemble.................................................................357 Assemble....................................................................357 Brake Switch and Handle Position Sensor - (Power Assist Steering................358 Brake Switch(es)............................................................358 Handle Potentiometer Sensor (Power Assist Steering ⇒5/2009).................359 Disassemble.............................................................359 Assemble................................................................360 Height Limit....................................................................363 Control Handle (Standard).......................................................364 Disassemble.................................................................364 Assemble....................................................................364 Proximity Switch (Power Assist Steering 6/2009⇒)................................366 Remove......................................................................366 Install.....................................................................366 Remote Control Box Switches.....................................................366 Remove......................................................................366 Install.....................................................................367 Motor Tests.....................................................................368 Excessive Current Draw......................................................368 Measuring Current Draw......................................................369 Excessive Resistance........................................................369 Troubleshooting.................................................................369 tables..............................................................................343 Table 1. Voltage Checks.........................................................352 ETACC Troubleshooting (1)...............................................................373 toc.................................................................................373 Troubleshooting and Adjustments Using the AC Controls Program (E................373 Safety Precautions Maintenance and Repair.......................................374 General.........................................................................377 Computer Requirements.......................................................377 Software, Install...........................................................377 Language Selection..........................................................377 Demo Mode...................................................................378 Connect PC to Lift Truck....................................................382 Starting AC Controls Program................................................383 Lift Truck Control Setup........................................................388 Change Lift Truck Serial Number or Hourmeter................................388 Setting Factory Default Values or Changing Lift Truck Parameters............390 Create New Custom Lift Truck Configuration..................................396 Lift Truck Configuration Properties.........................................399 Import New Lift Truck Configuration From Disk...............................402 Delete Custom Lift Truck Configuration or Password File.....................404 Dash Display....................................................................407 Custom Display Languages....................................................407 Download Display Language...................................................409 Clear Operator Log..........................................................409 Password Functions..............................................................412 Enable/Disable Password and Lift Truck Inspection Functions.................412 Truck Inspection Checklist..............................................412 Password................................................................412 Password Properties.........................................................412 Create New Password File....................................................417 Download Passwords..........................................................419 Upload Passwords............................................................419 Reports Menu....................................................................423 Devices Report..............................................................423 Custom Report...............................................................423 Password Report.............................................................423 Operator Report.............................................................430 Current Settings Report.....................................................433 Status Code Report..........................................................436 Status Codes Log............................................................439 Troubleshooting.................................................................441 Diagnostics.................................................................441 Help Menu.......................................................................444 General.....................................................................444 Contents....................................................................444 Technical Support...........................................................444 About Electric Truck AC Controls Program....................................444 ETACC Troubleshooting...................................................................451 toc.................................................................................451 Troubleshooting and Adjustments Using the AC Controls Program (E................451 Safety Precautions Maintenance and Repair.......................................452 General.........................................................................455 Computer Requirements.......................................................455 Software, Install...........................................................455 Language Selection..........................................................455 Demo Mode...................................................................456 Connect PC to Lift Truck....................................................460 Starting AC Controls Program................................................461 Lift Truck Control Setup........................................................466 Change Lift Truck Serial Number or Hourmeter................................466 Setting Factory Default Values or Changing Lift Truck Parameters............468 Create New Custom Lift Truck Configuration..................................474 Lift Truck Configuration Properties.........................................477 Import New Lift Truck Configuration From Disk...............................480 Delete Custom Lift Truck Configuration or Password File.....................482 Dash Display....................................................................485 Custom Display Languages....................................................485 Download Display Language...................................................487 Clear Operator Log..........................................................487 Password Functions..............................................................490 Enable/Disable Password and Lift Truck Inspection Functions.................490 Truck Inspection Checklist..............................................490 Password................................................................490 Password Properties.........................................................490 Create New Password File....................................................495 Download Passwords..........................................................497 Upload Passwords............................................................497 Reports Menu....................................................................501 Devices Report..............................................................501 Custom Report...............................................................501 Password Report.............................................................501 Operator Report.............................................................508 Current Settings Report.....................................................511 Status Code Report..........................................................514 Status Codes Log............................................................517 Troubleshooting.................................................................519 Diagnostics.................................................................519 Help Menu.......................................................................522 General.....................................................................522 Contents....................................................................522 Technical Support...........................................................522 About Electric Truck AC Controls Program....................................522 Frame (1)...............................................................................529 toc.................................................................................529 Frame...........................................................................529 Safety Precautions Maintenance and Repair.......................................530 General.........................................................................533 Frame Separation and Assembly...................................................533 Frame Separation............................................................533 Frame Assembly..............................................................533 Painting Instructions...........................................................535 Label Replacement...............................................................535 Frame...................................................................................541 toc.................................................................................541 Frame...........................................................................541 Safety Precautions Maintenance and Repair.......................................542 General.........................................................................545 Frame Separation and Assembly...................................................545 Frame Separation............................................................545 Frame Assembly..............................................................545 Painting Instructions...........................................................547 Label Replacement...............................................................547 Hydraulics (1)..........................................................................553 toc.................................................................................553 Walkie Hydraulic Systems........................................................553 Safety Precautions Maintenance and Repair.......................................554 General.........................................................................557 Description of Operation........................................................557 Lifting a Load..............................................................558 Lowering a Load.............................................................558 Hydraulic Lines.............................................................558 Hydraulic Oil...............................................................558 Clean.......................................................................561 Sound Level.................................................................561 Special Precautions.............................................................561 Hydraulic Reservoir.............................................................563 Description.................................................................563 Drive Unit Compartment Covers...................................................563 C60Z, C80Z, C60Z AC, and C80Z AC............................................563 Remove..................................................................563 Install.................................................................563 B60Z, B80Z, B60Z AC, B80Z AC, W60Z, W65Z, and W80Z..........................564 Remove..................................................................564 Install.................................................................565 Lift Pump and Motor.............................................................566 General.....................................................................566 Remove......................................................................566 Lift Pump and Motor Assembly............................................566 Disassemble.................................................................567 Remove Reservoir........................................................567 Remove Pump Motor.......................................................569 B60Z, B60Z AC, C60Z, C60Z AC, and W60Z..............................569 B80Z, B80Z AC, C80Z, C80Z AC, W65Z, and W80Z........................569 Disassemble Pump........................................................569 B60Z, B60Z AC, C60Z, C60Z AC, and W60Z..............................569 B80Z, B80Z AC, C80Z, C80Z AC, W65Z, and W80Z........................569 Assemble....................................................................571 Assemble Pump...........................................................571 B60Z, B60Z AC, C60Z, C60Z AC, and W60Z..............................571 B80Z, B80Z AC, C80Z, C80Z AC, W65Z, and W80Z........................571 Install Pump Motor......................................................571 Install Reservoir to Pump...............................................572 Install.....................................................................572 Lift Pump and Motor Assembly............................................572 Valve Repair....................................................................573 Lowering Valve..............................................................573 Remove..................................................................573 Install.................................................................573 Relief Valve................................................................574 B60Z, B60Z AC, C60Z, C60Z AC, and W60Z..................................574 Remove..............................................................574 Install.............................................................574 B80Z, B80Z AC, C80Z, C80Z AC, W65Z, and W80Z............................575 Remove..............................................................575 Install.............................................................575 Check Valve.................................................................575 B80Z, B80Z AC, C80Z, C80Z AC, W65Z, and W80Z............................575 Remove..............................................................575 Install.............................................................576 Lift Cylinder...................................................................576 Remove......................................................................576 Disassemble.................................................................578 Assemble....................................................................578 Install.....................................................................578 Relief Valve Adjustment.........................................................579 Relief Valve Pressure Check.................................................579 Adjust Relief Valve Pressure................................................580 B60Z, B60Z AC, C60Z, C60Z AC, and W60Z..................................580 B80Z, B80Z AC, C80Z, C80Z AC, W65Z, and W80Z............................581 Troubleshooting.................................................................582 Lift Assemblies.............................................................582 Lift Cylinders..............................................................583 Lift Pump and Motor Assembly................................................584 tables..............................................................................553 Table 1. Hydraulic Reservoir....................................................563 Table 2. Relief Valve Settings..................................................579 Hydraulics..............................................................................589 toc.................................................................................589 Walkie Hydraulic Systems........................................................589 Safety Precautions Maintenance and Repair.......................................590 General.........................................................................593 Description of Operation........................................................593 Lifting a Load..............................................................594 Lowering a Load.............................................................594 Hydraulic Lines.............................................................594 Hydraulic Oil...............................................................594 Clean.......................................................................597 Sound Level.................................................................597 Special Precautions.............................................................597 Hydraulic Reservoir.............................................................599 Description.................................................................599 Drive Unit Compartment Covers...................................................599 C60Z, C80Z, C60Z AC, and C80Z AC............................................599 Remove..................................................................599 Install.................................................................599 B60Z, B80Z, B60Z AC, B80Z AC, W60Z, W65Z, and W80Z..........................600 Remove..................................................................600 Install.................................................................601 Lift Pump and Motor.............................................................602 General.....................................................................602 Remove......................................................................602 Lift Pump and Motor Assembly............................................602 Disassemble.................................................................603 Remove Reservoir........................................................603 Remove Pump Motor.......................................................605 B60Z, B60Z AC, C60Z, C60Z AC, and W60Z..............................605 B80Z, B80Z AC, C80Z, C80Z AC, W65Z, and W80Z........................605 Disassemble Pump........................................................605 B60Z, B60Z AC, C60Z, C60Z AC, and W60Z..............................605 B80Z, B80Z AC, C80Z, C80Z AC, W65Z, and W80Z........................605 Assemble....................................................................607 Assemble Pump...........................................................607 B60Z, B60Z AC, C60Z, C60Z AC, and W60Z..............................607 B80Z, B80Z AC, C80Z, C80Z AC, W65Z, and W80Z........................607 Install Pump Motor......................................................607 Install Reservoir to Pump...............................................608 Install.....................................................................608 Lift Pump and Motor Assembly............................................608 Valve Repair....................................................................609 Lowering Valve..............................................................609 Remove..................................................................609 Install.................................................................609 Relief Valve................................................................610 B60Z, B60Z AC, C60Z, C60Z AC, and W60Z..................................610 Remove..............................................................610 Install.............................................................610 B80Z, B80Z AC, C80Z, C80Z AC, W65Z, and W80Z............................611 Remove..............................................................611 Install.............................................................611 Check Valve.................................................................611 B80Z, B80Z AC, C80Z, C80Z AC, W65Z, and W80Z............................611 Remove..............................................................611 Install.............................................................612 Lift Cylinder...................................................................612 Remove......................................................................612 Disassemble.................................................................614 Assemble....................................................................614 Install.....................................................................614 Relief Valve Adjustment.........................................................615 Relief Valve Pressure Check.................................................615 Adjust Relief Valve Pressure................................................616 B60Z, B60Z AC, C60Z, C60Z AC, and W60Z..................................616 B80Z, B80Z AC, C80Z, C80Z AC, W65Z, and W80Z............................617 Troubleshooting.................................................................618 Lift Assemblies.............................................................618 Lift Cylinders..............................................................619 Lift Pump and Motor Assembly................................................620 tables..............................................................................589 Table 1. Hydraulic Reservoir....................................................599 Table 2. Relief Valve Settings..................................................615 Lift Mechanism (1)......................................................................625 toc.................................................................................625 Lifting Mechanism...............................................................625 Safety Precautions Maintenance and Repair.......................................626 General.........................................................................629 Description of Operation........................................................629 Load Wheel......................................................................629 Remove......................................................................629 Install.....................................................................630 Caster Wheels...................................................................631 Caster Shim Adjustment......................................................631 Caster Replacement..........................................................633 Disassemble.................................................................634 Assemble....................................................................634 Caster Lubrication..........................................................635 Rear Link and Load Wheel Assembly...............................................636 Remove......................................................................636 Install.....................................................................638 Pull Rod........................................................................640 Remove......................................................................640 End Replacement.............................................................640 Install.....................................................................640 Adjust......................................................................641 Rear Fork Adjustment........................................................642 Rocker Arm......................................................................643 Remove......................................................................643 Install.....................................................................644 Upper Link......................................................................645 Remove......................................................................645 Install.....................................................................646 Troubleshooting.................................................................646 Lift Mechanism..........................................................................651 toc.................................................................................651 Lifting Mechanism...............................................................651 Safety Precautions Maintenance and Repair.......................................652 General.........................................................................655 Description of Operation........................................................655 Load Wheel......................................................................655 Remove......................................................................655 Install.....................................................................656 Caster Wheels...................................................................657 Caster Shim Adjustment......................................................657 Caster Replacement..........................................................659 Disassemble.................................................................660 Assemble....................................................................660 Caster Lubrication..........................................................661 Rear Link and Load Wheel Assembly...............................................662 Remove......................................................................662 Install.....................................................................664 Pull Rod........................................................................666 Remove......................................................................666 End Replacement.............................................................666 Install.....................................................................666 Adjust......................................................................667 Rear Fork Adjustment........................................................668 Rocker Arm......................................................................669 Remove......................................................................669 Install.....................................................................670 Upper Link......................................................................671 Remove......................................................................671 Install.....................................................................672 Troubleshooting.................................................................672 MDU (1).................................................................................677 toc.................................................................................677 Master Drive Unit...............................................................677 Safety Precautions Maintenance and Repair.......................................678 General.........................................................................681 Check Oil Level.............................................................682 Change Gear Oil ( T5-7Z AC, B60-80Z AC, C60-80Z AC and B60-80Z H............682 Safety Precautions..............................................................683 Drive Tire......................................................................685 Remove......................................................................685 Install.....................................................................685 Master Drive Unit...............................................................685 Remove......................................................................685 Install.....................................................................691 Troubleshooting.................................................................693 tables..............................................................................677 Table 1. Drive Unit Specifications..............................................681 MDU.....................................................................................697 toc.................................................................................697 Master Drive Unit...............................................................697 Safety Precautions Maintenance and Repair.......................................698 General.........................................................................701 Check Oil Level.............................................................702 Change Gear Oil ( T5-7Z AC, B60-80Z AC, C60-80Z AC and B60-80Z H............702 Safety Precautions..............................................................703 Drive Tire......................................................................705 Remove......................................................................705 Install.....................................................................705 Master Drive Unit...............................................................705 Remove......................................................................705 Install.....................................................................711 Troubleshooting.................................................................713 tables..............................................................................697 Table 1. Drive Unit Specifications..............................................701 PM (1)..................................................................................717 toc.................................................................................717 Periodic Maintenance............................................................717 Safety Precautions Maintenance and Repair.......................................718 General.........................................................................721 How to Move a Disabled Truck................................................721 How to Tow the Lift Truck...............................................722 How to Put a Lift Truck on Blocks...........................................722 How to Raise Drive/Steer Tire...........................................722 How to Raise Load Wheels................................................723 Accessing the Drive Unit Compartment........................................723 Special Precautions.............................................................724 Discharging the Capacitors..................................................724 Welding Repairs.................................................................726 Maintenance Schedule............................................................726 Maintenance Procedures Every 8 Hours or Daily...................................730 Checks With Key Switch Turned OFF...........................................730 Battery.................................................................730 Hydraulic Leaks.........................................................730 Drive Tire, Load Wheels, Casters, and Frame.............................731 Checks With Key Switch Turned ON............................................732 Operation...............................................................732 Maintenance Procedures Every 250 Hours or Every 6 Weeks.........................734 Caster Lubrication..........................................................734 Maintenance Procedures Every 500 Hours or Every 3 Months .......................735 Hydraulic System............................................................735 Hydraulic Oil...........................................................735 Hydraulic Reservoir Breather............................................735 Steering System.............................................................735 Power Assist Steering...................................................735 Lift Linkage and Load Wheels................................................736 Casters.....................................................................736 Caster Shim Check.......................................................736 Caster Shim Adjust......................................................737 Master Drive Unit...........................................................738 Change Gear Oil.........................................................738 Check Oil Level.........................................................738 Drive Tire Check............................................................739 Maintenance Procedures Every 2000 Hours or Yearly...............................739 Lubrication.................................................................739 Repack Load Wheel Bearings..............................................739 Repack Steer Bearings (Manual Steer Only) ..............................739 Hydraulic System............................................................739 Oil Change..............................................................739 Brake.......................................................................740 Electrical..................................................................740 MDU.........................................................................740 Oil Change..............................................................740 Battery Maintenance.............................................................741 How to Charge the Battery...................................................741 Equalizing Charge.......................................................741 Normal Charge...........................................................741 How to Change the Battery...................................................742 Transporting....................................................................743 Loading.....................................................................743 Unloading...................................................................743 Preparation for Storage.........................................................744 Short-Term Storage (1 to 6 months)..........................................744 Long-Term Storage (6 months or longer)......................................744 Preparation for Use.............................................................744 Preparation After Shipment..................................................744 Preparation After Storage...................................................744 tables..............................................................................717 Table 1. Maintenance Schedule...................................................727 Table 2. Specific Gravity Corrections...........................................741 PM......................................................................................747 toc.................................................................................747 Periodic Maintenance............................................................747 Safety Precautions Maintenance and Repair.......................................748 General.........................................................................751 How to Move a Disabled Truck................................................751 How to Tow the Lift Truck...............................................752 How to Put a Lift Truck on Blocks...........................................752 How to Raise Drive/Steer Tire...........................................752 How to Raise Load Wheels................................................753 Accessing the Drive Unit Compartment........................................753 Special Precautions.............................................................754 Discharging the Capacitors..................................................754 Welding Repairs.................................................................756 Maintenance Schedule............................................................756 Maintenance Procedures Every 8 Hours or Daily...................................760 Checks With Key Switch Turned OFF...........................................760 Battery.................................................................760 Hydraulic Leaks.........................................................760 Drive Tire, Load Wheels, Casters, and Frame.............................761 Checks With Key Switch Turned ON............................................762 Operation...............................................................762 Maintenance Procedures Every 250 Hours or Every 6 Weeks.........................764 Caster Lubrication..........................................................764 Maintenance Procedures Every 500 Hours or Every 3 Months .......................765 Hydraulic System............................................................765 Hydraulic Oil...........................................................765 Hydraulic Reservoir Breather............................................765 Steering System.............................................................765 Power Assist Steering...................................................765 Lift Linkage and Load Wheels................................................766 Casters.....................................................................766 Caster Shim Check.......................................................766 Caster Shim Adjust......................................................767 Master Drive Unit...........................................................768 Change Gear Oil.........................................................768 Check Oil Level.........................................................768 Drive Tire Check............................................................769 Maintenance Procedures Every 2000 Hours or Yearly...............................769 Lubrication.................................................................769 Repack Load Wheel Bearings..............................................769 Repack Steer Bearings (Manual Steer Only) ..............................769 Hydraulic System............................................................769 Oil Change..............................................................769 Brake.......................................................................770 Electrical..................................................................770 MDU.........................................................................770 Oil Change..............................................................770 Battery Maintenance.............................................................771 How to Charge the Battery...................................................771 Equalizing Charge.......................................................771 Normal Charge...........................................................771 How to Change the Battery...................................................772 Transporting....................................................................773 Loading.....................................................................773 Unloading...................................................................773 Preparation for Storage.........................................................774 Short-Term Storage (1 to 6 months)..........................................774 Long-Term Storage (6 months or longer)......................................774 Preparation for Use.............................................................774 Preparation After Shipment..................................................774 Preparation After Storage...................................................774 tables..............................................................................747 Table 1. Maintenance Schedule...................................................757 Table 2. Specific Gravity Corrections...........................................771 Specs (1)...............................................................................777 toc.................................................................................777 Capacities and Specifications...................................................777 Safety Precautions Maintenance and Repair.......................................778 Hydraulic System................................................................781 Hydraulic Oils..................................................................782 Gear Oils.......................................................................782 Grease..........................................................................782 Truck Weight....................................................................783 Tire Sizes......................................................................783 Torque Specifications...........................................................784 Caster Assembly.............................................................784 Drive Wheel Assembly........................................................784 Master Drive Unit...........................................................784 Standard Steering...........................................................784 Power Assist Steering.......................................................784 Brake.......................................................................784 Electrical..................................................................784 Lift Mechanism..............................................................784 Hydraulics..................................................................784 Battery Specifications..........................................................785 tables..............................................................................777 Table 1. B60Z AC................................................................785 Table 2. B80Z AC................................................................786 Specs...................................................................................789 toc.................................................................................789 Capacities and Specifications...................................................789 Safety Precautions Maintenance and Repair.......................................790 Hydraulic System................................................................793 Hydraulic Oils..................................................................794 Gear Oils.......................................................................794 Grease..........................................................................794 Truck Weight....................................................................795 Tire Sizes......................................................................795 Torque Specifications...........................................................796 Caster Assembly.............................................................796 Drive Wheel Assembly........................................................796 Master Drive Unit...........................................................796 Standard Steering...........................................................796 Power Assist Steering.......................................................796 Brake.......................................................................796 Electrical..................................................................796 Lift Mechanism..............................................................796 Hydraulics..................................................................796 Battery Specifications..........................................................797 tables..............................................................................789 Table 1. B60Z AC................................................................797 Table 2. B80Z AC................................................................798 Steering (1)............................................................................801 toc.................................................................................801 Steering Mechanism..............................................................801 Safety Precautions Maintenance and Repair.......................................802 General.........................................................................805 Accessing the Drive Unit Compartment........................................805 Special Precautions.............................................................806 Electromagnetic Shield (Power Assist 6/2009⇒)...............................807 Calibration.....................................................................807 Power Assist Steering.......................................................807 Control Handle..................................................................808 Control Handle Head.........................................................808 Control Handle..............................................................808 Standard Steering.......................................................808 Remove..............................................................808 Install.............................................................810 Power Assist Steering (⇒ 5/2009)........................................810 Remove..............................................................810 Install.............................................................812 Power Assist Steering (6/2009 ⇒)........................................815 Remove..............................................................815 Install.............................................................816 Gas Spring......................................................................818 Discharging the Gas Spring..................................................818 Remove .....................................................................818 Install ....................................................................819 Articulating Shaft and Pinions (Power Assist Models)............................820 Remove......................................................................820 Pinion Repair...............................................................820 Upper Pinion............................................................821 Lower Pinion............................................................822 Install.....................................................................823 Steer Motor Assembly............................................................823 Repair......................................................................823 Steer Motor, Replace....................................................823 Steer Motor Gear, Replace...............................................824 Gearbox/Complete Assembly, Replace......................................825 Steer Support Assembly..........................................................825 Standard Steering...........................................................825 Remove (Complete Unit)..................................................825 Disassemble.............................................................826 Assemble................................................................826 Install (Complete Unit).................................................828 Power Assist Steering (Option)..............................................829 Remove (Complete Unit)..................................................829 Disassemble.............................................................829 Support Base........................................................829 Steer Swivel........................................................831 Assemble................................................................831 Steer Swivel........................................................831 Support Base........................................................831 Install (Complete Unit).................................................833 Electronic Coast Control (Option)...............................................834 Disassemble.................................................................834 Assemble....................................................................836 Checks......................................................................836 Troubleshooting.................................................................837 Steering................................................................................841 toc.................................................................................841 Steering Mechanism..............................................................841 Safety Precautions Maintenance and Repair.......................................842 General.........................................................................845 Accessing the Drive Unit Compartment........................................845 Special Precautions.............................................................846 Electromagnetic Shield (Power Assist 6/2009⇒)...............................847 Calibration.....................................................................847 Power Assist Steering.......................................................847 Control Handle..................................................................848 Control Handle Head.........................................................848 Control Handle..............................................................848 Standard Steering.......................................................848 Remove..............................................................848 Install.............................................................850 Power Assist Steering (⇒ 5/2009)........................................850 Remove..............................................................850 Install.............................................................852 Power Assist Steering (6/2009 ⇒)........................................855 Remove..............................................................855 Install.............................................................856 Gas Spring......................................................................858 Discharging the Gas Spring..................................................858 Remove .....................................................................858 Install ....................................................................859 Articulating Shaft and Pinions (Power Assist Models)............................860 Remove......................................................................860 Pinion Repair...............................................................860 Upper Pinion............................................................861 Lower Pinion............................................................862 Install.....................................................................863 Steer Motor Assembly............................................................863 Repair......................................................................863 Steer Motor, Replace....................................................863 Steer Motor Gear, Replace...............................................864 Gearbox/Complete Assembly, Replace......................................865 Steer Support Assembly..........................................................865 Standard Steering...........................................................865 Remove (Complete Unit)..................................................865 Disassemble.............................................................866 Assemble................................................................866 Install (Complete Unit).................................................868 Power Assist Steering (Option)..............................................869 Remove (Complete Unit)..................................................869 Disassemble.............................................................869 Support Base........................................................869 Steer Swivel........................................................871 Assemble................................................................871 Steer Swivel........................................................871 Support Base........................................................871 Install (Complete Unit).................................................873 Electronic Coast Control (Option)...............................................874 Disassemble.................................................................874 Assemble....................................................................876 Checks......................................................................876 Troubleshooting.................................................................877 Sup. Interface (1)......................................................................881 toc.................................................................................881 User Interface..................................................................881 Safety Precautions Maintenance and Repair.......................................882 General.........................................................................885 Description.................................................................885 Dash Display Menu Access (Standard Handle)..................................885 Dash Display Menu Access (Metal Handle Option)..............................886 Menu Navigation.................................................................887 Standard Handle.............................................................887 Metal Handle Option.........................................................889 Dash Display Versions...........................................................890 Supervisor Menu.................................................................891 View Versions...............................................................892 Hourmeters..................................................................892 Diagnostics.................................................................892 Fault Log...............................................................893 Controller Inputs.......................................................894 Control Handle Inputs...................................................894 Run Diagnostics.........................................................895 Traction Motor......................................................896 Pump Motor and Valve................................................896 Control Handle......................................................896 Temperatures........................................................897 Power Steering......................................................897 Service Reminder............................................................897 Change Supervisor Password..................................................898 Operator Modes..............................................................899 Exit to Run Mode............................................................899 tables..............................................................................881 Table 1. Corresponding Buttons..................................................889 Table 2. Supervisor Menu........................................................891 Table 3. Diagnostics Menu.......................................................893 Table 4. Controller Inputs......................................................894 Table 5. Control Handle Inputs..................................................894 Table 6. Run Diagnostics Menu...................................................895 Sup. Interface..........................................................................903 toc.................................................................................903 User Interface..................................................................903 Safety Precautions Maintenance and Repair.......................................904 General.........................................................................907 Description.................................................................907 Dash Display Menu Access (Standard Handle)..................................907 Dash Display Menu Access (Metal Handle Option)..............................908 Menu Navigation.................................................................909 Standard Handle.............................................................909 Metal Handle Option.........................................................911 Dash Display Versions...........................................................912 Supervisor Menu.................................................................913 View Versions...............................................................914 Hourmeters..................................................................914 Diagnostics.................................................................914 Fault Log...............................................................915 Controller Inputs.......................................................916 Control Handle Inputs...................................................916 Run Diagnostics.........................................................917 Traction Motor......................................................918 Pump Motor and Valve................................................918 Control Handle......................................................918 Temperatures........................................................919 Power Steering......................................................919 Service Reminder............................................................919 Change Supervisor Password..................................................920 Operator Modes..............................................................921 Exit to Run Mode............................................................921 tables..............................................................................903 Table 1. Corresponding Buttons..................................................911 Table 2. Supervisor Menu........................................................913 Table 3. Diagnostics Menu.......................................................915 Table 4. Controller Inputs......................................................916 Table 5. Control Handle Inputs..................................................916 Table 6. Run Diagnostics Menu...................................................917 Tech. Interface (1).....................................................................925 toc.................................................................................925 User Interface..................................................................925 Safety Precautions Maintenance and Repair.......................................926 General.........................................................................929 Description.................................................................929 Dash Display Menu Access (Standard Handle)..................................929 Dash Display Menu Access (Metal Handle Option)..............................930 Menu Navigation.................................................................931 Standard Handle.............................................................931 Metal Handle Option.........................................................933 Dash Display Versions...........................................................934 Technician Menu.................................................................935 View Versions...............................................................936 Hourmeters..................................................................936 Diagnostics.................................................................937 Fault Log...............................................................937 Controller Inputs.......................................................938 Control Handle Inputs...................................................938 Run Diagnostics.........................................................939 Traction Motor......................................................940 Pump Motor and Valve................................................941 Control Handle......................................................941 Traction Temps......................................................941 Power Steering......................................................942 Service Reminder............................................................942 Change Supervisor Password..................................................943 Operator Modes..............................................................943 Set Performance.............................................................944 Extended Shift..........................................................945 Walk Speed..............................................................946 High Speed (FWD)........................................................946 High Speed (REV)........................................................946 Minimum Acceleration....................................................947 Maximum Acceleration....................................................947 Plugging................................................................947 ADS-Neutral.............................................................948 ADS-Throttle............................................................948 Pick Acceleration.......................................................948 Pick Deceleration.......................................................949 Battery Full............................................................949 Lift Interrupt..........................................................949 Min Steer Assist FWD (Power Steering Assist Only).......................950 Min Steer Assist REV (Power Steering Assist Only).......................950 Max Steer Assist (Power Steering Assist Only)...........................950 Defaults................................................................951 Save and Exit...........................................................951 Exit Without Saving.....................................................951 Set General Items...........................................................952 A/V Alarm (Audible/Visual)..............................................952 Clear Fault Log.............................................................953 Calibrations................................................................953 Throttle................................................................954 B60-80Z AC and B60-80Z HD Composite Handle ( ⇒ S/N B230N03907J......954 B60-80Z AC and B60-80Z HD Composite Handle ( S/N B230N03908J, B2....954 B60-80Z AC and B60-80Z HD Metal Handle..............................955 Steer Handle (Power Steering Assist Only)...............................956 Change Service Technician Password..........................................956 Exit to Run Mode............................................................957 tables..............................................................................925 Table 1. Corresponding Buttons..................................................933 Table 2. Technician Menu........................................................935 Table 3. Diagnostics Menu.......................................................937 Table 4. Controller Inputs......................................................938 Table 5. Control Handle Inputs..................................................938 Table 6. Run Diagnostics Menu...................................................940 Table 7. Performance Parameters.................................................944 Table 8. Set Performance Menu...................................................944 Table 9. Set General Items Menu.................................................952 Table 10. Calibrations Menu.....................................................953 Tech. Interface.........................................................................961 toc.................................................................................961 User Interface..................................................................961 Safety Precautions Maintenance and Repair.......................................962 General.........................................................................965 Description.................................................................965 Dash Display Menu Access (Standard Handle)..................................965 Dash Display Menu Access (Metal Handle Option)..............................966 Menu Navigation.................................................................967 Standard Handle.............................................................967 Metal Handle Option.........................................................969 Dash Display Versions...........................................................970 Technician Menu.................................................................971 View Versions...............................................................972 Hourmeters..................................................................972 Diagnostics.................................................................973 Fault Log...............................................................973 Controller Inputs.......................................................974 Control Handle Inputs...................................................974 Run Diagnostics.........................................................975 Traction Motor......................................................976 Pump Motor and Valve................................................977 Control Handle......................................................977 Traction Temps......................................................977 Power Steering......................................................978 Service Reminder............................................................978 Change Supervisor Password..................................................979 Operator Modes..............................................................979 Set Performance.............................................................980 Extended Shift..........................................................981 Walk Speed..............................................................982 High Speed (FWD)........................................................982 High Speed (REV)........................................................982 Minimum Acceleration....................................................983 Maximum Acceleration....................................................983 Plugging................................................................983 ADS-Neutral.............................................................984 ADS-Throttle............................................................984 Pick Acceleration.......................................................984 Pick Deceleration.......................................................985 Battery Full............................................................985 Lift Interrupt..........................................................985 Min Steer Assist FWD (Power Steering Assist Only).......................986 Min Steer Assist REV (Power Steering Assist Only).......................986 Max Steer Assist (Power Steering Assist Only)...........................986 Defaults................................................................987 Save and Exit...........................................................987 Exit Without Saving.....................................................987 Set General Items...........................................................988 A/V Alarm (Audible/Visual)..............................................988 Clear Fault Log.............................................................989 Calibrations................................................................989 Throttle................................................................990 B60-80Z AC and B60-80Z HD Composite Handle ( ⇒ S/N B230N03907J......990 B60-80Z AC and B60-80Z HD Composite Handle ( S/N B230N03908J, B2....990 B60-80Z AC and B60-80Z HD Metal Handle..............................991 Steer Handle (Power Steering Assist Only)...............................992 Change Service Technician Password..........................................992 Exit to Run Mode............................................................993 tables..............................................................................961 Table 1. Corresponding Buttons..................................................969 Table 2. Technician Menu........................................................971 Table 3. Diagnostics Menu.......................................................973 Table 4. Controller Inputs......................................................974 Table 5. Control Handle Inputs..................................................974 Table 6. Run Diagnostics Menu...................................................976 Table 7. Performance Parameters.................................................980 Table 8. Set Performance Menu...................................................980 Table 9. Set General Items Menu.................................................988 Table 10. Calibrations Menu.....................................................989
HYSTER D233 (E80ZAC) SERVICE MANUAL – PDF DOWNLOAD:
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