Hyster B234 Operating instructions

Hyster B234 (W60Z, W65Z, W80Z) Forklift

ELECTRICAL SYSTEM
B60Z [A230];
W60Z [A231, B231];
W65Z [A229, B229];
W80Z [A234, B234];
B80Z [A233]
PART NO. 1492462 2200 SRM 0929

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
•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 HOW TO 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 ex-
ceed 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 flamma-
ble. 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.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

©2016 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Electrical System Checks ........................................................................................................................................5
Safety Precautions ..............................................................................................................................................5
Repairs .....................................................................................................................................................................7
Controller, Replace ..............................................................................................................................................8
Remove ............................................................................................................................................................8
Install ..............................................................................................................................................................8
Contactor Coil, Check .........................................................................................................................................8
Contactor, Replace ..............................................................................................................................................8
Contactor Tips, Replace ....................................................................................................................................10
Remove ..........................................................................................................................................................10
Install ............................................................................................................................................................10
Fuses ......................................................................................................................................................................12
Brake Switch - W60Z, W65Z, W80Z, B60Z (→Aug. 2003) and B80Z (→Aug. 2003)...........................................13
Remove and Install ...........................................................................................................................................13
Brake and Interlock Switches - B60Z (Aug. 2003→) and B80Z (Aug. 2003→) ..................................................14
Disassemble .......................................................................................................................................................14
Assemble ............................................................................................................................................................14
Height Limit ..........................................................................................................................................................14
Control Handle ......................................................................................................................................................15
Disassemble .......................................................................................................................................................15
Control Handle Card (Old Style) ......................................................................................................................15
Control Handle Card (New Style) ....................................................................................................................16
Configure .......................................................................................................................................................16
Calibrate ........................................................................................................................................................18
Assemble ............................................................................................................................................................19
Remote Control Box Switches (B60Z and B80Z)..................................................................................................19
Remove .............................................................................................................................................................. 19
Install .................................................................................................................................................................19
Motor Maintenance - General ...............................................................................................................................21
Brush and Commutator Inspection ......................................................................................................................21
Commutator Problems ......................................................................................................................................23
Brush Replacement ...............................................................................................................................................27
Drive Motor ............................................................................................................................................................29
Remove .............................................................................................................................................................. 29
Disassemble .......................................................................................................................................................30
Assemble ............................................................................................................................................................31
Install .................................................................................................................................................................31
Lift Pump Motor ....................................................................................................................................................32
Remove .............................................................................................................................................................. 32
Install .................................................................................................................................................................32
Commutator Repairs .............................................................................................................................................32
Testing the Drive Motor ........................................................................................................................................33
Damaged Field and Armature ..........................................................................................................................33
Short Circuit in an Armature Winding ............................................................................................................33
Short Circuit in the Armature ..........................................................................................................................34
Open Circuit in a Field Coil ..............................................................................................................................34
Short Circuit in a Field Coil .............................................................................................................................34
Short Circuit Between Field and Motor Case ................................................................................................. 35
Brush Holder .....................................................................................................................................................35
Table of Contents
i

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TABLE OF CONTENTS (Continued)
Troubleshooting .....................................................................................................................................................35
This section is for the following models:
(B60Z) [A230];
(W60Z) [A231, B231];
(W65Z) [A229, B229];
(W80Z) [A234, B234];
(B80Z) [A233]
Table of Contents
ii

General
WARNING
DO NOT make repairs or adjustments unless you
have both authorization and training. Repairs and
adjustments that are not correct can create a
dangerous operating condition. DO NOT operate a
lift truck that needs repairs. Report the need for
repairs to your supervisor immediately. If repair is
necessary, put a DO NOT OPERATE tag on the
control handle. Remove the key from the key
switch.
This manual describes the electrical systems used
on the motorized hand lift trucks. Procedures are
outlined for the maintenance, adjustment, and
repair that may be required when servicing these
lift trucks. The drive control for the Motorized
Hand Trucks is a Curtis Transistor Motor
Controller 1297 Model, also known as a MOSFET
or PMC system. See Figure 1, Figure 2, and
Figure 3.
2200 SRM 0929 General
1

1. TRACTION MOTOR
2. ELECTRIC BRAKE
3. DRIVE UNIT
4. HYDRAULIC UNIT
5. HORN
6. IGNITION SWITCH
7. BATTERY GAGE/SPYGLASS
8. BATTERY CONNECTOR
9. CONTROLLER PANEL
10. PUMP CABLE (NEG.)
11. WIRE HARNESS-MAIN
12. CABLE (POS.)
13. CABLE (A1)
14. CABLE (A2)
15. CABLE (F1)
16. CABLE (F2)
17. PUMP CABLE (POS.)
Figure 1. Drive Unit Compartment (W60Z, W65Z, and W80Z)
General 2200 SRM 0929
2

1. TRACTION MOTOR
2. ELECTRIC BRAKE
3. DRIVE UNIT
4. HYDRAULIC UNIT
5. HORN
6. IGNITION SWITCH
7. BATTERY GAGE/SPYGLASS
8. BATTERY DISCONNECT
9. CONTROL PANEL
10. CAPSCREW
11. CAPSCREW
12. GRAB RAIL
13. CONTROL BOX
14. WIRE HARNESS-HANDRAIL
15. WIRE HARNESS-MAIN
16. CABLE (POS)
17. CABLE (A1)
18. CABLE (A2)
19. CABLE (F1)
20. CABLE (F2)
21. PUMP CABLE (POS.)
22. PUMP CABLE (NEG.)
Figure 2. Drive Unit Compartment (B60Z and B80Z)
2200 SRM 0929 General
3

1. WASHER
2. LOCKWASHER
3. CAPSCREW
4. CAPSCREW
5. WASHER
6. LOCKWASHER
7. WASHER
8. SCREW
9. SCREW
10. SCREW
11. FUSE-MOTORS
12. FUSE-CONTROLLER
13. MOUNTING PLATE
14. BUSS BAR
15. FUSE HOLDER
16. STAND-OFF
17. CONTROLLER
18. CONTACTOR
19. LOCKWASHER
20. NUT
21. NUT
22. LOCKWASHER
23. NUT
24. SCREW
25. CONVERTER - 12 V ONLY
26. WASHER
27. LOCKWASHER
28. CAPSCREW
29. RESISTOR
30. RELAY
31. SCREW
32. WASHER
33. LOCKWASHER
34. LABEL
35. LABEL
Figure 3. Controller Panel Assembly
General 2200 SRM 0929
4

Electrical System Checks
WARNING
Disconnect the battery and separate the connec-
tor before opening the compartment cover or in-
specting or repairing the electrical system. If a
tool causes a short circuit, the high current flow
from the battery can cause personal injury or
property damage.
The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted. To prevent electrical shock and personal in-
jury, discharge the capacitor before inspecting or
repairing any component in the drive unit com-
partment. Wear safety glasses. Make certain the
battery has been disconnected.
All checks, adjustments, and repairs in the drive
unit compartment are done with the compartment
cover removed. Remove the drive unit compartment
cover for access to the electrical components.
SAFETY PRECAUTIONS
WARNING
Some checks require the battery to be reconnec-
ted. DO NOT connect the battery until the proce-
dure tells you to do so. Make sure the drive wheel
is raised to prevent truck movement and possible
injury. Raise the drive wheel. The blocks must
prevent the lift truck from falling and causing per-
sonal injury or property damage.
CAUTION
To avoid controller damage, always disconnect
the battery before disconnecting any cables from
the controller. Discharge the capacitor, and never
put power to the controller with any power wire
disconnected. Never short any controller terminal
or motor terminal to the battery. Make sure to use
proper procedure when servicing the controller.
1. Block lift truck so the drive tire is raised
slightly off the floor to prevent unexpected
movement when making checks.
2. Turn the key switch to the OFF position and
disconnect the battery.
3. Discharge capacitors in controllers by connect-
ing a 200-ohm, 2-watt resistor across the con-
troller's B+ and B- terminals. See Figure 4. DO
NOT short across the motor controller termi-
nals with a screwdriver or jumper wire. Re-
move the 200-ohm, 2-watt resistor before recon-
necting the battery.
NOTE: These checks require a volt-ohmmeter with
a meter movement. Most digital meters will not op-
erate correctly for some of these checks. Specific
checks require additional equipment.
NOTE: The correct meter polarity is necessary for
the checks. The voltage checks are made between
the point indicated in Table 1 and battery negative.
Connect the meter negative to battery negative.
NOTE: The battery does not have to be removed to
check the specific gravity.
1. POSITIVE CONNECTION
2. NEGATIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
Figure 4. Discharging the Capacitors
2200 SRM 0929 Electrical System Checks
5

4. Using a hydrometer, check the specific gravity
of the battery. If the specific gravity is less than
1.260, the battery is not fully charged or is
damaged. A fully-charged battery has a specific
gravity of 1.270 to 1.290. A discharged battery
has a specific gravity of approximately 1.165.
5. The electric lift truck has a two-wire system.
The frame must not be a common electrical
path. Check for 50,000 ohms or more between
each battery terminal and a clean connection
on the frame. Remove any circuit paths be-
tween the controller and the frame of the lift
truck, such as a dirty battery case. Carbon dust
in a motor or other parts can cause a circuit
path. Check for additional equipment that may
cause a circuit path to the frame.
6. Check for voltage between each terminal of the
connector that fastens to the battery and a
clean connection on the frame. Normally, there
is small voltage (less than 30 percent of the bat-
tery voltage) between the battery and the
frame, even though the resistance is very high.
A higher voltage can indicate a dirty battery or
a damaged battery. Clean the battery and bat-
tery compartment as necessary.
7. Visually check for parts or wires that are loose
or damaged.
NOTE: Make an identification of any wires before
you disconnect them. The wires must be reconnec-
ted correctly after checks or repairs.
Table 1. Voltage Checks
LIFT TRUCK WILL NOT MOVE IN EITHER DIRECTION.
NO FAULT IS DISPLAYED ON THE CONTROLLER.
Possible Causes:
1. Battery not connected.
2. Control fuse is damaged.
3. Key switch or brake switch is damaged.
4. Transistor controller connector unplugged.
5. Transistor controller is damaged.
1.0 Check for battery voltage on the
battery side of control fuse. →→ -- 1.01 Battery voltage at control fuse. Check for open control fuse.
|
|-→
1.02 No battery voltage at control fuse. Connect
battery or check wiring between battery
and fuse.
1.1 Check for battery voltage at control
fuse terminal of key switch. →→
-- 1.1.1 Battery voltage at key switch. Check for
damaged key switch. Check connector.
|
|-→
1.1.2 No voltage at key switch. Wire to key
switch or connections is damaged.
1.3 Key switch closed. Brake switch
closed. Check for battery voltage at
B+ terminal of transistor controller. →→
--
1.3.1 Battery voltage at B+ terminal. Check
fault code. If no fault code, possible
damaged control handle card.
|
|-→
1.3.2 No voltage at B+ terminal. Check B-
terminal. Check fault code.
Electrical System Checks 2200 SRM 0929
6

Repairs
WARNING
DO NOT make repairs or adjustments unless you
have been properly trained and authorized to do
so. Improper repairs and adjustments can create
dangerous operating conditions. DO NOT operate
a lift truck that needs repairs. Report the need for
repairs to your supervisor immediately. If repair is
necessary, attach a DO NOT OPERATE tag to the
control handle and disconnect the battery.
Disconnect the battery and separate the connec-
tor before opening the drive unit compartment
cover or inspecting or repairing the electrical sys-
tem. If a tool causes a short circuit, the high cur-
rent flow from the battery can cause personal in-
jury or property damage.
The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted. To prevent electrical shock and personal in-
jury, discharge the capacitor before inspecting or
repairing any component in the drive unit com-
partment. Connect a 200-ohm, 2-watt resistor
across the B+ (positive) and B- (negative) connec-
tors of the controller. See Figure 5.
All checks, adjustments, and repairs in the drive
unit compartment are done with the compartment
cover removed. Remove the drive unit compartment
cover for access to the electrical components and
discharge the capacitor.
1. POSITIVE CONNECTION
2. NEGATIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
Figure 5. Discharging Controller
2200 SRM 0929 Repairs
7

CONTROLLER, REPLACE
WARNING
Some checks require the battery to be connected.
DO NOT connect the battery until the procedure
tells you to do so. Make sure the drive wheel is
raised to prevent movement and possible injury.
Raise the drive wheel. See the section Periodic
Maintenance 8000SRM0919 - How to Put a Lift
Truck on Blocks. The blocks must prevent the lift
truck from falling and causing personal injury or
property damage.
NOTE: Although the controller is factory program-
med, any custom parameters must be uploaded or
re-entered into the controller when replacing. See
the section Curtis 1297 Transistor Motor Con-
troller 2200SRM0928.
DO NOT replace the controller until you have thor-
oughly checked all other electrical components and
are sure the controller is malfunctioning. For the
following procedures, refer to Figure 6.
Remove
1. Move the truck to a safe, level location. Turn
the key switch to the OFF position, disconnect
the battery, and block the drive tire to prevent
unexpected movement.
2. Remove the drive unit compartment covers.
3. Discharge the capacitor. See Figure 5 in this
section.
4. Tag and disconnect wires from the controller.
5. Remove mounting screws and remove control-
ler.
Install
1. Install replacement controller on lift truck us-
ing mounting hardware.
2. Connect wires and cables to the proper termi-
nals as identified during the removal proce-
dure.
3. Connect battery, turn the key switch to the ON
position, and turn parking brake to the OFF
position.
4. Test for proper operation.
5. Install the drive unit compartment covers.
CONTACTOR COIL, CHECK
Disconnect coil wires. Test contactor coil using an
ohmmeter to measure the resistance. Use the high-
est resistance indication. The coil should read
23 ohms ±10% (14 ohms ±10% on models W65Z).
Remove and replace contactor if resistance readings
indicate a short circuit in both directions or if there
is an open circuit in both directions. Make sure coil
wires are connected to the proper terminals.
NOTE: The contactor contains no serviceable parts
and must be replaced as a complete assembly.
CONTACTOR, REPLACE
NOTE: Make an identification of any wires before
disconnecting them. The wires must be connected
correctly after checks or repairs.
Make sure battery is disconnected and capacitor in
controller is discharged. For the correct procedure
to discharge the controller, refer to Figure 5. If the
lift truck has an EE rating, remove cover of the con-
tactor box for access to the contactor terminals.
Make an identification of the wires and cables, and
disconnect them from the contactor assembly. Re-
move mounting screws and replace contactor as-
sembly. Install wires and cables as removed. Install
cover of contactor box on EE units.
Repairs 2200 SRM 0929
8

1. WASHER
2. LOCKWASHER
3. CAPSCREW
4. CAPSCREW
5. WASHER
6. LOCKWASHER
7. WASHER
8. SCREW
9. SCREW
10. SCREW
11. FUSE-MOTORS
12. FUSE-CONTROLLER
13. MOUNTING PLATE
14. BUSS BAR
15. FUSE HOLDER
16. STAND-OFF
17. CONTROLLER
18. CONTACTOR
19. LOCKWASHER
20. NUT
21. NUT
22. LOCKWASHER
23. NUT
24. SCREW
25. LABEL
26. LABEL
Figure 6. Controller Panel Assembly
2200 SRM 0929 Repairs
9

CONTACTOR TIPS, REPLACE
CAUTION
All contactor tips must be replaced at the same
time if any need replacing.
NOTE: If both the contactor tips and the coil will
be replaced, replace complete contactor as descri-
bed in Contactor, Replace. Perform only the proce-
dures necessary to complete the repairs.
The contactor tips are made of special silver alloy.
The contacts will look black and rough from normal
operation. This condition does not cause problems
with the operation of the lift truck. Cleaning is not
necessary. DO NOT USE A FILE ON THE CON-
TACTS. DO NOT LUBRICATE THE CONTACTS.
Replace contacts when the silver alloy is worn away
to the base support metal.
Remove
Refer to Figure 7 for the following procedures.
1. Remove contactor as described in Contactor,
Replace.
2. Remove screws (4) that fasten the top cover to
the coil and frame.
3. Remove cover, moving contact (2), and return
spring.
4. Remove capscrews, washers, and nuts that
make up the fixed contactor tips (1) from the
top cover.
5. If a coil will be replaced, remove coil frame and
remove end cap from frame.
6. Remove coil from frame.
Install
1. Install new coil on frame and install end cap.
2. Install moving contact (2) and return spring.
3. Install capscrews, washers, and nuts that make
up the fixed contactor tips (1) to the top cover.
NOTE: Check that the moving contactor and
springs move freely without binding.
4. Install cover to coil and frame using screws (4).
5. Install contactor assemblies on the lift truck as
described in Contactor, Replace.
Repairs 2200 SRM 0929
10

Figure 7. Contactor
Legend for Figure 7
1. FIXED CONTACTS
2. MOVING CONTACTS
3. TOP COVER
4. SCREW
5. RETURN SPRING
6. COIL AND FRAME
7. END CAP
2200 SRM 0929 Repairs
11

Fuses
WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted. To prevent electrical shock and personal in-
jury, discharge the capacitor before inspecting or
repairing any component in the drive unit com-
partment. Wear safety glasses. Make certain the
battery has been disconnected.
The motorized hand trucks use a single 5-amp (FU
2) fuse for the control circuit, and 400-amp (FU 1)
fuses for both the drive motor and the hydraulic
pump motor. The fuses are located on the contactor
panel. Remove and replace as required. See Fig-
ure 8 and Figure 9.
If it cannot be determined visually that a fuse has
failed, check for continuity using an ohmmeter. To
replace FU1, loosen nuts retaining it. Install a new
fuse and tighten nuts. FU2 is retained by a fuse
holder. Make certain that any replacement fuse is
of the right amperage before installation.
1. FUSE Figure 8. Control Circuit Fuse
1. BATTERY DISCONNECT SWITCH
2. NUT
3. WASHER
4. SCREW
5. FUSE
Figure 9. Electrical Components
1. BATTERY DISCONNECT SWITCH
2. NUT
3. WASHER
4. FUSE
Figure 10. Electrical Components (A230, A233)
Fuses 2200 SRM 0929
12

Brake Switch - W60Z, W65Z, W80Z, B60Z (→Aug. 2003) and B80Z
(→Aug. 2003)
REMOVE AND INSTALL
WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted. To prevent electrical shock and personal in-
jury, discharge the capacitor before inspecting or
repairing any component in the drive unit com-
partment. Wear safety glasses. Make certain the
battery has been disconnected.
Check the brake switch for continuity. Remove the
nut that retains the switch to the bracket. Remove
the switch.
Attach the brake switch to the bracket using the
nut. Install wires to the switch.
Connect the battery. Move the brake handle to
check that brake switch closes when the brake is
released and opens when the brake is engaged. See
Figure 11.
The brake switch is normally open until the control
handle is moved to the operating position. Refer to
Brakes 1800SRM0963.
Figure 11. Brake Operation
2200 SRM 0929 Brake Switch - W60Z, W65Z, W80Z, B60Z (→Aug. 2003) and B80Z (→Aug. 2003)
13

Brake and Interlock Switches - B60Z (Aug. 2003→) and B80Z
(Aug. 2003→)
DISASSEMBLE
1. Position the lift truck on a level surface. Turn
the key switch to the OFF position and discon-
nect the battery.
NOTE: The screws have been installed using Loc-
tite®290.
2. Remove the two screws and the nut plate re-
taining the switches to the control handle hub.
See Figure 12.
3. Remove switches from the hub and tag all wir-
ing connections to the switches for later use
when assembling the switches to the hub.
4. Remove the switch.
ASSEMBLE
1. Attach wiring to correct switch terminals.
2. Install switches into hub with two screws and
nutplate. Apply Loctite®290 to the screws, in-
stall, and tighten.
3. Connect battery and turn the key switch to the
ON position.
4. Test for proper operation before returning the
truck to service.
1. NUTPLATE
2. SCREW
3. REGEN SWITCH
4. BRAKE SWITCH
Figure 12. Brake and Interlock Switches
Height Limit
Height limiting is controlled by the height limit
switch in the 1297 Curtis controller. When the con-
troller senses a high current draw from the hy-
draulic pump, it will shut down the pump. There
are two separate incidents that will cause this cur-
rent draw: The first is when the lift cylinder rea-
ches maximum height, and the second is when the
load exceeds the rated capacity. In either case, the
controller will shut down the pump.
Brake and Interlock Switches - B60Z (Aug. 2003→) and B80Z (Aug. 2003→) 2200 SRM 0929
14