Hyster B60Z User manual

WALKIE HYDRAULIC
SYSTEMS
B60Z [A230]; B80Z [A233]; C60Z [A478];
C80Z [A479]; W60Z [A231]; W65Z [A229];
W80Z [A234]; B60ZAC [B230]; B80ZAC [B233];
C60ZAC [B478]; C80ZAC [B479]
PART NO. 1500201 1900 SRM 964

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.
•Donotliftheavypartsbyhand,usealiftingmechanism.
•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 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.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause 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.

Walkie Hydraulic Systems Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description of Operation.................................................................................................................................... 1
Lifting a Load................................................................................................................................................. 2
Lowering a Load ............................................................................................................................................ 2
Hydraulic Lines ............................................................................................................................................. 2
Hydraulic Oil ................................................................................................................................................. 2
Clean .............................................................................................................................................................. 5
Sound Level.................................................................................................................................................... 5
Special Precautions............................................................................................................................................ 5
Hydraulic Reservoir........................................................................................................................................... 7
Description ..................................................................................................................................................... 7
Drive Unit Compartment Covers...................................................................................................................... 7
C60Z, C80Z, C60ZAC,andC80Z
AC ................................................................................................................ 7
Remove....................................................................................................................................................... 7
Install......................................................................................................................................................... 7
B60Z, B80Z, B60ZAC,B80Z
AC, W60Z, W65Z, and W80Z............................................................................. 8
Remove....................................................................................................................................................... 8
Install......................................................................................................................................................... 9
Lift Pump and Motor ......................................................................................................................................... 10
General........................................................................................................................................................... 10
Remove ........................................................................................................................................................... 10
Lift Pump and Motor Assembly................................................................................................................ 10
Disassemble ................................................................................................................................................... 11
Remove Reservoir...................................................................................................................................... 11
Remove Pump Motor................................................................................................................................. 13
B60Z, B60ZAC,C60Z,C60Z
AC, and W60Z............................................................................................ 13
B80Z, B80ZAC,C80Z,C80Z
AC, W65Z, and W80Z................................................................................ 13
Disassemble Pump .................................................................................................................................... 13
B60Z, B60ZAC,C60Z,C60Z
AC, and W60Z............................................................................................ 13
B80Z, B80ZAC,C80Z,C80Z
AC, W65Z, and W80Z................................................................................ 13
Assemble ........................................................................................................................................................ 15
Assemble Pump ......................................................................................................................................... 15
B60Z, B60ZAC,C60Z,C60Z
AC, and W60Z............................................................................................ 15
B80Z, B80ZAC,C80Z,C80Z
AC, W65Z, and W80Z................................................................................ 15
Install Pump Motor................................................................................................................................... 15
Install Reservoir to Pump......................................................................................................................... 16
Install ............................................................................................................................................................. 16
Lift Pump and Motor Assembly................................................................................................................ 16
Valve Repair ....................................................................................................................................................... 17
Lowering Valve .............................................................................................................................................. 17
Remove....................................................................................................................................................... 17
Install......................................................................................................................................................... 17
Relief Valve .................................................................................................................................................... 18
B60Z, B60ZAC,C60Z,C60Z
AC, and W60Z ................................................................................................ 18
Remove .................................................................................................................................................. 18
Install..................................................................................................................................................... 18
B80Z, B80ZAC,C80Z,C80Z
AC, W65Z, and W80Z .................................................................................... 19
Remove .................................................................................................................................................. 19
Install..................................................................................................................................................... 19
Check Valve.................................................................................................................................................... 19
B80Z, B80ZAC,C80Z,C80Z
AC, W65Z, and W80Z .................................................................................... 19
©2008 HYSTER COMPANY i

Table of Contents Walkie Hydraulic Systems
TABLE OF CONTENTS (Continued)
Remove .................................................................................................................................................. 19
Install..................................................................................................................................................... 20
Lift Cylinder....................................................................................................................................................... 20
Remove ........................................................................................................................................................... 20
Disassemble ................................................................................................................................................... 22
Assemble ........................................................................................................................................................ 22
Install ............................................................................................................................................................. 22
Relief Valve Adjustment .................................................................................................................................... 23
Relief Valve Pressure Check ......................................................................................................................... 23
Adjust Relief Valve Pressure......................................................................................................................... 24
B60Z, B60ZAC, C60Z, C60ZAC, and W60Z................................................................................................ 24
B80Z, B80ZAC, C80Z, C80ZAC, W65Z, and W80Z .................................................................................... 25
Troubleshooting.................................................................................................................................................. 26
Lift Assemblies .............................................................................................................................................. 26
Lift Cylinders................................................................................................................................................. 27
Lift Pump and Motor Assembly.................................................................................................................... 28
This section is for the following models:
B60Z [A230];
B80Z [A233];
C60Z [A478];
C80Z [A479];
W60Z [A231];
W65Z [A229];
W80Z [A234];
B60ZAC [B230];
B80ZAC [B233];
C60ZAC [B478];
C80ZAC [B479]
ii

1900 SRM 964 Description of Operation
General
This section covers the troubleshooting and repair
procedures for the hydraulic components on B60Z,
B80Z,B60Z,B80Z
AC, C60Z, C80Z, C60Z, C80ZAC,
W60Z, W65Z, and W80Z lift trucks.
It also includes the remove and install procedures for
the solenoid coil used to activate the lowering valve.
For troubleshooting and repairs of the electrical com-
ponents, see the sections Electrical System 2200
SRM 929, Electrical System 2200 SRM 1052, Elec-
trical System 2200 SRM 1357, or Electrical Sys-
tem 2200 SRM 1287. See the sections Curtis 1297
Transistor Motor Controller 2200 SRM 928, AC
Motor Controller 2200 SRM 1352, or AC Motor
Controller 2200 SRM 1286 for Controller functions.
Description of Operation
The hydraulic system of the B60Z, B80Z, B60Z,
B80ZAC, C60Z, C80Z, C60Z, C80ZAC, W60Z, W65Z,
and W80Z lift trucks includes:
•Reservoir
•Pump
•Check Valve
•Relief Valve
•Lowering Valve
•Lift Cylinder
•Connecting Hoses and Tubes
WARNING
Always wear the proper protective equipment
including eye protection and petroleum-resis-
tant gloves when handling hydraulic oil. Thor-
oughly wash oil from exposed areas of skin as
soon as possible.
Never check for leaks by putting hands on
hydraulic lines or components under pressure.
Hydraulic oil under pressure can be injected
into the skin.
Completely lower forks to relieve hydraulic
pressure before disassembling any part of
the lift pump or disconnecting any hydraulic
hoses.
The hydraulic oil is hot at normal operating
temperatures. Be careful when draining the
oil.
CAUTION
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
system.
Never operate the pump without the proper
amount of oil in the hydraulic system. The
operation of the hydraulic pump with low oil
levels will damage the pump.
The reservoir contains the hydraulic fluid necessary
for the operation of the system. It acts as a heat sink
to provide cooling. As the hydraulic oil leaves the
reservoir, it passes through a strainer in the reser-
voir. See Figure 1.
The hydraulic pump provides the flow of the hy-
draulic oil which activates the cylinder.
A check valve allows flow of the hydraulic oil in one
direction only. In this hydraulic system, it prevents
the oil from flowing backwards through the pump.
A relief valve limits maximum system pressure to
protect the hydraulic system components.
The lowering valve is a normally closed valve. When
it opens, hydraulic oil from the lift cylinder is allowed
to return to the reservoir, and the forks lower.
The lift cylinder rod extends to operate the lift link-
ages to raise the forks.
The connecting hoses and tubing connect the various
hydraulic components in the lift truck to complete
the hydraulic circuit. See Figure 2 and Figure 3.
1