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

Description of Operation 1900 SRM 964
1. LOWERING SOLENOID VALVE
2. TO LIFT CYLINDER
3. CHECK VALVE
4. RELIEF VALVE
5. RESERVOIR
6. INLET LINE
7. PUMP MOTOR
8. LIFT PUMP
9. ORIFICE
Figure 1. Lift Pump and Motor Assembly
Schematic
LIFTING A LOAD
To raise a load, the lift button must be depressed. De-
pressing this switch will activate the lift pump mo-
tor. Torque is transferred to the pump from the mo-
tor through the motor shaft and the coupling.
Hydraulic oil is pumped through the system as
the pump begins to operate. Atmospheric pressure
forces oil into the low pressure area at the pump
inlet. Air, which is drawn into the reservoir through
the breather, displaces the pumped oil, allowing oil
to be sent through the system. See Figure 1.
As oil is pushed out of the pump, it passes through a
one-way check valve to the lift cylinder. The check
valve prevents oil from flowing back to the pump
when lifting ceases, holding the lift cylinder in the
raised position until lowered.
The piston will begin to lift the load when fluid pres-
sure acting against it is high enough to overcome the
weight of the load.
When the piston is fully extended to the end of its
stroke or if the load is too heavy, pressure will con-
tinue to build until the rated pressure needed to op-
erate the relief valve is reached. When this occurs,
the relief valve, which is normally closed, is forced
back against its spring, creating a path for the fluid
to flow back to the reservoir.
Once relief pressure is reached, hydraulic oil will con-
tinue to be diverted from the relief valve to the reser-
voir until the lift button is released, controller time-
out is reached, or electrical power is interrupted.
LOWERING A LOAD
A load is lowered by depressing the lower button.
When the lower button is depressed, electric current
is sent to the normally closed solenoid lowering valve,
which causes it to change position and open a path
for the trapped hydraulic oil to flow from the cylin-
der back to the reservoir.
HYDRAULIC LINES
1. All hydraulic hoses and tubes must be thor-
oughly cleaned before installation.
2. When making repairs, use the least number of
fittings and connections to minimize flow resis-
tance and the possibility of leakage.
HYDRAULIC OIL
The hydraulic oil in the system performs the dual
function of the power transmission and lubrication.
Using the correct fluid is essential to proper system
operation. See the section Periodic Maintenance
8000 SRM 919, Periodic Maintenance 8000 SRM
1032, Periodic Maintenance 8000 SRM 1368, or
Periodic Maintenance 8000 SRM 1298 for the rec-
ommended hydraulic oil.
The hydraulic oil level should be checked first when
troubleshooting lifting problems. Low oil levels may
make it appear that a problem exists with the battery
or hydraulic system.
2

1900 SRM 964 Description of Operation
1. CAPSCREW
2. MOUNTING BRACKET
3. LOCKWASHER
4. CAPSCREW
5. LIFT PUMP AND MOTOR ASSEMBLY
6. ADAPTER
7. ELBOW FITTING
8. HOSE ASSEMBLY
9. FITTING
10. LIFT CYLINDER ASSEMBLY
11. FITTING
12. TUBE ASSEMBLY
13. ADAPTER
Figure 2. Hydraulic System for B60Z, B60ZAC, C60Z, C60ZAC, and W60Z Lift Trucks
3

Description of Operation 1900 SRM 964
Figure 3. Hydraulic System for B80Z, B80ZAC,C80Z,C80Z
AC, W65Z, and W80Z Lift Trucks
4

1900 SRM 964 Special Precautions
Legend for Figure 3
1. SOCKET-HEAD SCREW
2. LOCKWASHER
3. MOUNTING BRACKET
4. LOCKWASHER
5. CAPSCREW
6. LOCKWASHER
7. CAPSCREW
8. LIFT PUMP AND MOTOR ASSEMBLY
9. ADAPTER
10. FITTING
11. TUBE ASSEMBLY
12. ADAPTER
13. ELBOW FITTING
14. HOSE ASSEMBLY
15. ELBOW FITTING
16. LIFT CYLINDER ASSEMBLY
CLEAN
Adhere to the following precautionary steps to en-
sure that the hydraulic system remains clean.
1. Clean the reservoir and pump area to prevent
contaminants from entering the hydraulic sys-
tem.
2. Clean (flush) the entire system when a failure is
encountered to make sure all paint, metal chips,
welding shot, and debris are removed.
3. Filter each change of oil to prevent the introduc-
tion of contaminants into the system.
4. Provide continuous protection from airborne con-
tamination by keeping the breather cap clean
and serviceable.
SOUND LEVEL
Hydraulic system noise may be caused by both im-
properly selected oil and loose or damaged system
components.
• Cavitation - Can be caused by high fluid viscos-
ity, cold fluid temperatures, or a restriction in the
inlet screen or inlet tubing. At startup, low temper-
atures can cause pump noises due to cavitation.
• Aerated Hydraulic Oil - Results in system noise
that is similar to cavitation. Aerated oil is caused
by the ingestion of air through the joints of the in-
let lines and high-velocity discharge lines. Aera-
tion can also be caused by oil discharging above the
fluid level in the hydraulic reservoir. Aerated hy-
draulic oil occurs when air does not have sufficient
time to escape from the fluid while in the reservoir
before recycling through the system.
Special Precautions
WARNING
The capacitor in the transistor controller can
hold an electrical charge after the battery is
disconnected. To prevent an electrical shock
and personal injury, discharge the capacitor
before inspecting or repairing any component
in the drive unit compartment. Wear safety
glasses. Make certain that the battery has
been disconnected.
CAUTION
To avoid controller damage, always disconnect
the battery, discharge the capacitor, and never
put power to the controller while any power
wires are disconnected. Never short any con-
troller terminal or motor terminal to the bat-
tery. Make sure to use proper procedure when
servicing the controller.
1. Verify that the key switch is in the OFF position
and the battery connector is completely discon-
nected.
2. Discharge the capacitors in the controllers by
connecting a 200-ohm, 2-watt resistor across
the controller’s B+ and B terminals. DO NOT
short across the motor controller terminals
withascrewdriverorjumperwire. Removethe
200-ohm, 2-watt resistor before reconnecting the
battery. See Figure 4 or Figure 5.
5

Special Precautions 1900 SRM 964
1. POSITIVE CONNECTION
2. NEGATIVE CONNECTION
3. JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
Figure 4. Discharging the Capacitors (B60Z,
B80Z, C60Z, C80Z, W60Z, W65Z, and W80Z)
1. POSITIVE CONNECTION
2. NEGATIVE CONNECTION
3. JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
Figure 5. Discharging the Capacitors (B60ZAC,
B80ZAC,C60Z
AC, and C80ZAC)
6