Hyster Forklift W40Z(B218) W45Z (C215) W50Z (D215) service manual

BRAKES W20-25ZA [A495]; W25-30ZA 2 [B495]; W40Z [B218]; W45Z [C215]; W50Z [D215]

PART NO. 1511565

1800 SRM 1005

Brakes

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Description .........................................................................................................................................................

Special Precautions............................................................................................................................................

Brake Assembly Repair .....................................................................................................................................

Brake Override ..............................................................................................................................................

Remove ...........................................................................................................................................................

Repair .............................................................................................................................................................

Install .............................................................................................................................................................

Troubleshooting..................................................................................................................................................

1 1 2 3 3 4 6 7 8

This section is for the following models: W20-25ZA [A495]; W25-30ZA 2 [B495]; W40Z [B218]; W45Z [C215]; W50Z [D215]

©2008 HYSTER COMPANY

i

1800 SRM 1005

Description

General WARNING DO NOT operate a lift truck that needs repairs.

If a repair is necessary, put a DO NOT OPERATE tag on the control handle. Remove the key from the key switch.

WARNING Before performing repairs or adjustments on the brake system, blocks must be placed under each side of the frame to raise the drive tire off the ground. The blocks must prevent the lift truck from falling and causing personal injury or property damage. See Periodic Maintenance 8000 SRM 1009, Periodic Maintenance 8000 SRM 1379, or Periodic Maintenance 8000 SRM 1048, How to Put a Lift Truck on Blocks.

WARNING

free before performing any service or repairs.

If the connector is not completely free, it can reconnect. Tag the connector: DO NOT CONNECT. This section has the description and repair procedures for the electric brake on the W20ZA, W25ZA, W25ZA 2, W30ZA 2, W40Z, W45Z, and W50Z lift trucks. Brake assemblies may vary in appearance.

Although some assemblies may APPEAR to be adjustable, brake assemblies used on these trucks ARE NOT ADJUSTABLE. Friction between parts inside the brake will produce brake dust, squeaking, and extreme heat under normal operating conditions.

Brake assemblies can generate surface temperatures up to 130 C (266 F) and odors during heavy operation. Functions of the brake assembly depend on a dry and clean environment. Small amounts of oil or grease on the friction surfaces of the brake can seriously compromise the brakes ability to function.

Always disconnect and separate the battery connector so that the connector is completely

Description Motorized hand trucks have three methods of braking: 1. Regenerative (Neutral) braking 2. Controlled plugging 3. Application of the spring-applied/electrically released friction brake NOTE: The preferred method of stopping the truck is: Regenerative (Neutral) braking or Controlled plugging Regenerative (Neutral) braking applies a retarding force to the drive wheel through the traction motor, allowing the unit to slow to a gradual stop. It is applied by returning the speed/direction control to the NEUTRAL position or by placing the hand brake lever(s) in the first stage position.

Controlled plugging is reversing the speed/direction control while traveling, causing the unit to slow to a stop. Return the speed/direction control to the NEUTRAL position to remain stopped. If the speed/direction control is not returned to the

NEUTRAL position after the truck is stopped, the lift truck will accelerate in the direction the handle is being turned. Controlled plugging should stop the truck within a few feet, depending on speed and load.

The parking brake is a spring-applied, electrically released friction brake mounted to the drive motor.

When the parking brake is applied, springs inside the brake assembly compress a rotating friction disk against two stationary plates.

To release the brake: 1. Connect the battery.

2. Turn the key switch to the ON position.

3. Lower the control handle arm to the operating or BRAKE OFF position. Refer to Figure 1.

4. Rotate direction/speed control (butterfly knobs) in the direction of travel.

1

Special Precautions

1800 SRM 1005 The parking brake is applied when the control handle arm is moved to the BRAKE ON position (full up or full down position) or if a traction fault occurs. The lift truck must meet the applicable HOLD ON GRADE requirements; the parking brake should be capable of holding the lift truck on a 10 percent grade with the maximum rated load.

Figure 1. Brake Operation

Special Precautions WARNING Block each side of the truck under the drive unit frame. Position blocks on both sides of the load wheels. The blocks must prevent the lift truck from falling and causing personal injury or property damage.

The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. Discharge the capacitors in the controller by connecting a 200-ohm, 2-watt resistor across the controller’s B+ and B terminals with insulated jumper wires. DO NOT use a screwdriver to discharge the traction motor controller. See Figure 2 or Figure 3.

To avoid personal injury and prevent electrical shock, perform the following steps before performing any troubleshooting or adjustments, and before connecting or disconnecting a handset or computer.

2

CAUTION To avoid controller damage, always disconnect the battery. Discharge the capacitor and never put power to the controller with any power wire disconnected. Never short any controller terminal or motor terminal to battery. Make sure to use proper procedure when servicing the controller.

1. Block the lift truck so that the drive wheel is off the floor. Refer to the proper section for your truck: Periodic Maintenance 8000 SRM 1009, Periodic Maintenance 8000 SRM 1379, or Periodic Maintenance 8000 SRM 1048 - How to Put a Lift Truck on Blocks.

2. Turn the key switch to the OFF position and disconnect the battery.

3. Discharge the capacitors in the controllers by connecting a 200-ohm, 2-watt resistor across the controller’s B+ and B terminals. See Figure 2 or Figure 3 for your truck. DO NOT short across the motor controller terminals with a screwdriver or jumper wire. Remove the 200-ohm, 2-watt resistor before reconnecting the battery.

1800 SRM 1005

1.

2.

3.

4.

Brake Assembly Repair

POSITIVE CONNECTION NEGATIVE CONNECTION INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR

1.

2.

3.

4.

Figure 2. Discharging Controller W40Z

NEGATIVE CONNECTION POSITIVE CONNECTION 200-OHM, 2-WATT RESISTOR INSULATED JUMPER WIRES

Figure 3. Discharging Controller W20-25ZA, W25-30ZA 2, and W45-50Z

Brake Assembly Repair BRAKE OVERRIDE CAUTION Never operate the lift truck while the brake override feature is being used.

The brake can be disengaged when a truck cannot be operated but needs to be moved. On the main wiring harness approximately 300 mm (12 in.) above the MDU, the brake wiring harness is connected. An extra four pin connector for the brake override feature is secured near this connection with wire ties. Disconnect the connectors and connect the brake wiring harness to the brake override connector. This will

energize the brake coil which will release the brake.

The drive motor will not activate while the jumper is installed. Roll the lift truck to a safe location and disconnect the brake override connector. The brake will apply when the brake override connector is disconnected or when power to the brake override circuit is interrupted. Reconnect the brake wiring harness to the main wiring harness and proceed with repairs. If the battery does not have sufficient charge, or if certain components of the lift truck are damaged, the brake may not release with the brake override circuit engaged. In this case, the malfunction must be corrected before the brake can be released. See Figure 4.

3

Brake Assembly Repair

1800 SRM 1005 MDU compartment to prevent personal injury and damage to the electrical system. Always wear safety glasses.

3. Discharge capacitors. Refer to Special Precautions in the front of this section.

4. Remove Allen-head screws (7) and washers (8) from the cover that secure motor and brake assembly to MDU. 5. Support drive motor with one hand and remove remaining Allen-head screw (2) and washer (3) with other hand.

6. Remove motor and brake assembly from MDU. 7. Tag and remove wires and cables from motor and unplug brake wire harness.

8. Place motor on workbench securely supported in an upright position.

9. Remove O-ring from housing.

10. Remove nut (9) from motor shaft.

1. BRAKE WIRING HARNESS 2. MAIN WIRING HARNESS 3. BRAKE OVERRIDE CONNECTOR Figure 4. Brake Override Connector

11. Remove gear (11) and woodruff key (16) from drive motor shaft.

12. Using a standard puller, remove the bearing (13) and oil slinger (12) from drive motor shaft.

REMOVE Move the truck to a safe location before beginning work and block the wheels to prevent movement. Remove the key from the switch and disconnect the battery connector.

NOTE: For the following instructions, refer to Figure 5.

1. Turn key switch to OFF position and disconnect battery. Block the drive tire to prevent movement.

2. Remove drive unit compartment covers and MDU covers.

WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. Discharge the capacitor before inspecting or repairing any component in the

4

CAUTION Brake assemblies may vary in appearance.

Some assemblies have three Allen-head screws on top of the brake coil. DO NOT REMOVE the Allen-head screws on TOP of the brake coil.

This can change the factory preset adjustment, rendering the brake inoperable. These brakes are preset from the factory and are NOT ADJUSTABLE. 13. Using a 3 mm Allen-head insert at least 55 mm long with a square socket adaptor, remove three Allen-head capscrews securing bottom plate of brake assembly to motor.

14. Slide brake from drive motor shaft.

15. Remove spacer (10), hub (18), and woodruff key (17).

1800 SRM 1005

1.

2.

3.

4.

5.

6.

MDU HOUSING ALLEN-HEAD SCREW WASHER DRIVE MOTOR COVER FILL PLUG

Brake Assembly Repair

7.

8.

9.

10.

11.

12.

ALLEN-HEAD SCREW WASHER NUT SPACER GEAR OIL SLINGER

13.

14.

15.

16.

17.

18.

BALL BEARING O-RING BRAKE ASSEMBLY WOODRUFF KEY (GEAR) WOODRUFF KEY (HUB) HUB

Figure 5. Brake Assembly

5

Brake Assembly Repair

REPAIR If a brake assembly is malfunctioning, the cause may be electrical, mechanical, or a combination of both. If the brake electrical system is functioning correctly, the brake should release with one solid "click" when energized. The brake coil is a large 24 V coil that acts as an electromagnet to pull the armature plate away from the friction disk. If the brake coil is too weak to compress the brake springs and release the friction disk, the brake must be replaced.

1. Disconnect the brake wiring harness (if brake is installed to truck).

1800 SRM 1005 assembly from the lift truck, visually inspect the brake. Use a feeler gauge to check the gap between the brake coil and armature plate in several places around the brake to determine if the brake is near the end of normal service life. Proper air gap measurements range from 0.2 to 0.6 mm (0.0078 to 0.024 in.). See Figure 6. The brake must be replaced if it no longer meets the proper air gap specifications or if otherwise malfunctioning. The brake hub and the brake assembly can be replaced separately.

However, if there is damage to the brake hub, there is most likely damage to the brake assembly.

2. Check voltage to the brake using a voltmeter. a. Turn the key switch to the ON position. b. Place the control handle arm in the BRAKE OFF position. c. Lightly rotate the directional controls to activate the brake coil circuit. d. Touch each lead of a voltmeter to each side of the MAIN WIRING HARNESS connector where the brake wiring harness connects. e. Voltage to the brake should read approximately 24 V. 3. Check the resistance of the brake coil using an ohmmeter. a. Touch each lead of the ohmmeter to each side of the brake wiring harness connector. b. If the brake coil resistance reads between 30.24 and 27.36 (ohms), the brake coil is functioning properly. c. If the resistance reading falls outside the specified range, the entire brake assembly must be replaced.

If the brake mechanical functions are not operating correctly, the brake will not hold a fully loaded lift truck on a 10% grade. The brake is NOT ADJUSTABLE and must be replaced when it will not hold to specification. If removing the drive motor

6

1.

2.

3.

4.

BRAKE COIL AIR GAP ARMATURE PLATE FEELER GAUGE Figure 6. Brake Assembly

1800 SRM 1005

INSTALL For the following instructions, refer to Figure 5.

1. Install woodruff key (17) to drive motor shaft and slide hub onto shaft and key. Make sure groove and key are aligned properly.

2. Install spacer (10) and brake assembly on to motor shaft and slide down on to hub. Make sure brake spline align with teeth on the hub.

CAUTION Brake assemblies may vary in appearance.

Some assemblies have three Allen-head screws on top of the brake coil. DO NOT TURN the Allen-head screws on TOP of the brake coil.

This can change the factory preset adjustment, rendering the brake inoperable. These brakes are preset from the factory and are NOT ADJUSTABLE.

Brake Assembly Repair 8. Place motor shaft assembly into housing. Position motor and brake correctly to align brake wiring harness in notch. See Figure 7. Hold the motor in place until next step is complete.

9. Install Allen-head screw (2) and washer (3).

10. Install Allen-head screws (7) and washers (8).

Torque all three Allen-head screws to 10 N•m (7 lbf ft).

11. Install MDU covers and drive unit compartment covers.

12. Reconnect battery, and remove blocks from wheels.

13. Brake should hold parked lift truck loaded to capacity on a 10% grade. Test for proper operation before returning to service.

3. Using a 3 mm Allen-head insert at least 55 mm long with a square socket adaptor, install three Allen-head capscrews securing bottom plate of brake assembly to motor. Torque to 2.8 N•m (25 lbf in) 4. Install bearing assembly (13), and oil slinger (12), on to shaft using a standard press.

5. Install woodruff key (16), gear (11), and nut (9) to shaft. Torque nut to 26 N•m (19 lbf ft).

6. Install O-ring into housing. Lubricate O-ring with grease to ensure proper installation of drive motor shaft assembly.

7. Reconnect wiring as removed.

CAUTION The brake wiring harness must be aligned with the notch in the MDU housing. If the motor and brake assembly is secured to the MDU incorrectly, the brake wiring harness may be damaged.

1. MDU HOUSING 2. BRAKE WIRE NOTCH Figure 7. MDU Brake Wire Notch

7

Troubleshooting

1800 SRM 1005

Troubleshooting PROBLEM Brake does not release.

Brake does not hold truck loaded to capacity on 10% grade.

8

POSSIBLE CAUSE

PROCEDURE OR ACTION

Key switch is in the OFF position.

Turn key switch to the ON position.

Handle is not in the BRAKE OFF position.

Move the handle to the BRAKE OFF position.

Control handle arm prox switch is out of adjustment/damaged.

Adjust/replace control handle arm prox switch. See the section Electrical System 2200 SRM 1007.

Coil is open.

Measure coil resistance. If resistance is too high (above 30.24 ), replace the brake assembly.

Coil has shorted to frame or between the windings.

Measure coil resistance. If resistance is too low (below 27.36 ), replace the brake assembly.

Check coil for short to frame using an ohmmeter. If shorted to frame, replace the brake assembly.

Incorrect or no voltage supplied to brake.

Measure voltage to brake using a voltmeter. If voltage is not 24 VDC Âą10%, check connector.

Troubleshoot electrical system.

Air gap is too large.

Replace the brake assembly.

Air gap is too large.

Replace the brake assembly.

Friction disk is too worn.

Replace the brake assembly.

Brake hub damaged.

Replace brake and hub assembly.

CAPACITIES AND SPECIFICATIONS W40Z [B218]; W45Z [C215]; W50Z [D215]

PART NO. 1499833

8000 SRM 1010

Capacities and Specifications

Table of Contents

TABLE OF CONTENTS Hydraulic Oils ....................................................................................................................................................

Gear Oils.............................................................................................................................................................

Grease .................................................................................................................................................................

Hydraulic System...............................................................................................................................................

Weight.................................................................................................................................................................

Basic Truck Without Battery ........................................................................................................................

Tires ....................................................................................................................................................................

Torque Specifications .........................................................................................................................................

Caster Assembly ............................................................................................................................................

Master Drive Unit .........................................................................................................................................

Steering ..........................................................................................................................................................

Brake ..............................................................................................................................................................

Lift Mechanism ..............................................................................................................................................

Battery Specifications and Adjustments ..........................................................................................................

4000 LB - 24 Volt ...........................................................................................................................................

4500 - 12 Volt .................................................................................................................................................

4500 and 5000 LB - 24 Volt ...........................................................................................................................

1 2 3 4 4 4 5 5 5 5 5 5 5 5 5 6 7

This section is for the following models: W40Z [B218]; W45Z [C215]; W50Z [D215]

©2006 HYSTER COMPANY

i

8000 SRM 1010

Hydraulic Oils

Hydraulic Oils W40/45Z (and W50Z Standard Construction Only) Type

For All Hydraulically Actuated Equipment

Ambient Air Temp. Condition

Normal

Anticipated Ambient Air Temperature Range

0 to +43 C (+32 to +109 F)

0 to

28 to +64 C (+18 to +147 F)

40 to +50 C ( 40 to +122 F)

Actual Useable Operation Oil Temperature Range

Cold Storage

S-215/92 Minimum

ASTM Viscosity Grade Number/Index (Ref.) Pour Point

32 C (+32 to

26 F)

S-376 Minimum

29 C ( 20 F)

60 C ( 76 F)

Approved Sources American (Amoco)

Rykon Number 21

No Product

Atlantic Richfield (Arco)

Duro AW-46

No Product

Burmah-Castrol

Hyspin AWH-46

No Product

Chevron Oil Company

Chevron AW Hyd. Oil 46

No Product

Cities Service (Citco)

Pacemaker XD-20

No Product

Exxon

Nuto H 46

UnivisÂŽ HVI 26

Fiske Brothers

Lubriplate HO-1

No Product

Gulf

Harmony 48AW

No Product

Houghton & Company

Hydro Drive HP 200

No Product

Keystone (Pennwalt)

KLC Number 5

No Product

Mobil Oil Co. (Mobil)

DTE 25

No Product

Pennzoil Oil Co.

Pennzoil AW 46

No Product

Phillips Petroleum

Magnus A-215

No Product

Shell

Tellus 46

No Product

Solene Ind. Lubricant

H-205-B

No Product

Sun Oil Co. (Sunoco)

Sunvis 821 WR

No Product

Texaco

Rando HD-46

No Product

Valvoline Oil Co.

Antiwear Number 20

No Product

Field Personnel Note: The hydraulic oils, as listed herein, are approved sources that meet or exceed the specifications annotated. The use of hydraulic oils other than the suppliers and products listed is unauthorized.

W50Z (Cold Storage/Arctic Package) Type Ambient Air Temp. Condition Anticipated Ambient Air Temperature Range

For All Hydraulically Actuated Equipment Cold Storage/Arctic Package 32 to 0 C ( 26 to +32 F)

1

Gear Oils

8000 SRM 1010

W50Z (Cold Storage/Arctic Package) 40 to +50 C ( 40 to +122 F)

Actual Useable Operation Oil Temperature Range

376

Viscosity /Index (Ref.) ASTM D 2270

60 C ( 76 F)

Pour Point Approved Sources Exxon

UnivisÂŽ HVI 26

Field Personnel Note: The hydraulic oils, as listed herein, are approved sources that meet or exceed the specifications annotated. The use of hydraulic oils other than the suppliers and products listed is unauthorized.

Gear Oils Operating Condition

Standard/CS/Freezer/Food Processing

Arctic

SAE Grade

80W-90

75W-90

Type

Multipurpose EP

Multipurpose EP

Base Oil

Conventional Petroleum

Synthetic

MIL-Specification No.

MIL-L-2105C

MIL-L-2105C

API Service Classification

GL-5

GL-5

Anticipated Ambient Temperature

26 to +38 C ( 15 to +100 F) Most HYSTER lift truck operations will fall within this temperature range.

As low as 51 C ( 60 F) Primarily intended for cold storage and/or Arctic conditions; can be used as high as +32 C (+90 F).

Approved Sources Chevron

Chevron Universal Gear Lube 80W/90

No Product

Exxon

Exxon Gear Oil GX 80W/90

No Product

Mobil

Mobilube HD 80W/90

Mobilube SHC 75W/90

Pennzoil

Pennzoil MP 4092

No Product

Phillips 66

Philube SMP Gear Oil 80W/90

No Product

Solene Lub. Inc.

Solene Gear Oil #905

No Product

Sun

Sunfleet GL-5 Gear Lube 80W/90

No Product

Union 76

Unocal MP Gear Lube LS 80W/90

No Product

Field Personnel Note: The products listed above are the approved sources that meet or exceed HYSTER specifications. The use of products other than that listed above is unauthorized.

2

8000 SRM 1010

Grease

Grease Fittings and Bearings Application

Standard/CS/Freezer

Arctic/Food Processing

Steer Bearings

Approved Vendor

Mobilgrease® 28

Amsoil GHD®

Amsoil GHD®

Oil

Synthetic

Synthetic

Synthetic

Thickener

Clay

Lithium Complex

Lithium Complex

Grade NGLI

1.5

2.0

2.0

Moly-Fortified

No

Yes

Yes

Dropping Pt.

310 C (590 F)

288 C (550 F)

288 C (550 F)

Field Personnel Note: The product listed above is the approved source that meets or exceeds HYSTER specifications. The use of products other than that listed above is unauthorized.

Required for W50Z - Cold Storage/Arctic Packages Application

Cold Storage/Arctic Package

Oil

Synthetic

Thickener

Lithium Complex

Dropping Point Approximately

+288 C (+550 F)

Base Oil Viscosity (SUS)

151 @ +40 C (+104 F)

Nominal Operating Temperature Range Identification

40 to +122 C ( 40 to +250 F) Container must be plainly marked with supplier’s product identification.

Approved Sources AMSOIL

GHD Synthetic NGLI #2 GC-LB

Field Personnel Note: The product listed above is the ONLY approved source that meets or exceeds HYSTER specifications. The use of products other than that listed above is unauthorized.

3

Weight

8000 SRM 1010

Hydraulic System Operating Pressure 1 Truck Size

Ampere Draw 2

Volts

Relief Setting

No Load

Rated Load

No Load

Rated Load

Pressure 3

Amp Draw

4000lb

24

2.1 MPa (300 psi)

7.7 MPa (1800 psi)

25

70

17.15 MPa (2450 psi)

85

4500lb

12

3.85 MPa (550 psi)

12.6 MPa (1800 psi)

60

100

19.6 MPa (2800 psi)

150

4500lb

24

3.08 MPa (440 psi)

11.9 MPa (1700 psi)

30

75

18.9 MPa (2700 psi)

110

5000lb

24

2.62 MPa (380 psi)

14.8 MPa (2152 psi)

24

98

20.0 MPa (2900 psi)

120

Standard Specifications Hydraulic Tank Capacity - 0.75 liter (25.4 oz) Pump Displacement (24 Volts) - 1.25 cm 3 /rev (0.076 in. 3 /rev) Pump Displacement (12 Volts) - 1.25 cm 3 /rev (0.076 in. 3 /rev) Creep Rate - 6.4 mm (0.25 in.) Maximum In 10 Minutes @ 21 C (70 F) Oil Temperature Footnotes ±0.35 MPa (±51 psi) @ 21 C (70 F) Oil Temperature 2 ±10 Amps @ 1.270 Battery Specific Gravity +0.6 to 0.0 MPa (+87 to 0 psi) @ 21 C (70 F) Oil Temperature Full Flow 1

3

Weight BASIC TRUCK WITHOUT BATTERY Battery Compartment Inside Dimension

Fork Length 900 mm (35.4 in.)

Weight

Fork Length 1050 mm (41.3 in.)

Weight

Fork Length 1200 mm (47.2 in.)

Weight

Fork Length 1400 mm (55.1 in.)

Weight

Fork Length 1500 mm (59.0 in.)

Weight

4000 lb

193 × 700 mm (7.6 × 27.5 in.)

243 kg (536 lb)

258 kg (568 lb)

272 kg (600 lb)

N/A

301 kg (665 lb)

4500 lb 12V

193 × 780 mm (7.6 × 30.7 in.)

238 kg (525 lb)

253 kg (557 lb)

267 kg (589 lb)

N/A

297 kg (654 lb)

4500 lb 24V

218 × 700 mm (8.6 × 27.5 in.)

249 kg (548 lb)

263 kg (580 lb)

278 kg (612 lb)

N/A

307 kg (677 lb)

5000 lb

218 × 700 mm (8.6 × 27.5 in.)

237 kg (522 lb)

245 kg (540 lb)

251 kg (553 lb)

260 kg (573 lb)

266 kg (586 lb)

Weight

4

8000 SRM 1010

Battery Specifications and Adjustments

Tires Weight and Voltage

Drive Tire

Load Wheel

4000 lb

9 × 4 in.

3.25 × 4.5 in.

4500 lb, 12 Volts

9 × 4 in.

3.25 × 4.5 in.

4500 lb, 24 Volts

9 × 4 in.

3.25 × 4.5 in.

5000 lb

9 × 4 in.

3.25 × 4.5 in.

Torque Specifications CASTER ASSEMBLY Mounting Capscrews (3 each) 57 N•m (42 lbf ft)

MASTER DRIVE UNIT Motor Mount Studs (3 each) 20 N•m (15 lbf ft) Transmission to Frame Mounting Bolts (4 each) Torque to 54 N•m (40 lbf ft) Then loosen, and torque to 34 N•m (25 lbf ft) Drain Plug 41 N•m (30 lbf ft)

Gas Springs Mounting Stud (1 each) 25 N•m (18.5 lbf ft) Control Arm Support Bracket Pivot Pins (2 each) 142 ±7 N•m (105 ±5 lbf ft)

BRAKE Mounting Capscrews (3 each) 11 N•m (25 lbf in) Traction Motor Power Wire Nuts (4 each) 5 N•m (44 lbf in) Controller Hardware Connections M5 metric screw 3 N•m (26.5 lbf in) M5 metric nut 4.5 N•m (40 lbf in) M5 metric screw and nut 88 N•m (115 lbf in)

Fill-Level Plug 41 N•m (20 lbf ft) 27 N•m (20 lbf ft)

LIFT MECHANISM

STEERING Steer Handle to Tiller Bracket Screws (2 each) 115 N•m (85 lbf ft)

Hydraulic Power Unit Mounting Capscrews (3 each) 24 N•m (18 lbf ft)

Butterfly Throttle Control to Handle Screws (2 each) 1 N•m (8.9 lbf in)

Battery Specifications and Adjustments 4000 LB - 24 VOLT Battery Compartment is shown in Figure 1.

5

Battery Specifications and Adjustments

8000 SRM 1010

Figure 1. Battery Compartment Ampere Hours (Max)

Kilowatt Hours (Max)

Compartment Length (X)

Compartment Width (Y) (Max)

Recommended Height (Max)

Weight (Max)

Standard Battery Pack with 25 amp charger

158

3.8

721.4 mm (28.4 in.)

200.7 mm (7.9 in.)

607 mm (23.9 in.)

141 kg (310 lb)

GNB PalletPro™ Battery Pack with 25 amp charger

195

4.4

693.4 mm (27.3 in.)

190.5 mm (7.5 in.)

670.6 mm (26.4 in.)

170 kg (375 lb)

85

170

4.0

635 mm (25 in.)

167.6 mm (6.6 in.)

591.8 mm (23.3 in.)

183 kg (403 lb)

Number of Cells

Cell Size

Ampere Hours (Max)

Kilowatt Hours (Max)

Compartment Length (X)

Compartment Width (Y) (Max)

Recommended Height (Max)

Weight (Max)

6

85

425

5.0

662.3 mm (26.1 in.)

195.6 mm (7.7 in.) d

591.8 mm (23.3 in.)

198 kg (436 lb)

Number of Cells

Cell Size

Industrial Battery, with 12 cells

4500 - 12 VOLT

6

8000 SRM 1010

Battery Specifications and Adjustments

Cell Size

Ampere Hours (Max)

Kilowatt Hours (Max)

Compartment Length (X)

Compartment Width (Y) (Max)

Recommended Height (Max)

Weight (Max)

6

85

425

5.0

792.5 mm (31.2 in.)

198 mm (7.8 in.)

591.8 mm (23.3 in.)

232 kg (512 lb)

6

85

510

6.0

777.3 mm (30.6 in.) a

195.6 mm (7.7 in.) c

591.8 mm (23.3 in.)

231 kg (510 lb)

Number of Cells

Note:If Y is less than 184 mm (7.25 in.), A supplemental spacer is required. a – Use 6.35 mm (1.26 in.) spacer. b – Use 25.4 mm (1 in.) spacer. c – Use 16 mm (0.63 in.) spacer. d – Use 32 mm (1.26 in.) spacer. e – Use 16 mm (0.63 in.) spacer.

4500 AND 5000 LB - 24 VOLT Number of Cells

Cell Size

GNB PalletPro™ Battery Pack with 25 amp charger

Ampere Hours (Max)

Kilowatt Hours (Max)

Compartment Length (X)

Compartment Width (Y) (Max)

Recommended Height (Max)

Weight (Max)

195

4.4

693.4 mm (27.3 in.)

190.5 mm (7.5 in.)

670.6 mm (26.4 in.)

163 kg (360 lb)

12

75

150

3.5

642.6 mm (25.3 in.) b

162.6 mm (6.4 in.) e

591.8 mm (23.3 in.)

186 kg (410 lb)

12

85

170

3.9

642.6 mm (25.3 in.) b

162.6 mm (6.4 in.) e

591.8 mm (23.3 in.)

193 kg (425 lb)

12

100

200

4.6

642.6 mm (25.3 in.) b

162.6 mm (6.4 in.) e

668 mm (26.3 in.)

213 kg (470 lb)

12

75

225

5.2

652.8 mm (25.7 in.) b

223.5 mm (8.8 in.)

591.8 mm (23.3 in.)

245 kg (540 lb)

12

85

255

6.0

652.8 mm (25.7 in.) b

223.5 mm (8.8 in.)

591.8 mm (23.3 in.)

245 kg (540 lb)

Note:If Y is less than 210 mm (8.25 in.), a supplemental spacer is required. a – Use 6.35 mm (1.26 in.) spacer. b – Use 25.4 mm (1 in.) spacer. c – Use 16 mm (0.63 in.) spacer. d – Use 32 mm (1.26 in.) spacer. e – Use 16 mm (0.63 in.) spacer.

7

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

8

DIAGRAMS W40Z [B218]; W45Z [C215]

PART NO. 1499812

8000 SRM 1011

Diagrams

Table of Contents

TABLE OF CONTENTS General Notes.....................................................................................................................................................

Diagrams, Schematics, or Arrangements .........................................................................................................

Figure 1. 1.8 Ton Schematic Diagram......................................................................................................

Figure 2. 1.8 Ton Schematic Diagram......................................................................................................

Figure 3. 1.8 Ton Schematic Diagram......................................................................................................

Figure 4. 1.8 Ton Schematic Diagram......................................................................................................

Figure 5. 2.0-Ton, 24-Volt Schematic .......................................................................................................

Figure 6. 2.0-Ton, 12-Volt Schematic .......................................................................................................

Figure 7. 2.0-Ton, 24-Volt Schematic .......................................................................................................

Figure 8. 2.0-Ton, 12-Volt Diagram..........................................................................................................

Figure 9. 2.0 Ton Diagram........................................................................................................................

1 1 2 3 4 5 6 8 10 12 14

This section is for the following models: W40Z [B218]; W45Z [C215]

Š2007 HYSTER COMPANY

i

8000 SRM 1011

Diagrams, Schematics, or Arrangements

General Notes All parts are shown in the normal position for the following conditions: • Unit is stopped.

• Operator is off the unit.

• Battery is disconnected.

• Reverse is travel in the direction of the forks.

• Broken lines are for options only.

• All unused terminals and connectors must be secured to a main wire harness branch.

• All connectors are drawn from front view and are enlarged for clarity.

• AC charger with internal relay key switch disconnected.

• AC charger included with standard flooded cell battery pack.

1

Diagrams, Schematics, or Arrangements

Figure 1. 1.8 Ton Schematic Diagram

2

8000 SRM 1011

8000 SRM 1011

Diagrams, Schematics, or Arrangements

Figure 2. 1.8 Ton Schematic Diagram

3

Diagrams, Schematics, or Arrangements

Figure 3. 1.8 Ton Schematic Diagram

4

8000 SRM 1011

8000 SRM 1011

Diagrams, Schematics, or Arrangements

Figure 4. 1.8 Ton Schematic Diagram

5

Diagrams, Schematics, or Arrangements

6

8000 SRM 1011

8000 SRM 1011

Diagrams, Schematics, or Arrangements

Figure 5. 2.0-Ton, 24-Volt Schematic

7

Diagrams, Schematics, or Arrangements

8

8000 SRM 1011

8000 SRM 1011

Diagrams, Schematics, or Arrangements

Figure 6. 2.0-Ton, 12-Volt Schematic

9

Diagrams, Schematics, or Arrangements

10

8000 SRM 1011

8000 SRM 1011

Diagrams, Schematics, or Arrangements

Figure 7. 2.0-Ton, 24-Volt Schematic

11

Diagrams, Schematics, or Arrangements

12

8000 SRM 1011

8000 SRM 1011

Diagrams, Schematics, or Arrangements

Figure 8. 2.0-Ton, 12-Volt Diagram

13

Diagrams, Schematics, or Arrangements

Figure 9. 2.0 Ton Diagram

14

8000 SRM 1011

ELECTRICAL SYSTEM W20-25ZA [A495]; W40Z [B218]; W25-30ZA 2 [B495]; W45Z [C215]; W50Z [D215]

PART NO. 1511566

2200 SRM 1007

Electrical System

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Description of Operation....................................................................................................................................

Special Precautions............................................................................................................................................

Moving a Disabled Lift Truck............................................................................................................................

Electrical System Checks ..................................................................................................................................

Safety Precautions.........................................................................................................................................

Repairs................................................................................................................................................................

Controller, Replace ........................................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Contactor Coil, Check....................................................................................................................................

Contactor, Replace .........................................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Key Switch Removal and Installation ..............................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Battery Indicator/Hourmeter Display ..............................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Fuses...................................................................................................................................................................

W40Z ..............................................................................................................................................................

W45-50Z .........................................................................................................................................................

W20-25ZA.......................................................................................................................................................

W25-30ZA 2 .....................................................................................................................................................

Control Handle Arm Proximity Switch ............................................................................................................

Repair .............................................................................................................................................................

Check and Adjust ......................................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Control Handle...................................................................................................................................................

Disassemble ...................................................................................................................................................

Control Handle Card (Old Style) ..................................................................................................................

Control Handle Card (New Style).................................................................................................................

Configure ...................................................................................................................................................

Calibrate ....................................................................................................................................................

Assemble ........................................................................................................................................................

Switches (ON/OFF and Proportional) ..........................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Traction Motor....................................................................................................................................................

Disassemble ...................................................................................................................................................

Assemble ........................................................................................................................................................

Lift Pump Motor.................................................................................................................................................

Repair (W20-25ZA and W25-30ZA 2).............................................................................................................

Lift Link Proximity Sensor (W50Z)...................................................................................................................

Check..............................................................................................................................................................

Repair .............................................................................................................................................................

Remove.......................................................................................................................................................

Test .............................................................................................................................................................

Install .........................................................................................................................................................

©2008 HYSTER COMPANY

1 2 4 6 7 7 7 7 7 10 10 10 10 11 11 11 11 11 12 12 12 12 12 12 12 13 13 13 13 14 14 14 15 16 16 17 18 20 20 20 21 21 21 23 23 24 24 24 24 25 25

i

Table of Contents

Electrical System

TABLE OF CONTENTS (Continued) Adjust .........................................................................................................................................................

Battery Charger (Early Models)........................................................................................................................

Description .....................................................................................................................................................

Operation .......................................................................................................................................................

Charging ....................................................................................................................................................

Equalize .....................................................................................................................................................

Signals........................................................................................................................................................

Protections .................................................................................................................................................

Troubleshooting .............................................................................................................................................

Battery Charger (Late Models) .........................................................................................................................

Description .....................................................................................................................................................

Operation .......................................................................................................................................................

LED Display ..............................................................................................................................................

Charging ....................................................................................................................................................

Troubleshooting .............................................................................................................................................

Battery Mode Selection (DPI Early Models) ................................................................................................

Changing Mode Setting (DPI Early Models) ...........................................................................................

Battery Mode Selection (DPI Late Models)..................................................................................................

Changing Mode Setting (DPI Late Models) .............................................................................................

Troubleshooting..................................................................................................................................................

This section is for the following models: W20-25ZA [A495]; W40Z [B218]; W25-30ZA 2 [B495]; W45Z [C215]; W50Z [D215]

ii

25 26 26 26 26 26 26 26 26 29 29 29 29 29 29 30 31 31 31 32

2200 SRM 1007

General

General This section includes removal, disassembly, checks, adjustments, assembly, and installation procedures for the electrical system components on the W20-25ZA [A495], W25-30ZA 2 [B495], W40Z [B218], W45Z [C215], and W50Z [D215] truck models. This section does NOT include the electrical components covered in other sections such as motors and industrial batteries. See Figure 1.

See the section ZAPI™ Controllers 2200 SRM 1064 for models W20-25ZA [A495] and W25-30ZA 2 [B495] ; ZAPI™ Controllers 2200 SRM 1006 for models W40Z [B218]; ZAPI™ Controllers 2200 SRM 1067 for models W45Z [C215] and W50Z [D215] for models for additional information on the ZAPI™ display

and for information on troubleshooting fault codes, adjusting parameters, and testing the ZAPI™ motor controller.

See the section DC Motor Maintenance 620 SRM 294 for general information on DC motors.See the section Periodic Maintenance 8000 SRM 1048 for models W20-25ZA [A495]; Periodic Maintenance 8000 SRM 1009 for models W40Z [B218], W45Z [C215], and W50Z [D215]; Periodic Maintenance 8000 SRM 1379 for models W25-30ZA 2 [B495].

See the section Diagrams 8000 SRM 1050 for models W20-25ZA [A495]; Diagrams 8000 SRM 1011 for models W40Z [B218] and W45Z [C215];Diagrams 8000 SRM 1228 for models W50Z [D215]; Diagrams 8000 SRM 1381 for models W25-30ZA 2 [B495].

Figure 1. Electrical Components

1

Description of Operation

2200 SRM 1007 Legend for Figure 1

1.

2.

3.

4.

5.

6.

7.

8.

BATTERY CONNECTOR BATTERY INDICATOR/HOURMETER DISPLAY KEY SWITCH POSITIVE BATTERY CABLE LIFT PUMP MOTOR WIRING HARNESS CONTROL HANDLE ARM PROXIMITY SWITCH DRIVE MOTOR

9.

10.

11.

12.

13.

14.

15.

MAIN CONTACTOR CONTROL FUSE HORN ZAPI™ MOTOR CONTROLLER POWER FUSE NEGATIVE BATTERY CABLE LOWERING VALVE

Description of Operation See Figure 2 for the logic diagram.

This section includes information on the following components: • Control handle switches (ON/OFF and proportional) • Hall effect directional/speed control • Control handle card • ZAPI™ motor controller • Traction motor • Main contactor • Brake coil • Lift pump motor • Lift time-out • Batteries ON/OFF switches are used for: • Single speed lift and lower functions • Half speed lift and lower functions • Horn • Traction reversing • Creep (Turtle) speed • Throttle neutral signal W20-25ZA and W25-30ZA 2: Standard lift switches are ON/OFF type. Standard left-side lift switches are at half speed. The right-side lift switches are at full speed. Optional proportional lifting switches are available on the right side. Proportional switches provide a variable output to regulate the speed of the lift and lower functions.

All lower switches are proportional type switches which allow the operator to maintain maximum control of the load when lowering.

W40-45-50Z: Use only full speed lift and lower switches.

A Hall effect throttle control is used to provide a directional/speed signal. The neutral switch verifies the neutral position during the self check at startup.

2

The Hall effect throttle control, neutral switch, traction reversing switch, horn switch, and creep (turtle) speed switch are an integral part of the control handle card and not serviced separately. The switches that control the hydraulic functions mount into the control handle and are serviced separately.

The Hall effect throttle control, the proportional switches and all the ON/OFF switches provide input signals to the control handle card. The control handle card uses serial communication to send these signals to the ZAPI™ motor controller.

The ZAPI™ motor controller contains the system logic. The motor controller receives the inputs, processes the commands, and provides outputs to the appropriate component to activate them.

The traction motor armature and separately excited field are powered directly by the motor controller. No contactors are involved in the traction circuit.

The main contactor opens to remove power from the truck to disable all traction and lift functions in the event of an electric failure.

Energizing the brake coil pulls the brake pressure plate away from the friction disc to disengage the brake. The controller powers the brake coil based on signals from the control handle arm proximity switch and the Directional/Speed Control. The controller also contains logic to engage the brake regardless of handle position if the truck is stationary.

W20-25ZA and W25-30ZA 2: The motor controller energizes the series wound lift pump motor when either lift function switch is depressed. The applied voltage to the motor varies to adjust motor RPM and pump output to the lift function.

W40-45-50Z: The motor controller energizes the series wound lift pump motor when either lift function switch is depressed.

2200 SRM 1007

Description of Operation

W20-25ZA and W25-30ZA 2: All trucks have a solenoid operated lowering valve at the pump. The motor controller activates the solenoid coil to open the lowering valve. The motor controller varies the voltage to the lowering solenoid to provide proportional lowering.

W40-45-50Z: All trucks have a solenoid operated lowering valve at the pump. The motor controller activates the solenoid coil to open the lowering valve.

The lift time-out protects the lift pump and motor assembly, eliminating the need for a height limit switch. Lift is disabled after the pump runs for a programmed amount of time. Lift is disabled on the W20-25ZA and W25-30ZA 2 trucks after operating continuously for approximately 45 seconds. Lift is disabled on the W40-45-50Z trucks after operating continuously for approximately six seconds. The lift time-out feature is reset once lower is selected.

The standard W20ZA, W25ZA 2, and W40Z trucks are equipped with a battery pack consisting of 4, 6 volt, deep cycle, automotive style batteries and an onboard 25-amp charger. The battery pack uses a 175-amp, X-type connector. This connector provides two auxiliary contacts for the truck inhibit circuit, allowing the batteries to remain connected to the truck while the charger is operating. The W20ZA, W25ZA 2, and W40Z can be configured with a standard 175-amp battery connector to accept the optional GNB PalletPro. The W25ZA, W30ZA 2, and W45-50Z are shipped without batteries. Standard trucks have a 175-amp battery connector and will accept industrial flooded cell batteries or maintenance free batteries, such as the GNB PalletPro.

Figure 2. Logic Diagram

3

Special Precautions

2200 SRM 1007

Special Precautions WARNING DO NOT make repairs or adjustments unless you have both authorization and training. Repairs and adjustments that are not correct 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.

WARNING Disconnect the battery and separate the connector before opening the drive unit compartment cover or inspecting 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.

WARNING Some checks and adjustments are done with the battery connected. DO NOT connect the battery until the procedure tells you to do so.

Never have any metal on your fingers, arms, or neck. Metal items can accidentally make an electrical connection and cause injury.

WARNING Before doing any tests or adjustments, raise the vehicle off the ground and block the lift truck to prevent unexpected movement. See the section Periodic Maintenance 8000 SRM 1048, Periodic Maintenance 8000 SRM 1009, or Periodic Maintenance 8000 SRM 1379 for your lift truck. Refer to How to Put a Lift Truck on Blocks.

4

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 controller terminal or motor terminal to the battery. Make sure to use proper procedure when servicing the controller.

1. Block load wheels to prevent lift truck from moving. See the section Periodic Maintenance 8000 SRM 1048, Periodic Maintenance 8000 SRM 1009, or Periodic Maintenance 8000 SRM 1379 for your lift truck.

2. Turn the key switch to the OFF position and disconnect the battery.

3. 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 with a screwdriver or jumper wire. See Figure 3 or Figure 4.

4. Remove the 200-ohm, 2-watt resistor before reconnecting the battery.

2200 SRM 1007

1.

2.

3.

4.

NEGATIVE CONNECTION POSITIVE CONNECTION 200-OHM, 2-WATT RESISTOR INSULATED JUMPER WIRES Figure 3. Discharging the Capacitor (W20-25ZA, W45-50Z, and W25-30ZA 2)

Special Precautions

1.

2.

3.

4.

POSITIVE CONNECTION NEGATIVE CONNECTION INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR

Figure 4. Discharging the Capacitor (W40Z)

5

Moving a Disabled Lift Truck

2200 SRM 1007

Moving a Disabled Lift Truck In order to move a disabled lift truck, the electric brake must be released by powering the brake coil with battery voltage. A jumper is provided in the wiring harness to supply battery voltage directly to the electric brake to release it. The truck will roll freely, but the drive motor will not activate while the jumper is installed.

WARNING Prior to releasing the electric brake, make sure the lift truck is blocked correctly to prevent movement, causing personal injury or damage to equipment.

CAUTION Always unplug the Brake Override Circuit and connect the Brake Harness prior to operating the lift truck.

9. Make sure the brake override circuit is disconnected from the brake harness. The brake will remain released until the battery or the brake override circuit is disconnected. Restore the harness connector to the normal operation connector correctly before attempting to operate the lift truck.

1. Turn the key switch to the OFF position.

2. Disconnect and separate the battery connectors.

3. Remove the upper drive unit compartment cover.

4. Remove the lower drive unit compartment cover.

5. On the main wiring harness approximately 300 mm (12 in.) above the MDU, the brake wiring harness is connected. An extra four-pin connector for the brake override feature is secured near this connection with wire ties.

6. Disconnect the connectors and connect the brake wiring harness to the brake override connector.

See Figure 5.

NOTE: The brake will release when battery is connected. The brake will remain released until the battery is disconnected or the brake override circuit is disconnected.

7. Connect the battery connectors.

8. Roll the lift truck to a safe, level area prior to performing any repairs on it.

1. BRAKE HARNESS CONNECTOR 2. BRAKE OVERRIDE CIRCUIT CONNECTOR 3. NORMAL OPERATION CONNECTOR Figure 5. Brake Override Connector

6

2200 SRM 1007

Repairs

Electrical System Checks SAFETY PRECAUTIONS NOTE: On some models, the dash indicator will display the code: EP 107 (or a higher number) for 1 to 2 seconds every time the key switch is turned to the ON position. This code represents the EEPROM software version and DOES NOT INDICATE A FAULT CODE. NOTE: These checks require a volt-ohmmeter. Specific checks require additional equipment.

NOTE: The correct meter polarity is necessary for the checks. The voltage checks are made between the individual points and battery negative. Connect the meter negative to battery negative.

1. Block lift truck so the drive wheels are off the floor. See the section Periodic Maintenance 8000 SRM 1048, Periodic Maintenance 8000 SRM 1009, or Periodic Maintenance 8000 SRM 1379 lift trucks. Refer to How to Put a Lift Truck on Blocks.

2. Turn the key switch to the OFF position.

3. Disconnect and separate the battery connectors.

4. Remove the upper drive unit compartment cover.

5. Remove the lower drive unit compartment cover.

6. Discharge the capacitor. tions.

See Special Precau-

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.

8. The truck has an isolated electrical system; neither battery terminal is connected to the truck frame. Check for 50,000 ohms or more between each terminal, one at a time, of the battery connector of the lift truck and a clean connection on the frame. Remove any circuit paths between 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.

9. 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% of the battery voltage) between the battery and the frame, even though the resistance is very high. A higher voltage can indicate a dirty or damaged battery. Clean battery and battery compartment as necessary.

10. 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 connected correctly after checks or repairs.

7. Check the specific gravity of the battery. If the specific gravity is less than 1.260, the battery is

Repairs CONTROLLER, REPLACE

Remove

When experiencing problems with the hydraulic functions, the controller may not be at fault. ALWAYS troubleshoot to verify the component(s) at fault before replacing the controller. Refer to the section ZAPI™ Controllers 2200 SRM 1064, ZAPI™ Controllers 2200 SRM 1006, or ZAPI™ Controllers 2200 SRM 1067 for your lift truck for additional information on the ZAPI™ display and for information on troubleshooting fault codes, adjusting parameters, and testing the ZAPI™ motor controller.

1. Move lift truck to a safe, level area.

NOTE: Some new controllers may have software upgrades which will not allow previous controller parameters and settings to be transferred.

2. If possible, prior to replacing the controller, note all special customer parameters and settings.

3. Turn the key switch to the OFF position.

4. Disconnect and separate the battery connectors.

7

Repairs

2200 SRM 1007

5. Block drive tire to prevent movement. See the section Periodic Maintenance 8000 SRM 1048, Periodic Maintenance 8000 SRM 1009, or Periodic Maintenance 8000 SRM 1379 for your lift truck.

NOTE: If removing the entire control panel assembly to include the electrical panel plate, it will be necessary to perform Step 6. If only removing the controller, contactor, horn, fuses, or wires, it is not necessary to perform Step 6. See Figure 6 or Figure 7.

6. Remove battery to gain access to control panel screws. Refer to the section Periodic Maintenance 8000 SRM 1048, Periodic Maintenance

1.

2.

3.

4.

5.

6.

MOUNTING PLATE BATTERY CONNECTOR (RED) CONTROLLER HORN WASHER LOCKWASHER

7.

8.

9.

10.

11.

12.

8000 SRM 1009, or Periodic Maintenance 8000 SRM 1379 for your lift truck, for instructions on how to remove the battery.

7. Remove the upper drive unit compartment cover.

8. Remove the lower drive unit compartment cover.

9. Discharge the capacitor. tions.

10. Remove the jumper assembly connector from the "E" terminal of the motor controller. If equipped, remove the LED assembly connector from the "D" terminal of the motor controller.

CAPSCREW CAPSCREW CAPSCREW NUT FUSE (175 AMP) FUSE (5 AMP)

Figure 6. Control Panel (W40Z)

8

See Special Precau-

13.

14.

15.

16.

17.

BOLT LOCKWASHER NUT DISPLAY IGNITION SWITCH

2200 SRM 1007

Repairs

11. Tag and remove the control wiring from the motor controller.

13. Remove four capscrews and lockwashers that hold controller to plate and remove controller.

12. Tag and disconnect the power wires from the motor controller.

1.

2.

3.

4.

5.

MOUNTING PLATE CONTROLLER CAPSCREW CONTACTOR BATTERY CONNECTOR MOUNT 6. WIRE CLAMP 7. LOCKWASHER

8. CONVERTER (12 V TRUCKS ONLY) 9. CAPSCREW 10. CAPSCREW 11. WASHER 12. WASHER 13. LOCKWASHER 14. CAPSCREW

15.

16.

17.

18.

19.

20.

21.

22.

NUT DISPLAY IGNITION SWITCH CAPSCREW LOCKWASHER NUT FUSE (250 AMP) HORN

Figure 7. Control Panel (W45-50Z, W20-25ZA, and W25-30ZA 2)

9

Repairs

2200 SRM 1007

Install

CONTACTOR COIL, CHECK

NOTE: If installing the entire control panel assembly to include the electrical panel plate, it will be necessary to perform Step 1. If only installing the controller, contactor, horn, fuses, or wires, it is not necessary to perform Step 1.

1. Move lift truck to a safe, level area.

1. Install control panel assembly to lift truck by aligning four holes of electrical panel plate with four holes in frame and inserting countersunk capscrews into holes from the battery box side.

Install washer, lockwasher, and nut on countersunk capscrews. Replace battery. See the section Periodic Maintenance 8000 SRM 1048, Periodic Maintenance 8000 SRM 1009, or Periodic Maintenance 8000 SRM 1379 for your lift truck, for instructions on how to install the battery.

2. Install replacement controller on electrical panel plate by aligning four holes of controller with four holes in electrical panel plate. Install four capscrews and lockwashers.

3. Connect wires and cables to the same terminals as identified during the removal procedure.

4. Connect the jumper assembly to the "E" terminal, located on the bottom of the controller. See Special Precautions for location. Use procedure that applies to your lift truck: a. To use a maintenance free battery, disconnect the wire terminals on the battery selector jumper. b. To use a flooded cell battery, connect the wire terminals on the battery selector jumper.

5. Reconnect battery connectors.

2. Turn the key switch to the OFF position and disconnect battery connectors.

3. Block drive tire to prevent movement. See the section Periodic Maintenance 8000 SRM 1048, Periodic Maintenance 8000 SRM 1009, or Periodic Maintenance 8000 SRM 1379 for your lift truck.

4. Remove the upper drive unit compartment cover.

5. Discharge the capacitor. tions.

6. Tag, identify, and disconnect the contactor coil wires.

7. Test contactor coil using an ohmmeter.

8. Touch the probes of the ohmmeter to the coil terminals and measure the resistance between the terminals.

9. Replace contactor if coil resistance readings measure outside of specifications. For contactor coil resistance values, refer to Table 1.

10. Connect contactor wires to the correct terminals.

Table 1. Contactor Coil Resistance Values Model

21 ±2.1

W40Z

52 ±5.2

W45-50Z

21 ±2.1

CONTACTOR, REPLACE

7. If available, install customer parameters and settings.

Remove

9. Install the lower drive unit compartment cover.

10. Install the upper drive unit compartment cover.

10

Resistance

W20-25ZA and W25-30ZA 2

6. Turn the key switch to the ON position.

8. Test lift truck in a safe area away from other personnel and equipment.

See Special Precau-

1. Move lift truck to a safe, level area.

2. Block drive tire to prevent movement. See the section Periodic Maintenance 8000 SRM 1048, Periodic Maintenance 8000 SRM 1009, or Periodic Maintenance 8000 SRM 1379 for your lift truck.

2200 SRM 1007

Battery Indicator/Hourmeter Display

3. Turn the key switch to the OFF position and disconnect battery connectors.

4. Remove the upper drive unit compartment cover.

5. Discharge the capacitor. tions.

See Special Precau-

6. Tag, identify, and disconnect the wires and cables.

7. Disconnect all wires and cables from the contactor.

8. Loosen two mounting screws and lockwashers that hold contactor to plate and remove contactor.

Install 1. Install contactor by aligning it with mounting screws on electrical plate and sliding into place.

Tighten mounting screws.

2. Connect wires and cables to the same terminals as identified during the removal procedure.

3. Reconnect battery connectors.

4. Install the upper drive unit compartment cover.

5. Turn the key switch to the ON position.

6. Test lift truck in a safe area away from other personnel and equipment.

Key Switch Removal and Installation REMOVE

9. Identify and disconnect electrical wires to switch.

1. Move the lift truck to a safe, level area.

INSTALL

2. Block drive wheel to prevent truck from rolling.

1. Connect wires to proper terminals.

3. Disconnect battery connectors and turn the key switch to the OFF position.

2. Mount the key switch in bracket.

4. Remove the upper drive unit compartment cover.

3. Install nut to retain the key switch. Make certain switch is properly aligned before tightening retaining nut.

5. Remove the lower drive unit compartment cover.

6. Discharge the capacitor. tions.

See Special Precau-

7. Remove nut retaining the key switch to bracket.

8. Remove the key switch.

4. Connect battery connectors.

5. Test the key switch by turning it ON and OFF. 6. Install the drive unit compartment covers as removed.

Battery Indicator/Hourmeter Display NOTE: On some models, the dash indicator will display the code: EP 107 (or a higher number) for 1 to 2 seconds every time the key switch is turned to the ON position. This code represents the EEPROM software version and DOES NOT INDICATE A FAULT CODE. The Battery Indicator/Hourmeter Display shows battery charge status, truck hours, and fault codes. See Figure 8.

Figure 8. Battery Indicator/Hourmeter Display

11

Fuses

2200 SRM 1007

REMOVE

INSTALL

1. Turn the key switch to the OFF position and disconnect battery.

1. Install gauge in control panel.

2. Remove the upper drive unit compartment cover.

3. Discharge the capacitor. See Special Precautions in this section.

4. Disconnect the wire harness plug from the back of the display. Locking tab is hidden underneath rubber boot.

5. Remove nuts and washers holding retaining bracket. Remove bracket and gauge from control panel.

2. Install retaining bracket, washers, and nuts.

Tighten nuts.

3. Reconnect display wire harness plug.

4. Connect battery and turn the key switch to the ON position.

5. Test operation of lift truck in a safe area.

6. Install the upper drive unit compartment cover.

Fuses WARNING Before checking or changing any fuses, make certain the battery has been disconnected.

Always wear safety glasses. Block the tires, remove the key from the key switch, disconnect battery, and discharge the capacitors before making checks or repairs in the drive unit compartment. See Special Precautions.

W40Z The W40Z 24-volt motorized hand trucks have two fuses. They are: 1. 175-amp (FU 1) protects both the lift pump motor and the drive motor 2. 5-amp (FU 2) protects the control circuits

W45-50Z The W45-50Z 24-volt lift trucks have two fuses. They are: 1. 250-amp (FU 1) protects both the lift pump motor and the drive motor.

2. 5-amp (FU 2) protects the control circuits.

The W45-50Z 12-volt lift trucks have three fuses.

They are: 1. 250-amp (FU 1) protects both the lift pump motor and the drive motor.

2. 5-amp (FU 2) protects the control circuits.

3. 5-amp (FU 3) protects the 12-volt DC to 24-volt DC converter circuit.

12

W20-25ZA The W20-25ZA 24-volt lift trucks have two fuses.

They are: 1. 250-amp (FU 1) protects both the lift pump motor and the drive motor.

2. 5-amp (FU 2) protects the control circuits.

If it cannot be determined visually that any of the fuses have failed, check for continuity using an ohmmeter. To replace FU 1, loosen retaining capscrews.

Install a new fuse and tighten capscrews. FU 2 is retained by a fuse holder. Make certain that any replacement fuse is of the right amperage before installation.

W25-30ZA 2 The W25-30ZA 2 24-volt lift trucks have three fuses.

They are: 1. FU 1 protects both the lift pump motor and the drive motor.

2. FU 2 protects the control circuits.

3. FU 3 protects the control circuits.

If it cannot be determined visually that any of the fuses have failed, check for continuity using an ohmmeter. To replace FU 1, loosen retaining capscrews.

Install a new fuse and tighten capscrews. FU 2 or FU 3 are retained by a fuse holder. Make certain that any replacement fuse is of the right amperage before installation.

2200 SRM 1007

Control Handle Arm Proximity Switch

Control Handle Arm Proximity Switch REPAIR

Remove

A proximity switch is used to sense the position of the control handle arm. A target, cast into the base of the control handle arm moves in front of the proximity switch when the handle is in the RUN position, activating the switch and sending a signal to the ZAPI™ Controller. A red LED on the switch illuminates when the target is sensed. Refer to Brakes 1800 SRM 1005.

1. Move the lift truck to a safe, level area before performing any repairs.

Check and Adjust

5. Remove the four capscrews from the two-piece shield over the MDU and remove the shields.

Check the proximity switch for proper operation. All connections must be attached. Take voltage readings from the back of the connector.

2. Turn the key switch to the OFF position and disconnect the battery.

3. Remove the upper drive unit compartment cover.

4. Remove the lower drive unit compartment cover.

6. Discharge the capacitor. tions.

See Special Precau-

1. Move the lift truck to a safe, level area before performing any repairs.

7. Cut the tie wrap located at the end of the proximity switch harness.

2. Turn the key switch to the OFF position.

8. Remove the proximity switch harness clamp, located beneath the drive unit housing.

3. Remove the upper drive unit compartment cover.

4. Remove the lower drive unit compartment cover.

5. Remove the four capcrews from the two-piece shield over the MDU and remove the shields.

6. Turn the key switch to the ON position.

9. Disconnect the proximity switch from the wiring harness.

10. Fully lower the control handle arm. Remove the two capscrews that mount the proximity switch assembly to the control handle arm. See Figure 9. Remove the proximity switch assembly.

7. Verify battery voltage at the proximity switch connector between pin #1 and pin #2.

8. Place negative lead on the battery ( ).

9. Place positive lead on the black wire pin #3 of the proximity switch connector.

10. Place the control handle arm in the operating position. Verify that battery voltage is present and the proximity switch LED is lit.

11. Place the control handle arm in the full up or down position. Verify that battery voltage is not present and the proximity switch LED is not lit.

If the proximity switch does not operate properly, check that the gap measurement is within specification and that the wiring harness and connections are good. Adjust the switch gap if necessary or repair any wiring problems. If the proximity switch continues not to function properly, it must be replaced.

1. PROXIMITY SWITCH 2. CAPSCREW 3. SWITCH BRACKET Figure 9. Proximity Switch Assembly

13

Control Handle

2200 SRM 1007

Install 1. Insert the proximity switch fully into the switch bracket. Route the proximity switch wire so that it will not be pinched or damaged when the control handle is installed.

CAUTION

a. LED comes on with the handle in RUN position. b. LED should go off with the handle approximately 10 from vertical position.

10. Install the two shield covers using four capscrews 11. Install the lower drive unit compartment cover.

DO NOT damage the plastic switch bracket or proximity switch by overtightening screws.

12. Install the upper drive unit compartment cover.

2. Install the proximity switch assembly to the drive unit housing with two capscrews through the switch bracket into the drive unit housing.

DO NOT tighten the capscrews until after the switch has been adjusted.

3. Check the gap between the proximity switch assembly and the control handle. The gap should measure 3.0 to 5.0 mm (0.12 to 0.20 in.) See Figure 10. If the gap distance is different, horizontally adjust the location of the proximity switch.

4. Connect the switch to the wiring harness.

5. Connect the battery and turn the key switch to the ON position.

6. With the handle at 10 from vertical, move the proximity switch until the LED turns on.

7. Slowly move the proximity switch in the opposite direction until the LED just turns off.

1. PROXIMITY SWITCH ASSEMBLY 2. GAP 3.0 to 5.0 mm (0.12 to 0.20 in.)

3. PROXIMITY SWITCH WIRE Figure 10. Proximity Switch Assembly Location

8. Torque the two capscrews to 4.17 N•m (37 lbf in).

9. Verify that the truck operates correctly with the handle in the following positions:

Control Handle DISASSEMBLE NOTE: It is not always necessary to remove and disassemble all the components that make up the control section of the steering handle to replace a damaged part. Perform only the steps necessary to replace the damaged parts. See Figure 15.

1. Move the lift truck to a safe, level area and block the drive wheel to prevent movement of the lift truck.

2. Turn the key switch to the OFF position and disconnect the battery.

14

3. Discharge the capacitor. tions.

See Special Precau-

NOTE: The handle is comprised of two molded-plastic halves and is held together by three capscrews.

4. Remove the three capscrews retaining the upper half of the control handle to the lower half.

5. Disengage the hooks under the auto-reverse switch. Slide the upper half off of the lower half using a gentle rocking motion while lifting and pulling the upper half away from lower half. See Figure 15.

2200 SRM 1007 6. Unplug the handle wiring harness from the control handle card.

Control Handle 7. Move the jumper on the J1 terminal to the calibrate mode. See Figure 11, view B.

7. Place upper half of the handle upside down on a secure, level work surface so the internal parts are facing up.

8. Remove lower half of the cover (only if damaged or needs replacing) from the control handle shaft by removing two capscrews.

NOTE: Make note of the position of the butterfly knobs relative to the handle BEFORE removal.

9. Remove one of the butterfly knobs by removing the screw that holds it on the shaft.

10. Using the remaining butterfly knob, slide the shaft out of the handle. Be careful not to rotate the shaft within the control handle card.

11. Refer to the wiring diagram, or draw a sketch of where each of the push button switches are plugged into the control handle card. Unplug switches from the control handle card and remove the card.

CONTROL HANDLE CARD (OLD STYLE) After servicing the control handle head, it is necessary to calibrate the control handle card. If replacing with a new style card (usually blue in color), refer to Control Handle Card (New Style).

1. Install the control handle card in the upper half of the control handle.

NOTE: When inserting knobs make sure that flange on one of the butterfly knobs inserts between the spring on the control handle.

2. Slide shaft and butterfly knob into the control handle card. Be careful not to rotate the shaft inside the control handle card.

3. Connect the switches and wire harness connectors.

4. Install the remaining butterfly knob. Apply LoctiteŽ 242 to the screw attaching the butterfly knob onto the upper half of the handle and tighten the screw to 1 N•m (9 lbf in).

5. Lubricate friction points on the butterfly knobs with silicone spray lubricant.

A. RUN MODE

B. CALIBRATE MODE

Figure 11. Control Handle Card Calibration 8. With the handle in the full upright position, turn the key switch to the ON position.

9. Slowly rotate the butterfly knobs in the forward direction and hold at maximum rotation for 5 seconds.

10. Slowly rotate the butterfly knobs back to the neutral position and leave for 5 seconds.

11. Slowly rotate the butterfly knobs in the reverse direction and hold at maximum rotation for 5 seconds.

12. Slowly rotate the butterfly knobs back to the neutral position and leave for 5 seconds.

NOTE: If control handle includes the optional proportional switches, it will be necessary to perform Step 13 through Step 16. If control handle includes only the full speed and half speed ON/OFF lift and lower switches, then go to Step 17.

6. Connect the battery.

15

Control Handle

2200 SRM 1007

13. Slowly press the proportional LIFT button and hold down five seconds.

14. Slowly release the proportional LIFT button and wait for five seconds.

15. Slowly press the proportional LOWER button and hold down for five seconds.

16. Slowly release the proportional LOWER button and wait for five seconds.

17. Move the jumper on the J1 terminal to the RUN mode. See Figure 11, view A. 18. Turn the key switch to the OFF position.

19. Install the upper half on the lower half. Refer to Assemble for instructions on how to install the upper half on the lower half.

20. Test the lift truck to verify correct travel, lift, and lower speeds.

1. JUMPER TERMINALS (SV2) 2. HORN SWITCH (S1) 3. THUMBWHEEL SWITCH (MAGNETIC HOLDER)

CONTROL HANDLE CARD (NEW STYLE) NOTE: New style control handle cards will be blue in color and should be used as replacement cards regardless of color of the card removed. If simply calibrating an existing old style card (green in color), refer to Control Handle Card (Old Style).

NOTE: Verify that the magnetic holder of the thumbwheel switch has been installed in the proper position. See Figure 12.

After servicing the control handle head, it may be necessary to configure and/or calibrate the control handle card.

Configure Refer to Figure 12 for the following instructions.

1. Partially assembly the control handle head. Refer to Assemble.

4. LED DISPLAY SCREEN 5. BELLY SWITCH (S) 6. TURTLE SWITCH (S2)

Figure 12. Control Handle Card (New Style)

16

2200 SRM 1007

Control Handle

2. Connect the control handle card wiring, verify that the battery is connected, and turn the key switch to the ON position.

7. Press and release the S2 (turtle) switch or S3 (horn) switch to change the number displayed on the LED to the correct value.

3. The LED will display the program setting for approximately five seconds. The proper control handle card setting for this model is number 3 for models W40-45-50Z or 4 for models W20-25ZA and W25-30ZA 2. If the correct number is displayed on the LED, the control handle card is configured correctly.

8. Press and release the S (belly) switch to save the value. A decimal will appear on the LED display beside the number showing it has been saved.

4. To begin configuring the card, turn the key switch to the OFF position.

5. Move the jumper from P (park) to C (configure).

See Figure 13.

6. Turn the key switch to the ON position and view the LED display.

9. Turn the key switch to the OFF position and move the jumper to the park (P) position.

10. Turn the key to the ON position and view the LED to verify the correct number has been saved.

The LED will display the program setting for approximately five seconds.

Calibrate Refer to Figure 12 for the following instructions.

1. Verify that the key switch is in the OFF position.

2. Move the jumper from P (park) to T (teach/calibrate). See Figure 13.

3. Verify that the battery is connected and turn the key switch to the ON position. The LED will display a dash symbol to signal that the card is in calibration mode. See Figure 14, view A.

1.

2.

3.

4.

5.

P (PARK/ HOME POSITION) D (NOT USED) T (TEACH/CALIBRATE) C (CONFIGURE) JUMPER TERMINAL (SV2) Figure 13. Jumper Terminal (SV2)

A. B. C. D.

CALIBRATION MODE ROTATION RIGHT SEGMENT COMPLETE ROTATION LEFT SEGMENT COMPLETE ALL SEGMENTS COMPLETE AND SAVED Figure 14. LED Views

17

Control Handle

2200 SRM 1007

NOTE: "Rotation Right" and "Rotation Left" directions are specified by labels printed on face of card.

3. Connect the switches and wire harness connectors.

4. Rotate the thumbwheel in the "Rotation Right" direction (toward the forks) and hold to the mechanical stop. Press the left side lift button (sideshift right button if equipped with sideshift option).

4. Install the remaining butterfly knob. Apply Loctite 242™ to the screw attaching the butterfly knob onto the upper half of the handle and tighten screw. Tighten screw to 1 N•m (9 lbf in).

5. The LED screen will change to show this segment complete. See Figure 14, view B. Release the thumbwheel so it returns to the neutral position.

NOTE: "Rotation Right" and "Rotation Left" directions are specified by labels printed on face of card.

6. Rotate the thumbwheel in the "Rotation Left" direction (toward the operator) and hold to the mechanical stop. Press the left side lower button (sideshift left button if equipped with sideshift option).

7. The LED screen will change to show this segment complete. See Figure 14, view C. Release the thumbwheel so it returns to the neutral position.

8. Move the jumper from T (teach/calibrate) to P (park). See Figure 13.

9. The LED screen will change to show a decimal beside the completed segments indicating they have been saved. See Figure 14, view D. 10. Recycle the key switch OFF and ON and test all truck functions for proper operation.

ASSEMBLE 1. Install control handle card in the upper half of control handle. See Figure 15.

NOTE: When inserting knobs, make sure that flange on one of the butterfly knobs inserts between spring on handle (9).

2. Slide shaft and butterfly knob into control handle card. Be careful not to rotate the shaft inside the control handle card.

18

5. Lubricate friction points on the butterfly knobs with silicone spray lubricant.

NOTE: It may not have been necessary to remove the lower half of the control handle cover. If the cover (lower half) is already installed to the control handle shaft, skip to Step 7.

6. Install lower half of control handle cover to control handle shaft and secure with two capscrews.

Torque to 27 N•m (20 lbf ft).

7. Plug handle wiring harness into control handle card.

CAUTION DO NOT force the upper half onto the lower half as this will cause damage to the retaining hooks of the upper half.

8. To install upper half of handle onto the lower half: a. Tip the upper half up and align the hooks under the auto-reverse switch. b. Lower the upper half onto the lower half.

9. Install capscrews to retain upper half of control handle to lower half.

10. Connect battery cable and test control handle operation.

2200 SRM 1007

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Control Handle

COVER (LOWER HALF) COVER (UPPER HALF) CONTROL HANDLE CARD ASSEMBLY SHAFT BUSHING BUTTERFLY KNOB (LH) WASHER SCREW SPRING BUTTERFLY KNOB (RH) SWITCH COVER

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

SPRING SWITCH COVER BUTTONS SWITCH - ON/OFF HORN SWITCH COVER LABEL LABEL LABEL SWITCH PROPORTIONAL SWITCH (OPTIONAL)

Figure 15. Control Handle

19

Control Handle

2200 SRM 1007

SWITCHES (ON/OFF AND PROPORTIONAL) Remove

9. Remove the switch by pressing the three tabs toward the switch and pushing the switch through upper half of cover.

10. Replace ON/OFF Switch:

NOTE: It is not always necessary to remove and disassemble all the components that make up the control section of the steering handle to replace a damaged part. Do only the steps necessary to replace the damaged parts. See Figure 15.

1. Move lift truck to a safe, level area and block the drive wheel to prevent movement of the lift truck.

2. Turn the key switch to the OFF position and disconnect battery.

a. Separate the button from the switch by spreading the four tabs to allow the switch to slide out of the button. b. To assemble, slide the ON/OFF switch into the ON/OFF button. Verify that the switch assembly locks into position.

Install

See Special Precau-

1. Install the switch assembly into the control handle. Verify that the switch assembly locks into position in the control handle.

NOTE: The handle is comprised of two molded-plastic halves and is held together by three capscrews.

2. Connect the switch assembly wiring to the control handle card.

4. Remove the three capscrews retaining upper half of control handle to lower half.

3. Plug handle wiring harness into control handle card.

3. Discharge the capacitor. tions.

5. Disengage hooks under the auto-reverse switch.

Slide upper half off the lower half using a gentle rocking motion while lifting and pulling upper half away from lower half. See Figure 15.

6. Unplug handle wiring harness from control handle card.

7. Place upper half of handle upside down on a secure, level work surface so the internal parts are facing up.

8. Refer to the wiring diagram, or draw a sketch of where the failed push button switch is plugged into the control handle card. Unplug failed switch from control handle card.

NOTE: Both ON/OFF and proportional switches use three tabs to keep the switches attached to the upper half of the control handle.

20

CAUTION DO NOT force the upper half onto the lower half as this will cause damage to the retaining hooks of the upper half.

4. Install upper half of handle onto the lower half: a. Tip the upper half up and align the hooks under the auto-reverse switch. b. Lower the upper half onto the lower half.

5. Install three capscrews to retain upper half of control handle to lower half.

6. Connect battery cable and test control handle operation.

NOTE: If adding optional proportional switches for the first time, make sure to perform Control Handle Card (Old Style).

2200 SRM 1007

Traction Motor

Traction Motor DISASSEMBLE 1. Remove the traction motor and brake assembly from the MDU. See Brakes 1800 SRM 1005.

CAUTION The pinion end cover and the armature are heavy components. Work carefully so the field coils, pole pieces, and armature are not damaged during disassembly and assembly.

2. Clean outside surfaces of motor before disassembly. Make index marks on the ends of the motor and field ring to ensure proper reassembly.

3. Remove brush cover, if used. Measure the brush in the brush holder, use a tire tread depth gauge or small scale to measure from the top of the brush holder to the back of the brush. a. Brush replacement is REQUIRED when the height of the brush measures 11 mm (0.44 in.) below the brush box. If the brush is worn 8 mm (0.31 in.) below the brush box, then brush replacement is RECOMMENDED. See the section DC Motor Maintenance 620 SRM 294 for the replacement of brushes and spring assemblies.

4. Remove capscrews from commutator end of motor. Carefully slide end cover from motor and armature shaft. DO NOT damage parts. A puller is often necessary to separate the end cover from the field ring.

a plastic or rubber hammer, as necessary, to loosen end cover.

6. Remove pinion end cover from armature.

7. Remove screws that fasten brush holder assembly to commutator end cover.

8. Disassemble components of motor, as necessary, to make repairs. See Figure 16 and the section DC Motor Maintenance 620 SRM 294.

ASSEMBLE 1. Make sure all components are clean. If bearings are worn, install new bearings in end cap.

2. Make sure field coils and pole pieces are installed correctly in housing.

3. Install brush holder assembly in commutator end cap.

4. Carefully install armature in housing. Install retaining rings.

5. Carefully install commutator end cover to housing. Install and tighten capscrews.

6. Install brushes and spring assemblies. Replace brush cover, if used. See Figure 16.

7. Install brake assembly to drive motor.

Brakes 1800 SRM 1005.

See

8. Install drive motor to MDU. Secure in place using motor mount studs.

5. Remove screws that fasten pinion end cover to field ring. Remove end cover and armature. Use

21

Traction Motor

1.

2.

3.

4.

END COVER ARMATURE BEARING MOUNTING STUD

2200 SRM 1007

5.

6.

7.

8.

HOUSING AND WINDINGS BRUSH AND SPRING COMMUTATOR END CAP COVER BAND

Figure 16. Disassembled Traction Motor

22

2200 SRM 1007

Lift Pump Motor

Lift Pump Motor The W40-45-50Z lift pumps cannot be disassembled.

The motors are serviced as an assembly.

REPAIR (W20-25ZA AND W25-30ZA 2) The lift pump motor is an electric motor mounted on top of the lift pump and hydraulic tank. The motor drives the lift pump supplying oil pressure to the hydraulic system. When repairing the lift pump motor ALWAYS check that the battery is charged and check all electrical connections BEFORE removing the motor from the truck:

motor for the W40Z is a 24-VDC motor where the W45-50Z offers both a 12-VDC and 24-VDC motor.

These motors are not serviceable and must be replaced when not functioning properly. Repair or replace the lift pump motor and install. See Walkie Hydraulic Systems 1900 SRM 1018 or Walkie High Lift Hydraulic System 2000 SRM 1044.

1. Check the specific gravity of the battery or the optional battery discharge indicator for proper battery charge. See Electrical System Checks for information on how to check the specific gravity.

2. Block the drive wheels to prevent movement.

3. Disconnect battery.

The lift pump motor used on the W20-25ZA and W2530ZA 2 is a 24-VDC motor and has only two serviceable items (see Figure 17): • Brushes • Brush Plate Remove brush cover, if used. Measure the brush in the brush holder, use a tire tread depth gauge or small scale to measure from the top of the brush holder to the back of the brush.

Brush replacement is REQUIRED when the height of the brush measures 5.5 mm (0.22 in.) below the brush box. If the brush is worn 4 mm (0.16 in.) below the brush box, then brush replacement is RECOMMENDED. See the section DC Motor Maintenance 620 SRM 294 for replacement of the brushes.

A. MINIMUM DIMENSION 1. TAPERED END (SPRING)

2. WEAR END 3. BRUSH SPRING

Figure 17. Pump Motor Brushes Inspection

If other components of the motor are damaged, then the entire motor must be replaced. The lift pump

23

Lift Link Proximity Sensor (W50Z)

2200 SRM 1007

Lift Link Proximity Sensor (W50Z) The lift link proximity sensor is located near the bottom of the control panel. This sensor detects the lift linkage position when the forks reach maximum lift height and stops the lift pump motor. In the event that the lift pump motor continues to run after the forks reach maximum height, check the lift link proximity switch for proper function and adjustment. See Figure 18.

b. If the lift pump and motor does not activate, troubleshoot the electrical system. c. If the forks raise properly but the lift pump and motor does not shut off when the forks reach maximum lift height, unplug and clean the proximity sensor connector. Reconnect the sensor with the wiring harness and check operation again. If the problem remains, proceed to the next step.

CAUTION Keep hands and fingers clear of lift linkage to avoid injury from pinch points.

3. Cover the face of the proximity switch with a piece of metal then press and release the lift button. a. If the lift pump and motor shut down when the sensor is covered, properly adjust the lift linkage proximity sensor. See Adjust. b. If the lift pump and motor assembly continues to operate when covered, test the lift linkage proximity switch. See Test.

REPAIR 1. CONTROLLER 2. PROXIMITY SENSOR 3. HORN Figure 18. Lift Proximity Sensor Location

The following repairs are performed with the key switch in the OFF position and the electrical compartment cover removed unless otherwise noted.

Replace the cover when repairs are complete.

CHECK

Remove

1. Remove the electrical compartment covers. Turn the key switch to the ON position and move the control handle arm to the RUN position. Check the battery discharge indicator for proper battery charge.

1. Disconnect the sensor wiring connector from the truck wiring harness.

2. Remove the front jam nut from the position sensor threads. See Figure 19.

2. Completely lower the forks then press and hold the lift button. The lift pump and motor assembly should activate, raise the forks to their maximum lift height, and turn off while the lift button is still depressed. a. If the lift pump and motor activates but does not raise the forks, the problem may be in the hydraulic or lift linkage systems.

24

Figure 19. Sensor and Jam Nuts

2200 SRM 1007 Legend for Figure 19 1.

2.

3.

4.

5.

SENSOR CONNECTOR SENSOR WIRING REAR JAM NUT FRONT JAM NUT SENSOR FACE

3. Remove the sensor from the mounting bracket on the truck frame.

4. Remove the rear jam nut if replacing the senor.

Lift Link Proximity Sensor (W50Z) 4. Connect the sensor wiring connector to the truck wiring harness connector as removed.

Adjust 1. Slightly loosen the front jam nut of the lift linkage proximity sensor.

2. Adjust both jam nuts equally to position the proximity sensor 2.5 mm (0.1 in.) from the upper lift linkage when the forks are in the fully raised position.

Test 1. Remove the lift linkage proximity sensor. See Remove.

3. Tighten the front jam nut to secure the proximity sensor in position. Verify the measurement.

4. Check for proper operation.

CAUTION DO NOT connect jumper wires to the truck wiring harness.

2. Connect jumper wires to the sensor wiring harness: a. Connect positive (24 volts) to the pin #1 of the connector. See Figure 20. b. Connect a ground to the pin #2 of the connector. c. Connect a voltmeter between pin #3 of the connector and a ground.

3. Position a piece of metal within 5.0 mm (0.2 in.) of the face of the sensor to activate the sensor. Remove your hand to deactivate. Voltmeter should read 24 volts when the sensor is activated and no voltage when it is deactivated. If the sensor does not operate correctly, it must be replaced.

Install 1. Position the rear jam nut onto the position sensor threads.

1. PIN #1 (BROWN WIRE) 2. PIN #2 (BLUE WIRE) 3. PIN #3 (BLACK WIRE) Figure 20. Sensor Connector (Front View)

2. Install the position sensor into the bracket on the frame of the lift truck as removed.

3. Install the front jam nut onto the position sensor threads. Snug jam nut to secure sensor in place.

25

Battery Charger (Early Models)

2200 SRM 1007

Battery Charger (Early Models) DESCRIPTION The battery charger supplied with the truck is a self contained 120 volt AC powered charger. The charger comes equipped with a short lead plug to allow connection to the 120 volt AC outlet using a 20 amp rated extension cord. The charger will operate from any wall outlet capable of supplying 108 to 126 volts AC protected by a 20 amp circuit breaker.

• AC mains failure • DC fuse blown • Power circuit break down

OPERATION

One of the following may be the cause in the event of battery failure and the red LED is ON: • The total security time, 14 or 15 hours, has expired.

• The security time before the battery gassing voltage, 10 hours, has expired.

• The battery voltage is lower than 2.05V per cell after one hour of charge.

Charging

Protections

Pressing the ON button at the top of the charger starts the charging cycle. A yellow LED will illuminate to indicate that charging has begun. Battery charging is automatic once the charging cycle has started. The green LED will illuminate once the charging cycle has been completed. See Figure 21.

The following describes the protections of the battery charger: • A fuse protects the DC circuit in the event of prolonged over-current or possible polarity inversion.

• An automatic device allows the charge to begin only after five minutes from the connection to the battery.

• In case of mains failure, the charge is cut off temporarily, the red LED blinks. The charge continues when the mains is restored.

TROUBLESHOOTING NOTE: If all the below steps have been taken and the charger still does not function properly, the charger should be replaced.

Figure 21. Charger LED Locations

Equalize The charger will automatically begin a equalizing cycle to equalize the charge of the batteries immediately after the batteries have been fully charged. The charger is equalizing when the yellow LED is flashing.

Signals The battery charger comes with a red LED that will illuminate or flash if a malfunction of the charger or battery occurs.

One of the following may be the cause in the event of charger failure and the red LED is blinking:

26

If the charger will not power up, proceed with the following: • Check AC wall outlet for power. Acceptable power range at the outlet should be between 108 and 126 volts on a 20 amp circuit.

• Check for blown AC input fuse, that is located on the charger bottom. See Figure 22.

• If the AC input fuse is blown, replace and reconnect the charger to the AC outlet. Check AC voltage while in operation to confirm the AC wall circuit is still within the acceptable range, 108 to 126 volts.

If the AC wall circuit is still within the acceptable limits, return the charger to service. If it is not, DO NOT return the charger to service until a building circuit with acceptable output can be found.

2200 SRM 1007

Battery Charger (Early Models)

1. INPUT FUSE Figure 22. Input Fuse Location If the charger will power up, but does not charge, proceed with the following: • Check condition of battery connections and clean them, if necessary.

• Verify that the batteries are properly connected.

See Diagrams 8000 SRM 1011, Diagrams 8000 SRM 1050, Diagrams 8000 SRM 1381, or Diagrams 8000 SRM 1228 for your lift truck. Identify and replace any batteries with open or shorted cells.

• Check battery output voltage to verify charge is actually necessary. Charger may not run if batteries are already sufficiently charged.

• If battery output voltage indicates need for charging and the unit will not charge, check the internal 50 amp DC output fuse and replace if necessary.

First remove the four Phillips head screws on the side of the charger and slide the cover off to access the fuse. See Figure 23.

• If the DC output fuse requires replacement, this could be an indication of an improperly wired battery pack. Verify that all battery connections are correct and remove all debris and metal fragments from the blown fuse before putting charger back in service.

• If the DC output fuse is good, verify that both retaining nuts are adequately tightened. Exercise caution not to over tighten the nuts, which could result in board damage.

NOTE: If the 50 amp DC output fuse has blown, some debris can be expected on the circuit board next to the fuse. However, care should be taken to remove the debris before putting the unit back in service. See Figure 24.

• Visually inspect for signs of heat damage on the circuit board and or transformer. If any heat damage is evident, reassemble and replace the charger.

Figure 23. 50 Amp DC Output Fuse

27

Battery Charger (Early Models)

2200 SRM 1007 2. If the charger is unable to raise the battery voltage above 2.05 volts/cell (24.6 volts total) within one hour after start up, it will stop charging and a constant red LED will light up.

3. If the charger is unable to raise the battery voltage above 2.42 volts/cell (29.0 volts total) within 10 hours after start up, it will stop charging and a constant red LED will light up.

4. If at any time during the charge cycle the transformer overheats, the charger will stop, the yellow LED will stay on, and the red LED will flash.

This may appear to be a charger issues, but it is caused by the batteries. If the battery voltage does not rise as it should, the charger output current will increase, which raises the transformer temperature. Eventually, it will become too hot, causing the charger to shut down to protect itself.

The charger will restart itself and begin charging again after the transformer has cooled down, but the same situation may occur again. If this happens within one hour after start up, the one hour timer will expire and shut the charger down as described in item 2 above.

All of the cases above are indicative of a set of batteries that are not responding properly to the charger due to one or more weak or failing cells.

1.

2.

3.

4.

5.

TRANSFORMER RECTIFIER BRIDGE CIRCUIT BOARD DC OUTPUT FUSE AC INPUT FUSE Figure 24. Battery Charger

If the charger begins the charge cycle, but stops before it is complete and an error light comes on, this usually indicates a problem with the batteries.

NOTE: The charger has an electronic safety timer that will detect if the batteries are not responding to the charge within the prescribed time period. The charger will shut itself down if it determines there is a problem with the batteries.

1. If the charger is unable to raise the battery voltage above 1.7 volts/cell (20.4 volts total) within one minute after start up, it will stop charging and a constant red LED will light up.

28

When any one of these situations occur, it is best to unplug the charger and inspect the batteries for one or more bad cells. This can be done with a load tester or a specific gravity test. If the variation between the highest and lowest specific gravity reading between the three cells in any one battery is 0.050 (50 gravity points) or more, there is a reason to suspect a weak or failing cell.

If a battery has a bad cell, it must be replaced. To improve battery life, and to get the maximum amount of run time out of each charge cycle, it is best to replace all four batteries at the same time.

If all the above steps have been taken and the charger still does not function properly, the charger should be replaced.

2200 SRM 1007

Battery Charger (Late Models)

Battery Charger (Late Models) DESCRIPTION The battery charger supplied with the truck is a self contained, 120 volt, AC powered charger. The charger comes equipped with a short lead plug to allow connection to the 120 volt AC outlet using a 20 amp rated extension cord. The charger will operate from any wall outlet capable of supplying 108 to 126 volts AC protected by a 20 amp circuit breaker.

Plugging the charger to the 120 volt AC outlet will begin the start up cycle. Approximately three seconds after connection to the AC power, all five LEDs on the top of the charger will illuminate and flash two times. This indicates the charger is set to charge U1800 type batteries. Following the start up flashing of the LEDs, the red, POWER ON, LED will illuminate to indicate AC power is applied to the charger and will begin the charging cycle.

OPERATION

The charger uses a 4-step charging process:

LED Display

1. Pre Qualification Test. During this step, the yellow, CHARGING, LED will flash on and off every two seconds. The charger is checking for faults prior to the start of charging. Depending on the condition and state of charge of the batteries, this step can take from 45 seconds up to 5 hours.

The charger has five colored LEDs located on the top of the charger. The LEDs are used to indicate the status of the charger during operation. See Table 2.

Table 2. Charger LEDs Indicator

Color

Function

Power On

Red

Illuminates continuously when AC power is present.

Abnormal Shutdown

Red

Flashes if abnormal shutdown has occurred.

Detection Error

Red

Flashes when battery is not connected to charger or battery voltage is less than 2V.

Charging

Yellow

Charge status indicator flashes during charging cycle.

Charged

Green

Illuminates continuously when battery is fully charged.

Charging CAUTION The charger comes factory set to charge 24V Interstate U1800 type batteries only. Using batteries other than U1800 type may cause severe damage to batteries or charger.

If using batteries other than U1800 type, see Changing Mode Setting (DPI Early Models) in this section.

2. Regulating Current.

During this step, the charger will be regulating current to the batteries and will be operating at full rated output.

The yellow, CHARGING, LED will be constantly illuminated during this step.

3. Regulating Voltage.

During this step, the charger will be regulating voltage to the batteries.

The yellow, CHARGING, LED will remain illuminated. When the batteries have reached 80 to 90 percent of full charge, the yellow, CHARGING, and the green, CHARGED, LEDs will be illuminated.

4. Charge Complete. During this step, the green, CHARGED, LED will remain illuminated. AC power can now be disconnected from the charger.

NOTE: If the charger noted an abnormal charge condition during the charging, the charger will attempt to shutdown and will flash one or all three of the red LEDs on the top of the charger. If this condition occurs, see Troubleshooting in this section.

TROUBLESHOOTING The three red LEDs are used to troubleshoot the charger. Observe the operation of the Power On, Abnormal Shutdown, and the Detection Error LEDs to determine the cause for the charger malfunction.

See Table 3.

29

Battery Charger (Late Models)

2200 SRM 1007 Table 3. LED Codes

Condition

Power On LED

Abnormal Shutdown LED

Detection Error LED

Battery Voltage High

Off

Off

Flashing

Battery Polarity Reversed

Off

Flashing

Off

Output Overload

Off

Flashing

Flashing

Charge Level Unbalanced

Flashing

Off

Off

Excessive Charging Time

Flashing

Off

Flashing

Excessive Overload

Flashing

Flashing

Off

Excessive Discharged

Flashing

Flashing

Flashing

Battery Voltage High indicates the charger is sensing it is connected to a battery pack with a voltage rating greater than 24 volts. Verify the battery pack is the correct voltage.

Battery Polarity Reversed indicates an incorrect connection of the battery charger to the battery pack.

Verify charger connections.

Output Overload indicates the charger sensed a high current draw during the charging cycle. Verify there is no load on the batteries during charging.

Charge Level Unbalanced indicates some batteries are at a much higher state of charge than other batteries in the battery pack. Check the condition of each battery.

Excessive Charging Time error occurs when the preset maximum charge time has been exceeded.

Verify there is no load on the battery pack during charging. Verify all batteries are in good condition and will accept a charge.

Excessive Overload error occurs if a heavy load is placed on the battery pack during charging and the charger senses a decreasing battery voltage. Remove external load.

Excessive Discharged error occurs when a battery pack will not reach 21 volts within five hours of charging.

BATTERY MODE SELECTION (DPI EARLY MODELS) NOTE: Certain battery chargers use Battery Mode Selection to set the charger for the specific battery being used. Other chargers use the Battery Type Selection to prepare the charger for the select battery.

Use the proper procedure for your lift truck. See Battery Mode Selection (DPI Early Models) or Battery Mode Selection (DPI Late Models).

The battery charger has three battery mode settings.

The mode setting is determined by the batteries being used in the battery pack. See Table 4.

Table 4. Battery Modes Mode

Battery

1

24 V Exide E3600

2

24 V Interstate U1800

3

24 V Trojan Battery T-605

CAUTION DO NOT use batteries that are not correct for the charger mode setting. Damage to the batteries or charger may occur if the mode setting is not correct for the type of batteries being used.

The charger is set to a default Mode 2 at the factory.

Any batteries other than U1800 type will require the mode setting to be changed.

30

2200 SRM 1007

Battery Charger (Late Models)

Changing Mode Setting (DPI Early Models) Mode settings are determined by the position of the jumpers on the main circuit board located inside the battery charger. Changing the mode setting requires removal of the battery charger from the battery tray assembly.

1. Remove the charger from the battery tray and place on a clean flat surface.

2. Remove the screws used to retain the cover to the charger and remove the cover.

BATTERY MODE SELECTION (DPI LATE MODELS) CAUTION DO NOT use batteries that are not correct for the charger mode setting. Damage to the batteries or charger may occur if the mode setting is not correct for the type of batteries being used.

3. Locate the jumpers on the circuit board. See Figure 25. The two jumpers used to make the model setting are labeled J3 and J4 on the circuit board.

These jumpers are located near the center red LED on the circuit board.

NOTE: Certain battery chargers use Battery Mode Selection to set the charger for the specific battery being used. Other chargers use the Battery Type Selection to prepare the charger for the select battery.

Use the proper procedure for your lift truck. See Battery Mode Selection (DPI Early Models) or Battery Mode Selection (DPI Late Models).

4. For Mode 1, remove the existing jumper from J3.

For Mode 3, remove the existing jumper from J3 and install on J4.

The battery charger has four battery mode settings.

The mode setting is determined by the batteries being used in the battery pack. See Table 5.

5. Replace the cover on the charger and install the mounting screws.

Table 5. Battery Modes

6. Install the charger in the battery tray.

Jumper Configuration

Battery

A and B

24 V Exide E3600

A and C

24 V Trojan T-605

A and D

24 V US Batt 1800/2200

C and D

24 V Trojan T-105

Changing Mode Setting (DPI Late Models) Mode settings are determined by the position of the jumpers on the jumper port under the Changing the mode setting requires removal of the battery charger from the battery tray assembly.

1. Remove the charger from the battery tray and place on a clean flat surface.

2. Remove the screws used to retain the jumper port cover to the charger and remove the cover.

3. Locate the jumpers on the port.

4. Arrange the jumpers in the proper configuration for you battery type.

1. J3 JUMPER

2. J4 JUMPER

Figure 25. Circuit Board

5. Replace the cover on the charger and install the mounting screws.

6. Install the charger in the battery tray.

31

Troubleshooting

2200 SRM 1007

Troubleshooting PROBLEM Lift truck will not move.

Mast will not raise the forks.

Operator controls do not work.

32

POSSIBLE CAUSE

PROCEDURE OR ACTION

Dead battery.

Recharge or replace battery.

Failed (Open) fuse.

Replace Failed (Open) fuse.

Brake is applied.

Test the brake to ensure wiring to brake is good.

Drive motor not operating.

Repair or replace drive motor.

Sequencing fault.

Return handle to rest and recycle.

Dead battery.

Recharge or replace battery.

Failed (Open) fuse.

Replace Failed (Open) fuse.

Lift pump motor wiring loose or disconnected.

Reconnect or tighten loose wiring connections.

Lift pump motor not operating.

Repair or replace lift pump motor.

Dead battery.

Recharge or replace battery.

Failed (Open) fuse.

Replace Failed (Open) fuse.

Control handle wiring loose or disconnected.

Check wiring and tighten or connect as needed.

An individual switch is damaged.

Check switch and replace if inoperative.

FRAME W40Z [B218]; W45Z [C215]; W50Z [D215]

PART NO. 1518993

100 SRM 1015

Frame

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Description .....................................................................................................................................................

Frame Repair .....................................................................................................................................................

Features .........................................................................................................................................................

Frame Separation and Assembly ......................................................................................................................

Separation ......................................................................................................................................................

Assembly ........................................................................................................................................................

Battery Compartment........................................................................................................................................

Battery Compartment Specifications ...........................................................................................................

Changing the Battery ....................................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Battery Spacer Adjustment ......................................................................................................................

Label Replacement.............................................................................................................................................

Painting Instructions.........................................................................................................................................

Load Wheels .......................................................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

1 1 2 2 2 2 2 3 3 3 4 4 4 4 6 6 6 6

This section is for the following models: W40Z [B218]; W45Z [C215]; W50Z [D215]

©2005 HYSTER COMPANY

i

100 SRM 1015

General

General DESCRIPTION The main frame has mounts for the lifting mechanism, the electrical system parts, the hydraulic pump assembly, and the master drive unit (MDU).

Repair procedures for major systems/parts that fasten to the main frame are found in separate SRM manuals. Models with a fork frame weldment have mounts for the lifting mechanism. See Figure 1. The

1.

2.

3.

4.

5.

FORKS FRAME UPPER COVER MOTOR COVER RH MOTOR COVER LH

fork frame weldment is fastened to the main frame by the links of the lifting mechanism. The base of the forks and the battery end of the weldment are lifted by the cylinder to raise the load. At the same time, the fork tips are lifted by linkage operating the load wheel assembly. There is also a mount for the optional casters. The mounting holes for the casters are in the main frame weldment.

6.

7.

8.

9.

COUNTERSUNK CAPSCREW LOWER COVER WASHER BUTTON HEAD CAPSCREW

Figure 1. Frame Weldment and Covers W40Z, W45Z, and W50Z

1

Frame Separation and Assembly

100 SRM 1015

Frame Repair WARNING Forklift truck frames and components may have polyurethane paint. Welding, burning, or other heat sufficient to cause thermal decomposition of the paint may release isocyanates.

These chemicals are allergic sensitizers to the skin and respiratory tract and overexposure Always may occur without odor warning. utilize good industrial hygiene practices including removal of all paint (prime and finish coats) to the metal around the area to be welded, local ventilation, and/or supplied-air respiratory protection when repairing the frame.

WARNING Do not make any repairs or adjustments unless you have proper authorization and training. Repairs and adjustments that are not correct can cause 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.

Most lift truck repairs are performed on the individual components that are bolted to the frame and not to the frame itself.

FEATURES The lift truck frames are offered in combinations of the following options: 1. Weight Capacity a. 1814 kg (4000 lb) b. 2041 kg (4500 lb) c. 2268 kg (5000 lb) 2. Fork Length a. 900 mm (36 in.) b. 1050 mm (42 in.) c. 1200 mm (48 in.) d. 1400 mm (54 in.) e. 1500 mm (60 in.)

3. Battery Compartment Size a. 206 mm (8 in.) × 724 mm (29 in.) b. 206 mm (8 in.) × 804 mm (32 in.) c. 232 mm (9 in.) × 724 mm (29 in.)

Frame Separation and Assembly SEPARATION In some cases a fork frame or a drive unit frame may be damaged, while the rest of the truck is still usable.

The two frames may be separated from each other by using the following steps.

1. Raise the motorized lift truck to its maximum height. Turn the key to the OFF position. Disconnect the battery.

2. Remove the drive unit compartment covers.

3. Position blocks under both sides of the truck in the area of the battery compartment and under both forks. See How to Put Lift Truck on Blocks in Periodic Maintenance 8000 SRM 1009.

4. Remove the battery.

5. Remove the top clevis pin securing the hydraulic cylinder to the frame. See Hydraulic Cylinder in Walkie Hydraulic Systems 1900 SRM 1018.

2

6. Remove both pivot pins securing the upper link to the drive unit frame. See Upper Link, Remove in Lifting Mechanism 4000 SRM 1008.

7. Remove both drive unit frame pivot pins securing the rocker arm to the drive unit frame. See Rocker Arm, Remove in Lifting Mechanism 4000 SRM 1008.

8. Carefully move one of the frames away from the other.

ASSEMBLY 1. Align both frames so the pins may be installed to assemble the frames to each other.

2. Install both drive unit frame pivot pins to secure the rocker arms to the drive unit frame.

See Rocker Arm, Install in Lifting Mechanism 4000 SRM 1008.

100 SRM 1015

Battery Compartment

3. Install both pivot pins to secure the upper link to the drive unit frame. See Upper Link, Install in Lifting Mechanism 4000 SRM 1008.

4. Install the pivot pin to secure the hydraulic cylinder to the fork frame. See Hydraulic Cylinder, Install in Walkie Hydraulic Systems 1900 SRM 1018.

5. Install the battery.

6. Install the drive unit compartment covers.

7. Connect the battery and turn the key switch to the ON position.

8. Remove the blocks and lower the lift truck to the floor.

9. Test the operation of the truck before returning to service.

Battery Compartment BATTERY COMPARTMENT SPECIFICATIONS WARNING Batteries are heavy. Use care to avoid injury.

Always use a battery roller stand or tray when trucks are equipped with optional battery rollers or slide. Always wear protective clothing and eye protection when working with or near the battery.

The battery compartment is available in two sizes: 205 mm (8 in.) or 230 mm (9 in.).

Battery rollers may be installed in the floor of the battery compartment. Gates are installed on both sides of the battery to prevent movement on the rollers during operation. Spacers are available to secure batteries that fit loosely in the battery compartment.

The battery compartment must be kept clean to ensure proper operation and safety. Any fluids on or around the battery is an indication that electrolyte is spilling or leaking out. Leaking batteries must be repaired or replaced and the battery compartment must be cleaned.

WARNING Never place tools or other objects on top of the battery.

truck. Never allow tools or other objects to be placed on top of the battery. Water levels in the battery must be checked regularly and filled to specifications if the level is too low.

NOTE: Battery water levels can be maintained without removing the battery from the truck.

See Periodic Maintenance 8000 SRM 1009 for more information on regularly scheduled battery maintenance.

CHANGING THE BATTERY WARNING Batteries are heavy. Use care to avoid injury.

Always use a battery roller stand or tray when trucks are equipped with optional battery rollers or slide.

WARNING Always wear protective clothing, gloves, and goggles when handling batteries and electrolyte.

Make sure the capacity of the crane and spreader bar is greater than the weight of the battery. The weight of the battery is normally shown on the battery case.

The maximum battery weight is shown on the lift truck nameplate. The spreader bar must NOT be made of metal, or it must have insulated straps. See Figure 2.

Contact of objects between the battery posts can result in personal injury and severe damage to the lift

3

Label Replacement

100 SRM 1015

Install WARNING Before connecting the battery, make sure the key switch is in the OFF position and the control handle is in the UP position (brake applied).

CAUTION The replacement battery must fit the battery compartment correctly. Adjust the brackets on each side of the battery and tighten the capscrews, lockwashers, and nuts to retain the battery.

CAUTION

1. CRANE 2. SPREADER BAR

3. INSULATED STRAPS 4. BATTERY

Figure 2. Changing the Battery

Make sure the voltage and weight of the replacement battery is correct as shown on the nameplate.

Make sure the battery is the correct size and weight for the lift truck.

For the following instructions, refer to Figure 2.

1. Remove any obstructions in battery compartment (i.e., battery cables or tools).

Remove

2. Lower new battery into battery compartment.

1. Move lift truck under overhead crane or other suitable lifting device.

3. Connect battery cable connector. Adjust location of battery to allow proper connection of cables.

2. Block drive tire to prevent movement of lift truck.

4. Adjust the brackets on each side of the battery and tighten the capscrews, lockwashers, and nuts to retain the battery.

3. Turn key switch OFF, disconnect battery connector, and move it out of the way.

4. Loosen one of the battery spacers and move it out of the way. See Figure 2.

5. Remove spreader bar and insulated straps from battery.

Battery Spacer Adjustment 5. Connect spreader bar to battery using insulated straps and lift battery out of lift truck.

The battery spacers are designed to hold the battery in place during normal operation. The spacers are adjusted by adding or removing spacers as required to prevent the battery from moving.

Label Replacement WARNING Replace damaged Warning or Caution labels immediately.

If labels or information plates are missing or damaged, they must be replaced. See Figure 3.

4

NOTE: The nameplate cover is installed using rivets.

Remove old rivets before installing a new nameplate cover. See your Hyster lift truck dealer to make sure the nameplate cover information is correct and complete before installing a new nameplate cover. Fasten the nameplate cover with the rivet heads outside.

100 SRM 1015

Label Replacement

1. Make sure the surface is dry and free of oil or grease. Do not use solvent on new paint. Clean the surface of old paint using a cleaning solvent.

2. Remove the paper from the back of the label. Do not touch the adhesive surface.

1.

2.

3.

4.

5.

6.

LABEL (HYSTER) COVER LABEL (WARNING) RIVET LABEL (PINCH WARNING) LABEL (US PATENTS AND TRADEMARKS)

NOTE: The label cannot be moved after it touches the surface.

3. Carefully hold the label in the correct position above the surface. Put the label in the correct position on the surface. Make sure all air is removed from under the label and the corners and edges are tight.

7.

8.

9.

10.

11.

LABEL (DASH) NAMEPLATE LABEL OPERATORS MANUAL LABEL (HYSTER) LABEL (BATTERY DISCHARGE NOTICE)

Figure 3. Label and Decal Location

5

Load Wheels

100 SRM 1015

Painting Instructions WARNING Always use solvents and paints in an area with ventilation. Do not use solvents or paints near heat or fire.

WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. Wear protection for eyes and skin. When using cleaning solvents, always follow the recommendations of the manufacturer.

2. Remove the top surface of paint and all rust from the metal using sandpaper. Paint all metal surfaces where the paint is completely removed using primer. Apply the primer before applying the color paint.

3. Protect all surfaces that will not be painted. Do not paint cylinder rods, cables, labels, plates, or controls.

4. Paint the surfaces using Hyster paint. Follow the directions on the container. Paint all surfaces the original color.

1. Remove all dirt from the surface to be painted.

Clean the area to be painted using a solvent for painted surfaces. Remove all oil and grease.

Load Wheels REMOVE WARNING Put blocks under both forks and on both sides of the drive tire. The blocks must prevent the lift truck from falling and causing personal injury or property damage.

1. Use the lift button to raise the lift truck to its maximum height.

2. Put blocks under both forks and on both sides of the drive tire. See the section How to Put a Lift Truck on Blocks in the Periodic Maintenance manual.

3. Drive the roll pin retaining the axle shaft to the rear axle link out of the link and axle.

4. Lower the hoist cylinder using the lower button.

This will raise the load wheels off the floor.

5. Move the key to the OFF position. Disconnect the battery. Remove the battery.

6. Remove the axle shaft. Remove bearings and load wheel from the link. It may be necessary to drive the bearing out of the wheel. Drive the bearing out from the opposite sides. See Figure 4.

6

7. Remove all old lubricant. Clean and inspect all parts. Replace all defective parts.

INSTALL 1. Prelubricate the bearings with the recommended grease. Install the bearings in the load wheel.

2. Align the load wheel and bearings inside the link and insert the axle shaft.

3. Install the roll pin in the link and through the axle shaft.

4. Raise the load wheels. Lubricate the load wheel.

5. Install the battery in the battery compartment and connect the battery.

6. Remove the blocks from under the forks and from each side of the drive tire. Turn the key to the ON position and use the lower button to lower the lift truck to its minimum height. The truck should lift and lower evenly.

7. Test the operation of the motorized hand truck before returning the truck to service.

The function of the load wheels is further explained in Lifting Mechanism 4000 SRM 1008.

100 SRM 1015

1.

2.

3.

4.

LOAD WHEEL FITTING ROLLER BEARING

Load Wheels

5.

6.

7.

8.

BUSHING AXLE FITTING PIN

Figure 4. Load Wheel and Link Assembly

7

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

8

INDUSTRIAL BATTERY ALL ELECTRIC LIFT TRUCKS

PART NO. 899648

2240 SRM 1

Industrial Battery

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Lead-Acid Batteries ...........................................................................................................................................

Specific Gravity ..................................................................................................................................................

Chemical Reaction in a Cell ..............................................................................................................................

Electrical Terms .................................................................................................................................................

Battery Selection................................................................................................................................................

Battery Voltage ..................................................................................................................................................

Battery as a Counterweight ..............................................................................................................................

Battery Ratings..................................................................................................................................................

Kilowatt-Hours ..............................................................................................................................................

Battery Maintenance .........................................................................................................................................

Safety Procedures ..........................................................................................................................................

Maintenance Records ....................................................................................................................................

New Battery ...................................................................................................................................................

Cleaning Battery ...........................................................................................................................................

Adding Water to Battery ...............................................................................................................................

Hydrometer ....................................................................................................................................................

Battery Temperature .....................................................................................................................................

Charging Battery ...........................................................................................................................................

Types of Battery Charges..........................................................................................................................

Methods of Charging .................................................................................................................................

Troubleshooting Charger ..........................................................................................................................

Knowing When Battery Is Fully Charged ...............................................................................................

Where to Charge Batteries............................................................................................................................

Equipment Needed ....................................................................................................................................

Battery Connectors........................................................................................................................................

Battery Care ..................................................................................................................................................

1 1 2 2 3 4 5 5 6 6 6 6 7 7 7 9 10 10 11 12 13 14 14 14 14 15 15

This section is for the following models: All Electric Lift Trucks

Š2008 HYSTER COMPANY

i

2240 SRM 1

Lead-Acid Batteries

General This section describes how to select and do the maintenance for large batteries used in electric lift trucks.

This information is for service personnel that must do the maintenance on large lead-acid batteries. Battery repair requires special training and equipment.

Do not try to repair a battery unless you have the correct tools, equipment, and experience. Most battery repairs are done by a special repair service. Some

batteries have a nameplate attached to the face of the battery cover. This nameplate communicates specific information about the battery including the name of the battery manufacturer, battery type, serial number, nominal voltage, capacity in amperes at the fivehour rate, and service mass (with ballast if used to compensate for lack of battery mass).

Lead-Acid Batteries A lead-acid battery converts chemical energy into electrical energy. See Figure 1. Chemical changes within the battery give the electrical energy. When the chemical reaction has occurred so the battery will not give its rated voltage and current, the battery is discharged. A reverse chemical action must occur so the battery can be used again. The batteries described in this section can be charged again by an electric voltage and current from an outside source so there is a reverse chemical action. The lead-acid chemicals store the electric energy until the electric energy is needed to operate an electric device.

Figure 1. Lead-Acid Industrial Battery A lead-acid battery is made from several lead-acid batteries called cells. Each cell has positive and negative plates with dielectric spacers between each plate. All of the plates are within a solution of electrolyte. See Figure 2.

1. VENT AND FILL CAP 2. POST 3. POST SEAL 4. PLATE PROTECTOR (SHIELD)

5.

6.

7.

8.

9.

10.

POSITIVE PLATE EXPANSION MATS RETAINER SEPARATOR NEGATIVE PLATE BATTERY JAR

Figure 2. Battery Cell

1

Chemical Reaction in a Cell

2240 SRM 1

Specific Gravity The strength of the electrolyte is measured in points of specific gravity. For example, a solution of sulfuric acid has a specific gravity of 1.835. Water has a specific gravity of 1.000. Electrolyte is 27 percent acid and 73 percent water and has a specific gravity of 1.275.

Chemical Reaction in a Cell WARNING NEVER pour water into concentrated acid.

Combining these liquids creates the rapid production of heat which can cause the water to boil and the acid to erupt and splash out of the container. ALWAYS pour concentrated acid into water when making a dilute solution of acid.

In a fully-charged cell, the electrolyte has a specific gravity of 1.270 to 1.130. NEVER discharge a battery below a specific gravity of 1.130. The battery can have permanent damage if discharged below 1.130.

The cell generates a voltage (potential difference) when two different types of metal are in the electrolyte. The two metals in a lead-acid cell are lead peroxide (PbO 3) for positive plates, and sponge lead (Pb) for negative plates. See Figure 3. A potential difference of approximately 2 volts per cell is generated. The potential difference does not vary according to the size of the cell.

During the discharge of the cell, lead peroxide and sponge lead mix with sulfuric acid to make lead sulfate (PbSO 4) on both plates. See Figure 4. This action decreases the voltage in the cell. When the sulfuric acid is removed from the electrolyte, the specific gravity of the electrolyte decreases. See Figure 5.

The potential difference of a discharged cell is approximately 1.75 volts.

When a direct current is applied to a discharged cell, the lead sulfate is changed into lead and sulfuric acid.

The lead goes to the positive plate and stays as lead and to the negative plate and stays as lead peroxide.

See Figure 6. The concentration of sulfuric acid in the electrolyte increases. The specific gravity of the electrolyte increases as the concentration of sulfuric acid increases. In a fully charged cell, the positive plate again contains the lead peroxide and the negative plate contains the sponge lead.

Figure 4. Discharging Cell

Figure 3. Fully Charged Cell

2

2240 SRM 1

Electrical Terms

Figure 5. Discharged Cell

Figure 6. Charging Cell

Electrical Terms Voltage: Is an electromotive force (EMF) (also called "potential difference") caused by the difference in electric charge between two points. See Figure 7.

Ampere: Is a measurement of electric current.

Watt: Is a measure of electric power. The number of watts is equal to the number of volts multiplied by the number of amperes. A kilowatt-hour is 1000 watts of electric power used in 1 hour.

Ohms: Is the measurement of electrical resistance.

Polarity: In a battery, the electric current is shown to flow from the positive terminal to the negative terminal.

Maintenance-Free Battery: The electrolyte level in the battery does not need to be checked during the life of the battery. Maintenance-free batteries use a calcium alloy of lead instead of an antimony alloy, which reduces the amount of electrolysis. In a

maintenance-free battery, the amount of free-standing electrolyte above the plates is much higher, ensuring enough electrolytes to keep the plates covered during extended periods of use. Therefore, there is no need to add water to a maintenance-free battery during the course of its life.

Flooded Cell: This is a lead acid battery that has free flowing electrolyte fluid in each cell of the battery. The electrolyte is a mixture of sulfuric acid and water.

Direct Current (DC): When the voltage between the two terminals is always the same polarity, the current flow and voltage are called Direct Current.

Alternating Current (AC): When the polarity of voltage between two terminals is changing between positive and negative at a quick and constant rate, the voltage is called Alternating Current.

3

Battery Selection

2240 SRM 1

Figure 7. Electrical Terms

Battery Selection NOTE: The capacity of the battery can be found on the lift truck’s Nameplate. See the Frame section or Operating Manual for your lift truck for the location of the Nameplate.

The battery needed to operate a period of 8 hours depends on many conditions. Operations that require the lift truck to go up ramps or require the use of additional attachments increase the use of power from the battery. Some work conditions require that more than one battery must be used during a work period.

The number of 8-hour work periods per day is normally equal to the number of batteries needed. For example, for three work periods, you need three batteries. The capacity of the battery you need is found as follows: • The size of the lift truck and the attachments.

• The type of work. Heavy-duty operation or normal operation for one 8-hour work period.

Lift trucks are available in various voltage ranges.

See Figure 8. The small "walkie" lift trucks are normally 12 or 24 volts. The larger sit-down rider lift trucks are normally 24, 36, 48, 72, or 80 volts. The number of cells in a lead-acid battery gives the battery voltage. See Figure 9. A fully charged cell has a potential difference of approximately 2 volts. See Figure 8. This potential difference does not change with size of the cell.

4

Figure 8. Cell Voltage

2240 SRM 1

Battery as a Counterweight

Figure 9. Multicell Battery for Electric Lift Truck

Battery Voltage NOTE: The voltage of the battery can be found on the lift truck’s Nameplate. See the Frame section or Operating Manual for your lift truck for the location of the Nameplate.

The battery voltage you need is found as follows: • Will your lift truck operate on more than one voltage?

• If you have more than one lift truck in operation, do the battery voltages need to be the same?

To reach the necessary battery voltage, the cells are connected in series. For example: 24 volts = 12-cell battery 36 volts = 18-cell battery 48 volts = 24-cell battery 72 volts = 36-cell battery 80 volts = 40-cell battery

Battery as a Counterweight On electric lift trucks that use the battery as part of the counterweight, the battery is part of the capacity of the lift truck to lift loads. The minimum weight of the battery is shown on the nameplate. If the battery is not the minimum weight, the capacity of the lift truck is reduced. If the battery used in the lift truck is less than the size of the battery compartment, blocks and spacers must be installed to hold the battery in position.

See the Frame or Periodic Maintenance service manual or Operating Manual for your lift truck model for the correct measurements for installing battery spacers.

5

Battery Maintenance

2240 SRM 1

Battery Ratings The ratings of batteries are measured in amperehours and kilowatt-hours at a constant rate of discharge. A rating of 6 hours is the standard. Amperehours is the measurement of battery capacity. To calculate ampere-hours, multiply amperes by hours.

See Table 1. For example, 5 amperes times 5 hours is 25 ampere-hours. You cannot change the potential difference of a cell. You can increase the ampere-hour rating by increasing the number of plates in a cell, or by installation of larger plates. The constant rate of discharging can be compared to a measurement of the battery capacity and ampere-hours. For example, a battery with a rating of 600 ampere-hours during a work period of 6 hours will generate 100 amperes per hour for 6 hours. The same battery cannot generate 300 amperes for 2 hours. The heat generated within the battery will damage the battery.

Table 1. Battery Capacity Terms Amperes × Hours = Ampere-Hours 600 Ampere Hours = 100 Amperes for 6 Hours Volts × Amperes × Hours/1000 = Kilowatt-Hours (KWH)

KILOWATT-HOURS A kilowatt is 1000 watts. A watt is a measure of electric power. The capacity in kilowatt-hours is the total power generated by the battery. Watt-hours are measured by multiplying the voltage by amperehours. To measure the kilowatt-hours, divide the watt-hours by 1000. volts × amperes × hours 1000

= kilowatt-hours or kWh

To calculate the kilowatt-hours for a battery that has a rating of 600 ampere-hours and a 48-volt system, use this formula: 48 volts × 600 amperes × hours 1000

= 28.8 kWh

The watt-hours can be converted to kilowatt-hours to indicate the battery needed for the operation. Always select the correct type of battery. Remember, a battery that has a rating of 300 ampere-hours will not do the same job as a battery that has a rating of 600 ampere-hours. Do not permit the specific gravity to go below the limits shown in the manual.

Battery Maintenance Battery maintenance must include the following items: • A good battery charger • A clean battery • Keep the electrolyte at the correct level (see Figure 13) • Keep a record of the battery • An Equalization Charge once a month

SAFETY PROCEDURES 1. Wear a rubber apron, gloves, boots, and goggles or a face shield when doing maintenance on batteries.

match or a lighter. Do not smoke and do not create sparks.

3. Lift batteries correctly with a crane or equipment designed for the job. Always use a spreader bar designed and adjusted for the battery. Move batteries with a lift truck or a conveyor or rollers designed for that purpose. If the battery does not have a cover, a rubber mat or insulating material must be put over the top of the battery to prevent a short circuit with other equipment. Make sure the lifting equipment has enough capacity for the job. Do not use chain or wire rope slings.

4. Never put metal materials or tools on a battery.

2. Batteries generate hydrogen gas when they are being charged. Keep open fire away from batteries. Do not check the electrolyte level with a

6

5. Disconnect battery from lift truck before doing maintenance or repairs.

2240 SRM 1 6. When maintenance on the battery or the battery charger is required, disconnect both the AC and DC power. If the battery connectors must be replaced, make sure the positive and negative terminals and cables are kept separate and insulated from each other. Even a momentary short circuit can cause an explosion and damage the battery.

7. Keep water readily available to flush spilled electrolyte. Electrolyte in the eyes must be flushed with water immediately, and then quickly get medical attention. Special showers and eye wash systems are required in areas where battery maintenance is done.

8. If electrolyte is spilled on a work surface or the floor, flush area with water, use a solution of soda (sodium bicarbonate) to make the acid neutral.

9. Only trained persons are permitted to do maintenance on batteries and battery chargers. Make sure the regulations by government safety agencies, government insurers, private insurers, and private organizations are followed when doing maintenance on batteries.

MAINTENANCE RECORDS NOTE: Follow the same sequence when you record the cell number. Always begin the record with a positive cell. Follow a sequence so the last cell is always the cell for the negative cable.

Record the beginning ampere reading of the charger each time the battery is charged. Any difference in the daily ampere reading can indicate a problem with the battery or the charger.

NEW BATTERY CAUTION Always use a spreader bar and slings that lift vertically on the lifting eyes of the battery. DO NOT use a chain or sling without a spreader bar or you will damage the battery case.

Use the correct blocks or spacers to hold the battery in position in the lift truck. Make sure the battery compartment is clean and dry. All

Battery Maintenance vent caps must be in position when the battery is in service. If the vent caps are not installed, the electrolyte will leak, causing corrosion on the battery case and in the battery compartment.

Inspect a new battery for damage. Make sure the electrolyte in each of the cells is at the correct level.

Charge the battery for 6 hours or until the specific gravity is correct. Make sure the battery is correctly installed in the lift truck. Use a spreader bar with slings designed for the battery to lift and move the battery. See Figure 10.

Always complete the Battery Inspection Report and the Daily Battery Report. See Figure 11 and Figure 12.

CLEANING BATTERY WARNING Compressed air can move particles so that they cause injury to the user or to other personnel.

Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

Keep the battery compartment clean and dry. Use a clean cloth to wash the battery with water. Dry with compressed air.

CAUTION Do not clean the battery with steam or hot water. Do not use a high-pressure hose.

Remove any electrolyte from the battery compartment to prevent corrosion. If there is electrolyte on the top of the battery, apply a solution of bicarbonate of soda. Mix a solution containing 0.5 kg of soda for every 4 liters of water. Apply the solution, then flush the solution from the battery with clean water. Wash the battery and battery compartment as needed, but within a 6-month period as the maximum time.

NOTE: If the top of the battery is wet from electrolyte, check that the electrolyte level is not too high or the battery charger is not operating correctly.

7

Battery Maintenance

2240 SRM 1 Legend for Figure 10 1. INSULATED SPREADER BAR 2. INSULATED STRAPS

Figure 10. Change the Battery

Figure 11. Battery Inspection Report

8

2240 SRM 1

Battery Maintenance

Figure 12. Daily Battery Report

ADDING WATER TO BATTERY NOTE: Some batteries have sealed cells. These batteries do not need water added to the electrolyte.

vent plugs. The electrolyte can flow out of the cell through the fill hole. The correct electrolyte level is shown in Figure 13.

Some water is lost from the electrolyte of each cell during the charge and discharge cycle when the battery is in service. Check the electrolyte level daily.

Some service persons check some of the cells each day so all cells are checked each week. If the level of the electrolyte goes below the level of the top of the separators for the plates, the cell can be damaged.

KEEPING THE ELECTROLYTE LEVEL WITHIN THE CORRECT LIMITS IS THE MOST IMPORTANT ITEM OF BATTERY MAINTENANCE. See the instructions from the manufacturer of your battery for the operating level of the electrolyte. Always use distilled water. If you add distilled water, wait 5 minutes before measuring the specific gravity with a hydrometer. DO NOT add water to a cell before or during the charging cycle; water must be added after the charging cycle. If water is added before the charging cycle, the electrolyte level may rise, which will cause electrolyte to be forced out of the

1.

2.

3.

4.

5.

6.

7.

FILL TUBE BOTTOM OF FILL TUBE CELL COVER MAXIMUM LEVEL OF ELECTROLYTE MINIMUM LEVEL OF ELECTROLYTE PLATE PROTECTOR TOP OF SEPARATORS Figure 13. Electrolyte Level

9

Battery Maintenance

2240 SRM 1

HYDROMETER NOTE: Some batteries have sealed cells. The specific gravity of the electrolyte cannot be checked on these batteries.

Use a hydrometer to measure the specific gravity of the battery. Make sure there is enough electrolyte in the battery cells. See Adding Water to Battery in this section. A high level or low level of the electrolyte can change the specific gravity measurement. When the

1. HIGH FLOAT MEANS HIGH SPECIFIC GRAVITY. 2. LOW FLOAT MEANS LOW SPECIFIC GRAVITY.

electrolyte level is low, the percent of sulfuric acid in the electrolyte increases. When the electrolyte level decreases by 3 mm (1/8 in.), the specific gravity measurement can increase by 3 to 5 points.

When you use the hydrometer, make sure there is enough liquid in the barrel to let the float move freely.

The float must not touch the side, top, or bottom of the barrel. See Figure 14 for the correct method of reading the hydrometer.

3. CORRECT METHOD OF READING HYDROMETER: EYE LEVEL EVEN WITH SURFACE OF ELECTROLYTE.

Figure 14. Reading Hydrometer

BATTERY TEMPERATURE The temperature of the electrolyte will change the reading of the specific gravity. When the temperature increases approximately 6 C (10 F), the specific gravity will decrease by 0.003 point. See Figure 15 for making specific gravity corrections. If the hydrometer you are using does not have a temperature correction, you will have to use a thermometer. Special battery thermometers are available that will indicate the correction factor directly and add or subtract the correct number of points. See Figure 16.

NEVER charge a battery at a rate that will raise the electrolyte temperature above 49 C (120 F). NEVER let a battery stay discharged for long periods. A temperature above this amount will damage the battery.

The cells in the center of the battery are normally at the highest temperature. If the battery temperature is too hot, make sure the ventilation of the battery

10

is increased and make sure the charge or discharge rate is not too high. A recommendation for a battery in service is 8 hours of use (discharge), followed by 8 hours of charging, followed by 8 hours of cooling.

To charge the battery, a direct current must pass through the cells in the opposite direction to the discharging current. The ampere-hours must be equal to the discharging ampere-hours plus the energy lost as heat. This additional amount of charge will vary according to the battery and the temperature, but the average additional charge is 12 percent. When the battery is nearly charged, the final charging must be at a low rate. A charging rate that is too high will cause heating in the battery and a high loss of water from the electrolyte. The charging of the battery must be done correctly, or the service life of the battery will be decreased.

2240 SRM 1

Battery Maintenance has sealed cells. The sealed batteries require a different charger. The electrolyte level or specific gravity cannot be checked, and water cannot be added to the electrolyte of these sealed batteries.

WARNING The acid in the electrolyte can cause injury.

If electrolyte is spilled, use water to flush the area. Make the acid neutral with a solution of sodium bicarbonate.

Batteries generate explosive fumes when they are being charged. Keep fire, sparks, and burning material away from the battery charger area. Prevent sparks from the battery connectors.

Specific Gravity Reading

Electrolyte Temp.

Correction Points

Correct Value

1.210

31 C (88 F)

+0.003

1.213

1.210

27 C (81 F)

+0.001

1.211

1.210

25 C (77 F)

0.000

1.210

1.210

18 C (64 F)

0.004

1.206

+0.001 or 0.001 for each 2 degrees C from the 25-degree base value.

Figure 15. Specific Gravity Check

Charge batteries only in the special area for charging batteries. When charging the batteries, keep the vent caps clean. The battery charger area must have ventilation so that explosive fumes are removed. Open the hood over the battery or remove the cover if the battery has a cover.

Disconnect the battery when doing cleaning and maintenance.

If the lift truck has been operated with a low battery, check the contactors for welded contacts before a charged battery is connected.

The circuit will not reset and lift truck operation cannot be controlled if the contacts are welded. To check the contacts, see the Contactor inspection procedure for your lift truck.

CAUTION Use only battery chargers approved by the battery manufacturer or dealer.

CAUTION NEVER connect the battery charger plug to the plug of the lift truck. You can damage the traction control circuit. Make sure the charger voltage is the correct voltage for the battery.

Figure 16. Battery Thermometer

CHARGING BATTERY NOTE: There can be one of two types of batteries.

One type has removable cell caps. The other type

Correct use of the hydrometer (see Figure 14) and proper operation of the battery charger is important. Also see Figure 15. Follow the instructions of the charger manufacturer. NEVER let the battery discharge below the minimum value given by the battery manufacturer. A fully charged battery will have a specific gravity of 1.265 to 1.310 at 25 C

11

Battery Maintenance

2240 SRM 1

(77 F). See Figure 15. NEVER charge a battery at a rate that will raise the electrolyte temperature above 49 C (120 F). Never let a battery stay discharged for long periods.

Types of Battery Charges 1. NORMAL CHARGE. This charge is usually given to a battery that is discharged from normal operation. This is often an 8-hour charge.

Many customers charge the battery at regular intervals that depend on use. This procedure will keep the battery correctly charged if the battery is not discharged below the limit. Always use a hydrometer to check the battery if the battery is charged at regular intervals. Frequent charging of a battery that has a 2/3 or more charge can decrease the life of the battery.

2. EQUALIZING CHARGE. This charge is at a low rate and balances the charge in all the cells. The equalizing charge is usually given approximately once a month. It is a charge at a slow rate for 3 to 6 hours in addition to the regular charging cycle. Do not give an equalizing charge more than once a week. The most accurate specific gravity measurements for a charged battery will be after an equalizing charge. If the specific gravity difference is more than 0.020 between cells of the battery after an equalizing charge, there can be a damaged cell. Consult your battery dealer.

NOTE: Many customers have battery chargers that can follow a program to automatically charge a battery according to recommendations of the battery manufacturer. Use the recommendations of the battery manufacturer for charging the battery.

Figure 17. Specific Gravity Versus Percent Discharge

The discharge limits and the limits for the specific gravity before the battery must be charged again are shown in Figure 17. NEVER discharge a battery below the limits shown in Figure 18. Discharging a battery beyond the design limits will decrease the service life of the battery.

NOTE: Sometimes the capacity of a battery is not enough to complete a work period. Check for the following conditions: • The battery is too small for the job.

• The battery is not fully charged.

• The battery charger is not operating correctly.

• The battery is near the end of its service life.

12

Figure 18. Specific Gravity Compared to Charging Time

2240 SRM 1

Methods of Charging There are three methods of charging a battery.

1. GRADUAL CHARGE. This method uses a solid-state automatic battery charger.

The charging rate begins at 20 to 25 amps/100 amp-hours and decreases to less than 5 amps/100 amp-hours when the battery is 80 percent charged. The charging current decreases when the voltage across the cell increases during the charging cycle shown in Figure 19. The increase in the voltage from the charger is approximately the same as the increase in the specific gravity in the cells.

Battery Maintenance a lower rate. Two resistors control the charging rate. One resistor controls the charging rate at the beginning of the cycle and a second resistor reduces the charging rate when the voltage in the cells reaches 2.37 volts. A relay automatically controls the second resistor. The two-rate charging cycle is shown in Figure 21.

Figure 20. Modified Constant Voltage Charger

Figure 19. Specific Gravity Compared to Charging Time 2. MODIFIED CONSTANT VOLTAGE. This method uses a generator to generate a constant voltage that is controlled by a resistor.

When the charging current decreases, the voltage across the resistor increases. The increasing voltage across the resistor causes an increasing voltage at the battery terminals. The charging is similar to the gradual charge. The resistor must be correctly set, or the charging rate will be wrong. The typical graphs for a modified constant voltage charger are shown in Figure 20.

3. TWO-RATE CHARGE. This method also uses a high charging rate at the beginning followed by

Figure 21. Two-Rate Charging Cycle NOTE: Many users have battery chargers that can follow a program to automatically charge a battery according to recommendations of the battery manufacturer. Use the recommendations of the battery manufacturer for charging the battery.

13

Battery Maintenance

Troubleshooting Charger Battery chargers normally operate automatically without constant attention. It is necessary to make a periodic check that the charger is operating correctly. Check for the following conditions: 1. Battery temperature is too high. The temperature in a battery will not normally rise more than 14 C (25 F) during an 8-hour charging period. Higher temperatures indicate the charging rate needs adjustment.

2. Continuous operation of the charger. Check the automatic controls on the charger. Check the charging rate. A low charging rate can be the problem.

3. Continuous operation of a charger at a high rate.

Normally, the charging rate begins at a high rate and decreases as the battery becomes charged.

If the rate does not decrease, the controls need repair or adjustment.

Knowing When Battery Is Fully Charged WARNING Always connect the positive cable to the positive terminal and connect the negative cable to the negative terminal. Any other connection will cause injury and damage.

Always charge the battery at the end of the work period (shift). Never let the specific gravity decrease to a level less than the limits shown in the manual.

Always de-energize the charger before you connect or disconnect the charger from the battery.

NEVER connect the battery charger plug to the plug of the lift truck. You can damage the traction control circuit. Make sure the charger voltage is the correct voltage for the battery.

1. During charging, the voltage increases slowly.

When the battery is fully charged, the voltage level is constant.

2. Remove a vent cap and look in the opening. If you see bubbles in the electrolyte, the battery is

14

2240 SRM 1 either fully charged or in the final stage of charging.

3. The specific gravity reading is constant and within the limits of a charged battery. If the temperature increases after the battery is charged, the specific gravity will decrease a small amount.

4. Constant meter indications on the charger will indicate the end of the charging cycle.

WHERE TO CHARGE BATTERIES To increase the service life and reduce maintenance, a special area is needed for charging the batteries.

The following information is necessary for the design of this area: • Location of power supply • Ventilation; hydrogen gas comes from the batteries during charging • Drains for cleaning the batteries • Type and size of the batteries • Type of lift trucks • Distances the lift trucks must travel for service • Safety regulations and instructions

Equipment Needed • A lifting device to remove the battery from the lift truck • Racks to hold the batteries during charging and storage (these racks must be made of wood or must not be metal; metal racks that are covered with an insulating material can be used) • A battery charger that will charge your batteries • Tools for maintenance • An area with a drain for cleaning batteries and battery compartments • Distilled water • Air and water supplies for cleaning • Maintenance records (see Figure 11 and Figure 12) • A workbench • Spare parts and repair equipment • Protective clothing and safety equipment for handling batteries • Water source for washing eyes and preventing acid burns • Install a NO SMOKING sign in the service area • Keep the charger in a clean, dry area with good ventilation

2240 SRM 1

BATTERY CONNECTORS A special heavy-duty connector is used to connect the battery to the electrical system of the lift truck. See Figure 22 and Figure 23. When a connector has a handle and is within the operator’s reach, the connector is also a safety device that can be used to quickly disconnect the battery in an emergency. Most connectors have a handle to connect the two halves of the connector. The connector can be quickly disconnected by pulling the handle upward. This action separates the two halves of the connector. The connector and its attached handle must be kept in good repair so that it will function correctly. The battery connector must be disconnected when maintenance is done on the lift truck that does not require electric power.

The SBE, SBX, and FEM or DIN 12- volt battery connectors are shown in Figure 23.

Battery Maintenance Legend for Figure 22 1. SB CONNECTOR FOR BATTERY CABLES 2. SB CONNECTOR FOR POWER CABLES TO LIFT TRUCK 3. BRACKET 4. CONNECT AND DISCONNECT HANDLES

BATTERY CARE 1. Keep batteries clean. Remove any spilled electrolyte.

2. DO NOT overcharge the battery. This action will damage the battery.

3. DO NOT discharge the battery to less than the recommendation. A deep discharge will shorten the battery life.

4. Charge batteries in an area with good ventilation to remove explosive gases and acid fumes.

5. Keep the electrolyte at the correct level. Check the electrolyte level before and after charging the battery. Use distilled water. Do not add acid.

6. Prevent batteries from freezing.

7. Keep batteries charged. A discharged battery in storage will shorten the battery life.

8. Use a battery charger that is correct for the battery. A battery charger that is set for an ampere-hour rate that is too high will cause a high internal heat and damage the battery. A low ampere-hour rate setting on a battery charger can require a longer charging time but will not damage the battery.

9. When batteries are moved, make sure a short circuit does not occur. See the Safety Procedures in Battery Maintenance of this section.

Figure 22. SB Battery Connector

15

Battery Maintenance

2240 SRM 1

NOTE: INDICATOR INSERT (2). GREEN - FOR BATTERY WITH CELL CAPS. GRAY - FOR BATTERY WITH SEALED CELLS. NOTE: CONNECTOR BODY COLOR [ANDERSON SBE CONNECTOR ONLY (1)]. GRAY - 36-VOLT BATTERY. BLUE - 48-VOLT BATTERY. GREEN - 72-VOLT BATTERY. BLACK - 80-VOLT BATTERY. A. ANDERSON SBE OR SBX CONNECTOR

B. FEM OR DIN CONNECTOR

1. HALF OF CONNECTOR SET 2. RED HOUSING FOR +12 VOLT "BATTERY TAP" 3. LOCK SPRING (TIP OF CONTACT MUST LOCK OVER TOP OF LOCK SPRING) 4. BLACK CONNECTOR HOUSING (ASSEMBLED ON RED HOUSING WITH SLOTS FOR LOCK PINS ALIGNED AS SHOWN - NO WIRE OR CONTACT IN HOUSING) 5. SLOT FOR LOCK PIN 6. CONTACT FOR CONNECTOR OF +12 VOLT BATTERY TAP 7. KEY [RED (2) AND BLACK (4) CONNECTORS ALIGN ON KEY] 8. LOCK PINS FOR +12 VOLT CONNECTOR (MUST INSTALL FROM FRONT OF CONNECTOR THROUGH RED AND BLACK CONNECTORS)

9. +12 VOLT WIRE TO TRUCK (TRUCK HALF) OR TO BATTERY (BATTERY HALF) 10. INDICATOR INSERT FOR BATTERY VOLTAGE AND BATTERY TYPE [ROTATE FOR CORRECT VOLTAGE IN WINDOW (12); COLOR SHOWS BATTERY TYPE] 11. LOCK FOR ALL CABLE TERMINALS AND INDICATOR 12. WINDOW SHOWING BATTERY VOLTAGE 13. IN-LINE FUSE ASSEMBLY AND CONTACT FOR +12 VOLT CONNECTOR (TRUCK HALF OF BATTERY CONNECTOR ONLY) (SBE/SBX CONTACT SHOWN)

Figure 23. Detail of Battery Connectors With +12 Volt Tap

16

LIFTING MECHANISM W40Z [B218]; W45Z [C215]; W50Z [D215]

PART NO. 1511567

4000 SRM 1008

Lifting Mechanism

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Lift Linkage ...................................................................................................................................................

Load Wheel.........................................................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Rear Link and Load Wheel................................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Compression Rod................................................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Lower Link .........................................................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Upper Link .........................................................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Caster Wheels (Optional) ..................................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Replace ...........................................................................................................................................................

1 1 2 2 2 3 3 4 4 4 5 5 5 5 6 6 7 8 8 8 8

This section is for the following models: W40Z [B218]; W45Z [C215]; W50Z [D215]

©2005 HYSTER COMPANY

i

4000 SRM 1008

General

General LIFT LINKAGE This section has the description and repair procedures for the W40/45/50Z units. The lifting mechanism is operated by the hydraulic system. Hydraulic fluid extends the lift cylinder, operates the lift linkage, and raises the forks.

On all motorized lift trucks, when the lift button on the control handle is depressed, the hydraulic pump

1. LOWER LINK (RH) 2. LOWER LINK (LH)

sends high pressure hydraulic fluid to the lift cylinder. This action extends the cylinder, operates the lift linkage, and raises the forks. At the same time, the rocker arms and the rear links mounted under the drive unit platform are pulled upward. This causes the push rod assembly to be pushed toward the load wheel end of the truck. The movement of the push rods in this direction causes the load wheels to pivot down on their pivot pins. See Figure 1.

3. FORK 4. LOAD WHEEL Figure 1. Lift Linkage

1

Load Wheel

4000 SRM 1008

Load Wheel REMOVE WARNING Put blocks under both forks and on both sides of the drive tire. The blocks must prevent the lift truck from falling and causing personal injury or property damage.

1. Remove the battery from the lift truck. Position the battery close enough to the lift truck to allow power cable connection during servicing. Connect the battery and turn the key switch to the ON position.

2. Use the lift button to raise the lift truck to its maximum height.

bearings. Sealed bearings in need of service must be replaced.

8. Remove all old lubricant. Clean and inspect all parts. Replace all defective parts.

INSTALL NOTE: Some models are equipped with sealed bearings. Do not attempt to clean or lubricate sealed bearings. Sealed bearings in need of service must be replaced.

1. Prelubricate the bearings with the recommended grease. Install bearings into the load wheel and install the bushings into the bearings.

3. Put blocks under both forks and under the drive end of truck. See the section How to Put a Lift Truck on Blocks.

2. Position the load wheel assembly into the link.

Insert the axle shaft through the link, bushings, and bearings. Insert a punch to align the roll pin hole in the axle shaft with the hole in the link.

4. Press the lower button just enough to relieve pressure from the load wheels.

3. Install the roll pin through the link to secure the axle shaft.

5. Move the key to the OFF position. Disconnect the battery.

4. Reconnect the battery. Move the key to the ON position.

6. Drive out the roll pin retaining the load wheel axle shaft to the link. Repeat for other side.

5. Press the lift button to fully extend the lift link.

7. Remove the axle shaft and bushings from the link. Remove bearings and load wheel assembly from the link. It may be necessary to drive the bearing out of the wheel using a soft punch.

Drive the bearing out from the opposite side. See Figure 2.

NOTE: Some models are equipped with sealed bearings. Do not attempt to clean or lubricate sealed

2

6. Remove the blocks from under the forks and drive end of truck. Lubricate the load wheel and link fittings then press the lift and lower buttons to raise and lower the forks. The truck should lift and lower evenly.

7. Install the battery in the battery compartment.

8. Test the operation of the motorized hand truck before returning the truck to service.

4000 SRM 1008

1.

2.

3.

4.

Rear Link and Load Wheel

LINK GREASE FITTING ROLLER BEARING

5.

6.

7.

8.

BUSHING AXLE SHAFT FITTING ROLL PIN

Figure 2. Load Wheel and Link Assembly

Rear Link and Load Wheel REMOVE WARNING Put blocks under both forks and on both sides of the drive tire. The blocks must prevent the lift truck from falling and causing personal injury or property damage.

1. Remove the battery from the lift truck. Position the battery close enough to the lift truck to allow power cable connection during servicing. Connect the battery and turn the key switch to the ON position.

2. Use the lift button to raise the lift truck to its maximum height.

3. Put blocks under both forks and under the drive end of truck. See the section How to Put a Lift Truck on Blocks.

4. Press the lower button just enough to relieve pressure from the load wheels.

5. Move the key to the OFF position. Disconnect the battery.

3

Compression Rod

4000 SRM 1008

6. Disconnect the load wheel link from the compression rod yoke:

2. Install the load wheel and link assembly to the fork:

a. Remove the roll pin securing the pivot pin in the yoke.

a. Align the pallet exit roller and load wheel link with mounting holes in fork.

b. Remove the pivot pin.

b. Install the connecting pivot pin and align holes with a punch.

7. Remove the load wheel link from the fork frame: a. Remove the roll pin securing the link and exit roller to the fork. b. Drive out the roll pin securing the pivot pin to the fork. c. Remove the pivot pins. d. Remove any bushings as necessary.

8. Disassemble the load wheel. See Load Wheel.

9. Remove all old lubricant. Clean and inspect all parts for damage. Replace all defective parts.

INSTALL 1. Assemble the load wheel assembly to the link.

See Load Wheel.

NOTE: Some models are equipped with bushings in the load roller link where the compression rod yoke attaches. Install new bushings if removed as required.

c. Secure with the roll pin.

3. Connect the load wheel link with the compression rod: a. Check condition of yoke components including bushings and compression rod jam nuts.

Replace as required. b. Align the compression rod yoke and the load wheel link. c. Install the connecting pivot pin and secure with the roll pin.

4. Connect the power cables and turn the key switch to the ON position. Press the lift button to fully extend the load wheels. Remove the blocks from under the forks and from each side of the drive tire.

5. Lubricate the load wheel link fittings. Lift and lower the lift truck to check for proper operation.

The truck should lift and lower evenly.

6. Install the battery into the battery compartment.

Compression Rod REMOVE WARNING Put blocks under both forks and on both sides of the drive tire. The blocks must prevent the lift truck from falling and causing personal injury or property damage.

WARNING Batteries are heavy and can cause a personal injury. Use care to avoid injury. Do NOT put hands, arms, feet, and/or legs between the battery and a solid object. Make sure the capacity of the lifting device and spreader bar is greater than the weight of the battery. The weight of the battery is normally shown on the battery

4

case. The maximum battery weight is shown on the lift truck nameplate. The spreader bar must NOT be made of metal or it must have insulated straps.

1. Use the lift button to raise the lift truck to its maximum height.

2. Put blocks under both forks and on both sides of the drive tire. See How to Put a Lift Truck on Blocks.

3. Lower the hoist cylinder using the lower button.

This will raise the load wheels off the floor.

4. Move the key to the OFF position. Disconnect the battery. Remove the battery.

4000 SRM 1008

Lower Link

5. Remove the roll pin retaining the load wheel link pivot pin to the fork frame. Remove the pivot pin.

6. Remove drive unit and lower cover.

7. Remove the roll pin retaining the lower link pivot pin to the compression rod. Remove the pivot pin.

8. Remove all old lubricant. Clean and inspect all parts. Replace defective parts.

INSTALL 1. Install pivot pin retaining lower link and compression rod. Install roll pin.

2. Align and install the pivot pin connecting the compression rod and the load wheel. Install roll pin.

3. Install the pivot pin connecting the load wheel link and pallet entry/exit roller and install the roll pin to retain the pivot pin.

4. Raise the load wheels. Lubricate the load wheel and all linkage pivot pins.

5. Install the battery in the battery compartment and connect the battery.

6. Remove the blocks from under the forks and from each side of the drive tire. Turn the key to the ON position and use the lower button to lower the lift truck to its minimum height. The truck should lift and lower evenly.

7. Test the operation of the motorized hand truck before returning the truck to service.

Lower Link REMOVE WARNING Batteries are heavy and can cause a personal injury. Use care to avoid injury. Do NOT put hands, arms, feet, and/or legs between the battery and a solid object. Make sure the capacity of the lifting device and spreader bar is greater than the weight of the battery. The weight of the battery is normally shown on the battery case. The maximum battery weight is shown on the lift truck nameplate. The spreader bar must NOT be made of metal or it must have insulated straps.

WARNING

5. Remove the roll pin retaining the drive frame pivot pin to the lower link. Use a drift to drive the pivot pin out of the lower link and the drive frame. See Figure 3.

6. Remove the roll pin retaining the lower link pin to the fork frame. Drive the pin out of the frame using a drift pin.

7. Remove the bushings from the lower link.

8. Remove all old lubricant. Clean and inspect all parts. Replace all defective parts.

INSTALL 1. Install new bushings into the lower link using the grease fitting hole as a guide.

Put blocks under both forks and on both sides of the drive tire. The blocks must prevent the lift truck from falling and causing personal injury or property damage.

2. Align the lower link with the fork frame and install the lower link pivot pin. Install the roll pin to retain the pivot pin.

1. Use the lift button to raise the lift truck to its maximum height.

3. Align the lower link with the drive frame and install the drive frame pivot pin. Install the roll pin to retain the drive frame pivot pin.

2. Move the key to the OFF position. Disconnect and remove the battery.

3. Put blocks under both forks and on both sides of the drive tire. See the section How to Put a Lift Truck on Blocks.

4. Align the pull rod and the lower link and install the pivot pin. Install the roll pin to retain the pivot pin.

5. Lubricate the grease fittings.

4. Remove covers.

5

Upper Link

4000 SRM 1008

6. Remove the blocks from under the forks and from each side of the drive tire.

7. Install the battery in the battery compartment.

Connect the battery.

1. FITTING 2. PIN 3. FITTING

8. Turn the key to the ON position and use the lower button to lower the lift truck to its minimum height.

9. Test the operation of the motorized hand truck before returning the truck to service.

4. PIVOT PIN 5. PIN Figure 3. Lower Link

Upper Link REMOVE WARNING Put blocks under both forks and on both sides of the drive tire. The blocks must prevent the lift truck from falling and causing personal injury or property damage.

1. Disconnect the battery.

2. Put blocks under both forks and on both sides of the drive tire. See the section How to Put a Lift Truck on Blocks.

6

3. Remove the drive unit compartment cover to access the upper link. See Figure 4.

4. Use a drift pin to remove the roll pin retaining the pivot pin to the drive unit frame. Drive the pivot pin out of the frame and upper link.

5. Remove the screw, washer, and nut retaining the pivot pin to the fork frame. Drive the pivot pin out of the fork frame and upper link.

4000 SRM 1008

Upper Link

INSTALL

3. Install the drive unit compartment cover.

1. Align the pivot pin with the fork frame and upper link and install the pivot pin. Install the screw, washer, and nut to retain the pivot pin to the fork frame. Repeat for opposite side.

4. Remove the blocks from under the forks and from each side of the drive tire. Connect the battery.

5. Test for proper operation before returning the truck to service.

2. Align the pivot pin with the drive unit frame and the upper link and install the pivot pin. Install a roll pin to retain the pivot pin.

1.

2.

3.

4.

FITTING UPPER LINK CAPSCREW LOCKWASHER

5. NUT 6. PIN 7. PIVOT PIN Figure 4. Upper Link

7

Caster Wheels (Optional)

4000 SRM 1008

Caster Wheels (Optional) REMOVE

3. Repeat Step 2 to remove other caster if necessary.

INSTALL

WARNING Put blocks under both forks and on both sides of the drive tire. The blocks must prevent the lift truck from falling and causing personal injury or property damage.

1. Raise the drive wheel off the floor. Block the lift truck. See How to Put a Lift Truck on Blocks.

Disconnect the battery.

2. Remove the three screws retaining the caster and spacer to the frame. Remove the caster wheel.

See Figure 5.

1. Align the caster and spacer with the holes in the frame and install the three screws. Tighten the nuts to 56 N•m (42 lbf ft).

2. Repeat Step 1 to install other caster if necessary.

3. Remove the blocks from under the lift truck and lower the truck to the floor. Test the operation of the truck prior to returning the truck to service.

REPLACE WARNING Put blocks under both forks and on both sides of the drive tire. The blocks must prevent the lift truck from falling and causing personal injury or property damage.

NOTE: The caster wheel does not have to be removed from the lift truck frame to replace the wheel or the wheel axle. To replace the wheel or wheel axle, follow these steps: 1. Raise the drive wheel off the floor. Block the lift truck. See How to Put a Lift Truck on Blocks.

2. Remove the lock nut retaining the wheel on the wheel axle. Drive the wheel axle out of the arms and remove the wheel.

3. Align the wheel between both arms and install the wheel axle. Install the nut on the wheel axle.

Tighten the nuts to 34 to 47 N•m (25 to 35 lbf ft).

1. CASTER ASSEMBLY 2. PLATE 3. BOLT

4. LOCKWASHER 5. NUT

Figure 5. Caster Wheel

8

4. Remove the blocks from under the lift truck and lower the truck to the floor. Test the operation of the truck prior to returning the truck to service.

MASTER DRIVE UNIT W20-25ZA [A495]; W25-30ZA 2 [B495]; W40Z [B218]; W45Z [C215]; W50Z [D215]

PART NO. 1511563

630 SRM 1003

Master Drive Unit

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Description .........................................................................................................................................................

Special Precautions............................................................................................................................................

Master Drive Unit Repair..................................................................................................................................

Remove ...........................................................................................................................................................

Disassemble ...................................................................................................................................................

Repair .............................................................................................................................................................

Assemble ........................................................................................................................................................

Install .............................................................................................................................................................

Troubleshooting..................................................................................................................................................

1 1 1 3 3 5 6 6 6 7

This section is for the following models: W20-25ZA [A495]; W25-30ZA 2 [B495]; W40Z [B218]; W45Z [C215]; W50Z [D215]

©2008 HYSTER COMPANY

i

630 SRM 1003

Special Precautions

General This section has the description and repair procedures for the master drive unit (MDU). The traction motor, steering, and brake repair procedures are in separate sections. The main parts of the drive unit are the housing, pinion (motor), first intermediate gear set, second intermediate gear set, drive gear, bearings, axle, wheel, and spindle. The spindle is bolted to the top of the drive unit has tapered bearings installed for the mounting of the MDU to the frame. The steering control handle fastens to the MDU. The traction motor fastens to the drive unit.

The drive unit and the traction motor turn as a unit for steering.

In some instances, it may only be necessary to remove the drive motor and brake assembly to work on the MDU, while in other cases, the MDU must be completely removed. Determine the extent of disassembly required before proceeding with any repairs.

See the section Steering Mechanism 1600 SRM 1004 for troubleshooting and repairs on the steering components.

See the section Electrical System 2200 SRM 1007 and DC Motor Maintenance 620 SRM 294 for troubleshooting and repairs on the electrical components of the MDU. See the section Brakes 1800 SRM 1005 for troubleshooting and repairs of the brake components.

See the section Periodic Maintenance 8000 SRM 1048, Periodic Maintenance 8000 SRM 1379, or Periodic Maintenance 8000 SRM 1009 for instructions on checking and changing the drive unit gear oil.

Description The MDU is a triple reduction drive unit. The three sets of gears do not need adjustment for wear. All the parts that rotate have ball bearings or tapered roller bearings. The ball bearings are lubed by gear oil and the tapered roller bearings are packed with multipurpose #2 grease with 2% to 4% molybdenum disulfide. A pinion gear on the motor armature drives the first of the three reduction gears. The second intermediate gear engages the drive gear. The drive gear

is mounted on the drive axle. The drive axle is the mount for the final drive gear and the wheel.

A spring applied/electrically released friction brake is mounted to the drive motor between the motor and the MDU. See the section Brakes 1800 SRM 1005 for additional information on the electrical brake.

Special Precautions WARNING Block each side of the truck under the drive unit frame. Position blocks on both sides of the load wheels to prevent the truck from falling.

WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. Discharge the capacitor before inspecting or repairing any component in the MDU compartment to prevent personal injury and damage to the electrical system. Make certain the battery has been disconnected. DO

NOT use a screwdriver to make a short circuit across the B+ and B terminals of the transistor controller. Always wear safety glasses.

WARNING Perform the following steps before performing any troubleshooting or adjustments, and before connecting or disconnecting a handset or personal computer to avoid personal injury and prevent electrical shock.

1. Verify that the key switch is in the OFF position and the battery connector is completely disconnected.

1

Special Precautions

630 SRM 1003 Legend for Figure 1

WARNING To avoid controller damage, always disconnect the battery, discharge the capacitor, and never put power to the controller with any power wire disconnected. Never short any controller terminal or motor terminal to battery. Make sure to use proper procedure when servicing the controller.

1.

2.

3.

4.

POSITIVE CONNECTION NEGATIVE CONNECTION INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR

1.

2.

3.

4.

NEGATIVE CONNECTION POSITIVE CONNECTION 200-OHM, 2-WATT RESISTOR INSULATED JUMPER WIRES

2. Discharge capacitors. Carefully connect a 200ohm, 2-watt resistor between B+ and B on controller using insulated jumper wires and hold for 5 seconds. Remove the 200-ohm, 2-watt resistor before reconnecting the battery. See Figure 1 or Figure 2

Figure 2. Discharging Controller - W20ZA, W25ZA, W25ZA 2, W30ZA 2, W45Z, and W50Z

Figure 1. Discharging Controller - W40Z

2

630 SRM 1003

Master Drive Unit Repair

Master Drive Unit Repair REMOVE Separate parts of the MDU can be removed without removing the complete MDU. It is not necessary to perform each step of the entire procedure to remove some parts of the MDU. This procedure has steps to remove the complete MDU. Read the entire procedure first and do only the steps necessary to make the required repairs.

WARNING Block each side of the truck under the drive unit frame. Position blocks on both sides of the load wheels to prevent the truck from falling.

WARNING Keep the MDU supported at all times using a sling and an overhead hoist to avoid personal injury when removing the MDU from the lift truck.

WARNING Always disconnect the battery connector so that the connector is completely free before performing repairs. If the connector is not completely free, it can reconnect the battery.

Tag the connector - DO NOT CONNECT. 1. Block lift truck. Raise drive wheel off floor. Refer to the proper section for your lift truck: Periodic Maintenance 8000 SRM 1009, Periodic Maintenance 8000 SRM 1379, or Periodic Maintenance 8000 SRM 1048 - How to Put a Lift Truck on Blocks.

2. Turn key switch to OFF position and disconnect battery.

b. Remove the two screws securing the lower drive unit compartment cover to the frame.

Remove the lower drive unit compartment cover.

5. Remove the four Allen-head screws from the two piece shield over the MDU and remove the shield.

WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. Discharge the capacitor before inspecting or repairing any component in the MDU compartment to prevent personal injury and damage to the electrical system. Always wear safety glasses.

6. Discharge capacitors. Refer to Special Precautions.

7. Remove control handle. Refer to the section Steering Mechanism 1600 SRM 1004.

8. Remove drive wheel and tire assembly by removing capscrews (23) and washers (22).

CAUTION Be careful not to damage the wiring when disconnecting from the motor and the brake or when removing the motor and the brake from the housing.

9. Remove drive motor and brake assembly and pull the wires out of the top of the spindle (12). See the section Brakes 1800 SRM 1005.

10. Support drive unit with sling ran through the center of the spindle and a hoist or overhead crane.

3. Remove the upper drive unit compartment cover.

4. Use the following procedure that applies to your lift truck:

11. Loosen bearing lockwasher by bending tab and then remove lock nut.

12. Lower MDU from frame.

a. Remove the lower drive unit compartment cover.

3

Master Drive Unit Repair

630 SRM 1003

Figure 3. Drive Unit and Brake Assembly

4

630 SRM 1003

Master Drive Unit Repair Legend for Figure 3

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

WIRE HARNESS SLEEVE NUT LOCKWASHER FLAT WASHER BEARING CONE AND CUP ASSEMBLY BEARING CONE BEARING CUP BEARING CUP BEARING CONE ALLEN-HEAD SCREW SPINDLE O-RING BALL BEARING SPACER

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

BRAKE ASSEMBLY BRAKE HUB KEY KEY DRIVE MOTOR PIVOT BUSHING WASHER CAPSCREW DRIVE TIRE AND WHEEL MDU DRIVE AXLE BEARING CONE AND SEAL ASSEMBLY 28. BEARING CUP 29. PIN 30. DRIVE GEAR

DISASSEMBLE Refer to Figure 3 for the following instructions.

NOTE: Total disassembly may not be necessary to repair the MDU. Do only the steps necessary to complete repairs.

The MDU can be removed from the lift truck to be completely disassembled. See Remove. However, certain components may be removed with the MDU installed in the truck. The drive motor, brake, drive wheel and tire assembly, and pivot bushing (21) may be removed with the MDU installed on the truck.

The gear oil may also be changed with the MDU installed. Where partial disassembly of the MDU while installed is possible, assembly, cleaning, and inspection of the MDU is much easier when completely removed. The following steps refer to the disassembly of an MDU which has been removed from the drive unit compartment. See Figure 3.

1. Remove MDU from lift truck. Refer to Remove.

2. Place the MDU on a clean workbench.

3. Detach steering spindle by removing Allen-head screws (11) if necessary.

4. Remove pivot bushings (21) if necessary.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations.

5. Remove cover and drain oil:

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

NUT BALL BEARING GEAR AND PINION ASSEMBLY GEAR AND PINION ASSEMBLY NUT GEAR OIL SLINGER CASTING LOCKWASHER CAPSCREW FILL PLUG ALLEN-HEAD SCREW LOCKWASHER COVER ALLEN-HEAD SCREW LOCKWASHER

a. Remove eight capscrews (40) and lockwashers (39). b. Remove two Allen-head screws (42) and washers (43). c. Using the slots provided, gently pry the top and bottom sides of cover alternately from the MDU. d. Remove cover and place on a clean workbench. e. Remove two pins (29) from MDU housing if necessary.

CAUTION Use a hammer and a soft punch when removing bearings to avoid damage to bearings and/or casting.

6. Remove drive axle and bearings: a. Remove nut (31) and gear (30). b. Remove drive axle. c. Remove bearing cone and seal assembly (27).

7. Remove gear and pinion assemblies and bearings: a. Remove gear and pinion assemblies (33, 34) by hand. b. Remove bearings (32) from casting and cover.

5

Master Drive Unit Repair

REPAIR WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. Wear protection when handling solvents and always follow the recommendations of the manufacturer.

Clean all of the parts of the MDU assembly thoroughly with solvent. Inspect each part for damage and replace any damaged or excessively worn parts.

Bearings should fit snug where they ride on the shaft.

If there is excessive play, replace the bearing and/or shaft. Check the bearings for smooth operation. If a clean bearing does not roll smoothly, it must be replaced. Check the teeth on the gears and on the gear and pinion assemblies; see Figure 3, above. If the teeth are chipped or show wear, they must be replaced. Inspect keys and keyway grooves for damage.

Never reuse a damaged key. Always check the used gear oil for metallic chips and shavings. If there are chips or shavings in the oil, there is wear or damage in the MDU.

ASSEMBLE Assembly of the MDU is basically the opposite of disassembly. The major difference is installation of the bearing assemblies. Use a bearing driver and hammer to drive the bearings into place. Be careful not to damage the casting with the bearing driver and make sure the bearing is completely seated. The following instructions refer to the assembly of new or undamaged parts in a clean work environment.

630 SRM 1003 d. Install drive axle. e. Install gear (30) with the flat side facing out toward the cover. Install nut (31) and torque to 175 N•m (129 lbf ft).

2. Install gear and pinion assemblies and cover: a. Clean and inspect the ball bearings for wear or damage. Replace as needed. b. Lubricate the ball bearings with gear oil. c. Install bearings (32) into casting and cover. d. Install gear and pinion assemblies (33, 34) by hand. e. Install gear case cover: (1)

Clean mounting surface of cover and housing thoroughly to remove oil, old sealant, and dirt.

(2)

Apply Loctite 510™ around mounting flange of cover.

(3)

Install cover to housing using eight capscrews (40) and washers (39).

(4)

Torque capscrews to 23 N•m (17 lbf ft).

3. Install steering spindle to MDU using the Allen-head screws (11). Apply Loctite 242™ to the Allen-head screws and torque to 23 N•m (17 lbf ft).

INSTALL CAUTION Use a hammer and proper size driver when installing bearings to avoid damage to bearings and/or casting.

1. Install drive axle and bearings:

The following steps refer to the installation of clean parts that are new or that have been inspected and meet specifications.

1. Support MDU with sling and hoist or overhead crane and raise to a vertical position.

a. Clean and inspect the tapered roller bearings for wear or damage. Replace as needed.

2. Clean and inspect the steer bearings for wear or damage. Replace as needed.

b. Grease the tapered roller bearings, using a standard bearing packing device, with multipurpose #2 grease with 2% to 4% molybdenum disulfide.

3. Grease the steer bearings, using a standard bearing packing device, with multipurpose #2 grease with 2% to 4% molybdenum disulfide.

4. Install lower steer bearing on spindle.

c. Install bearing cone and seal assembly (27) into casting and properly position seals.

6

630 SRM 1003

Troubleshooting

5. Raise MDU slowly and insert steer shaft through drive frame.

12. Install control handle. Refer to the section Steering Mechanism 1600 SRM 1004.

6. Install upper steer bearing, flat washer, lockwasher, lock nut, and wire guard sleeve.

13. Remove fill plug (41) and fill MDU to correct level with gear oil. Install fill plug and torque to 40 N•m (30 lbf ft).

7. Torque steer bearing lock nut to 54 N•m (40 lbf ft). Loosen nut and retorque to 34 N•m (25 lbf ft).

8. Bend locking tab into slot on bearing lockwasher.

9. Feed main wire harness through the spindle.

14. Install two piece shield on the MDU using the four Allen-head screws to secure.

15. Use the following procedure that applies to your lift truck: a. Install the lower drive unit compartment cover.

CAUTION Be careful not to damage the wiring when installing the drive motor and brake assembly to the MDU.

b. Install the lower drive unit compartment cover and install the two screws to secure the cover to the frame.

10. Install drive motor and brake assembly to MDU. See the section Brakes 1800 SRM 1005.

16. Install the upper drive unit compartment cover.

11. Mount drive wheel on axle shaft; install washers, and wheel bolts. Torque wheel bolts to 115 N•m (85 lbf ft).

17. Lower truck and connect battery. Check for proper operation before returning to service.

Troubleshooting PROBLEM Lift truck will not move.

MDU makes noise.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Battery not properly connected.

Check electrical connections.

Battery is dead.

Recharge or replace battery.

Motor not operating.

Check wiring or repair motor.

Damaged gears or bearings.

Replace gears or bearings.

The wrong lubricant is used.

Drain incorrect lubricant and refill with correct gear oil. Refer to Periodic Maintenance 8000 SRM 1009, Periodic Maintenance 8000 SRM 1379, or Periodic Maintenance 8000 SRM 1048.

There is not enough lubricant.

Fill with gear oil to proper level.

Dry or damaged bearings.

Replace bearings.

Worn or damaged gears.

Replace gears.

7

Troubleshooting

PROBLEM Oil leaks.

8

630 SRM 1003

POSSIBLE CAUSE

PROCEDURE OR ACTION

Loose case cover.

Tighten case cover.

Loose fill plug.

Tighten fill plug.

Worn or damaged axle oil seal.

Replace bearing cone and seal assembly.

METRIC AND INCH (SAE) FASTENERS ALL MODELS

PART NO. 910442

8000 SRM 231

Metric and Inch (SAE) Fasteners

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Threaded Fasteners.......................................................................................................................................

Nomenclature, Threads.................................................................................................................................

Strength Identification ..................................................................................................................................

Cotter (Split) Pins..........................................................................................................................................

Fastener Torque Tables .................................................................................................................................

Conversion Table ...........................................................................................................................................

1 1 1 2 2 7 9

This section is for the following models: All Models

©2004 HYSTER COMPANY

i

8000 SRM 231

General

General THREADED FASTENERS Threaded fasteners, like bolts, nuts, capscrews, and studs, are made to specifications that describe the mechanical strength and hardness of the fastener.

A fastener used in a design application is selected according to its specifications. Hyster® Company buys parts from many countries. Parts that are purchased must be to Hyster® Company standards.

There are several standards used by these countries in the manufacture of threaded fasteners. Many of these fasteners are similar, but cannot be used as a direct replacement. To make sure that you have the correct fastener, order fasteners and parts through the Hyster® Parts Depot.

Service persons must use replacement fasteners that have the same specifications. Fasteners made to each specification have identification marks for that specification. This specification is commonly called "Grade" for SAE standards and "property class" for metric standards. This section describes the identification of some common fasteners.

The metric system used by Hyster® Company is described as SI (Le Systeme d’Unites or the International System of units, also called SI in all languages). The SI System of measurement is described in ISO Standard 1000, 1973. A conversion table of common measurements is shown in Table 7.

shown first in the series [M12 = 12 mm, M20 = 20 mm (1/2 = 1/2 in., 3/4 = 3/4 in.)].

The number of threads per inch is normally not shown for inch nomenclature and only the UNC (Unified National Coarse) or UNF (Unified National Fine) is shown. This number of threads per inch is not shown because a UNC or UNF fastener has a standard number of threads per inch for a specific diameter. Metric fasteners show the number of threads per millimeter.

The length of the shank is often indicated as part of the description of a fastener. This length is shown in inches for inch fasteners and in millimeters for metric fasteners.

A capscrew will have the following description: Metric

Inch

M12 × 1.75 × 50

1/2 × 13 UNC × 1-1/2

ABC

ABCD

A = Thread Size

A = Shank Diameter

B = Pitch

B = Number of Threads Per Unit of Length

C = Length

C = type of Thread D = Shank Length

NOMENCLATURE, THREADS The thread design is specified by a series of numbers and letters for inch and metric fasteners. See Figure 1. The diameter of the shank of the fastener is

Figure 1. Thread Design

1

General

8000 SRM 231

STRENGTH IDENTIFICATION CAUTION When fasteners must be replaced, the new fasteners must be of the same strength or greater than the original fasteners. The new fasteners must also be the correct size.

NOTE: Identification marks are according to bolt strength. The higher the number or the increase in the number of marks indicates increased bolt strength.

The most common property classes for metric fasteners are 8.8 and 10.9. The property class is marked with a number on the head of the capscrew or on a nut. Property classes less than 8.8 are often not marked. Grades for inch bolts go from 2 to 8. Grade 2 fasteners normally do not have any marks. The following tables show the marks that identify the grades and property classes for different fasteners.

Figure 2. Minimum Angle Between Cotter Pin Legs Unless otherwise specified, the legs of chain anchor cotter (split) pins are to be bent against the pin. See Figure 3.

COTTER (SPLIT) PINS Cotter (split) pins are used in many applications on your forklift. They are typically used to retain parts such as pins and nuts. Cotter (split) pins are typically not used as load-bearing members. Service personnel must use new cotter (split) pins. Do not reuse a cotter (split) pin. Replacement cotter (split) pin must be of the correct size. See Table 8.

The legs of a cotter (split) pin are bent for the following reasons: • To retain the cotter (split) pin in the part • To provide clearance between the cotter pin legs and other parts or members. One or both cotter (split) pin legs must be bent to provide a minimum 90 angle between the legs. See Figure 2.

2

1. COTTER PIN Figure 3. Cotter (Split) Pins Used On Mast Chain Anchors

8000 SRM 231

General Table 1. Bolts and Screws

3

General

8000 SRM 231 Table 2. Studs and Nuts

4

8000 SRM 231

General Table 3. Torque Nuts

5

General

8000 SRM 231 Table 4. Torque Nuts With Nylon Insert

6

8000 SRM 231

General

FASTENER TORQUE TABLES Table 5. Torque Values for Metric Fasteners*

Size and Pitch

Property Class 5.8 1

Grade 8.8 2

Grade 10.9 3

N•m

lbf ft

N•m

lbf ft

N•m

lbf ft

M3 × 0.5 M3.5 × 0.6 M4 × 0.7 M5 × 0.8 M6 × 1

0.62 0.97 1.44 2.91 4.94

0.5 0.7 1.1 2.1 3.6

0.99 1.55 2.30 4.65 7.90

0.7 1.1 2.1 3.6 6

1.34 2.11 3.13 6.33 10.8

1.0 1.6 2.3 4.7 8

M8 × 1.25 M8 × 1 M10 × 1.5 M10 × 1.25

12.0 12.8 23.8 25.1

9 9 18 19

19.2 20.5 38.0 40.1

14 15 28 30

26.1 27.9 52 55

19 21 38 41

M12 × 1.75 M12 × 1.25 M14 × 2 M14 × 1.5

41.4 45.3 66 72

31 33 49 53

66 72 105 115

49 53 77 85

90 98 145 155

66 72 105 115

M16 × 2 M16 × 1.5 M20 × 2.5 M20 × 1.5

105 110 200 225

77 81 150 165

165 175 320 355

122 130 235 260

225 240 435 485

165 175 320 360

345 375 505 550

255 275 370 405

555 605 810 875

410 445 600 645

755 820 1,100 1,190

560 605 810 880

690 715 765 940 1,030

510 530 565 695 760

1,100 1,140 1,220 1,500 1,640

810 840 900 1,100 1,210

1,500 1,550 1,660 2,040 2,240

1,100 1,140 1,230 1,510 1,660

1,200 1,280 1,560 1,640

885 945 1,150 1,210

1,930 2,040 2,490 2,630

1,430 1,510 1,840 1,940

2,620 2,780 3,390 3,570

1,940 2,050 2,500 2,640

1,930 2,070 2,410 2,580 2,900 3,160

1,430 1,530 1,780 1,910 2,140 2,330

3,080 3,320 3,850 4,120 4,630 5,040

2,280 2,450 2,840 3,040 3,420 3,720

4,200 4,510 5,240 5,610 6,300 6,860

3,100 3,330 3,870 4,140 4,650 5,060

M24 M24 M27 M27

× × × ×

3 2 3 2

M30 × 3.5 M30 × 3 M30 × 2 M33 × 3.5 M33 × 2 M36 M36 M39 M39

× × × ×

4 3 4 3

M42 × 4.5 M42 × 3 M45 × 4.5 M45 × 3 M48 × 5 M48 × 3

* Unless otherwise specified 1 Approximately equal to Grade 2 2 Approximately equal to Grade 5 3 Approximately equal to Grade 8

7

General

8000 SRM 231 Table 6. Torque Values for Inch Fasteners* Grade 21

Size and Pitch

Grade 52

lbf ft

N•m

lbf ft

N•m

lbf ft

N•m

1/4 1/4

20 UNC 28 UNF

4 5

6 6

6 7

9 10

9 10

12 14

5/16 5/16

18 UNC 24 UNF

8 9

11 13

13 14

18 20

18 20

25 28

3/8 3/8

16 UNC 24 UNF

15 17

20 23

23 26

31 36

33 37

44 50

7/16 7/16

14 UNC 20 UNF

24 27

33 36

37 41

50 56

52 58

71 79

1/2 1/2

13 UNC 20 UNF

37 41

50 56

57 64

77 86

80 90

110 120

9/16 9/16

12 UNC 18 UNF

53 59

72 80

82 91

110 125

115 130

155 175

5/8 5/8

11 UNC 18 UNF

73 83

99 110

115 130

155 175

160 180

215 245

3/4 3/4

10 UNC 16 UNF

130 145

175 195

200 225

270 300

280 315

380 425

7/8 7/8

9 UNC 14 UNF

125 140

170 185

320 355

435 480

455 500

615 680

1 1

8 UNC 14 UNF

185 210

255 285

485 540

655 735

680 765

925 1,040

1-1/8 1-1/8

7 UNC 12 UNF

265 300

360 405

595 670

805 905

965 1,080

1,310 1,470

1-1/4 1-1/4

7 UNC 12 UNF

375 415

510 565

840 930

1,140 1,260

1,360 1,500

1,850 2,050

1-3/8 1-3/8

6 UNC 12 UNF

490 560

665 760

1,100 1,250

1,490 1,700

1,780 2,040

2,420 2,760

1-1/2 1-1/2

6 UNC 12 UNF

650 735

885 995

1,460 1,650

1,980 2,230

2,370 2,670

3,210 3,620

* Unless otherwise specified 1 Approximately equal to metric Property Class 5.8 2 Approximately equal to metric Property Class 8.8 3 Approximately equal to metric Property Class 10.9

8

Grade 83

8000 SRM 231

General

CONVERSION TABLE Table 7. Conversion Table for Metric and English Units By

Multiply

To Get

Multiply

By

To Get

× 0.155

= inches

Area inches feet

2

2

2

(in. )

(ft 2)

× 6.452

= centimeters

× 0.093

= meters

2

2

2

(cm )

centimeters

(m 2)

meters

2

2

(cm 2)

(m 2)

× 10.764 = feet

2

2

(in. 2)

(ft 2)

Linear inches (in.)

× 25.4

= millimeters (mm)

millimeter (mm)

× 0.039

= inches (in.)

feet (ft)

× 0.305

= meters (m)

meter (m)

× 3.281

= feet (ft)

yards (yd)

× 0.914

= meters (m)

meter (m)

× 1.094

= yards (yd)

miles (mi)

× 1.609

= kilometers (km)

kilometer (km)

× 0.621

= miles (mi)

Mass ounces (oz)

× 28.35

= grams (g)

grams (g)

× 0.035

= ounces (oz)

pounds (lb)

× 0.454

= kilograms (kg)

kilograms (kg)

× 2.205

= pounds (lb)

tons (2,000 lb)

× 907.18

= kilograms (kg)

kilograms (kg)

× 0.001

= tons (2,000 lb)

tons (2,000 lb)

× 0.907

= metric ton (t)

metric ton (t)

× 1.102

= tons (2,000 lb)

× 1.34

= horsepower (hp)

Power horsepower (hp)

× 0.746

= kilowatts (kW)

kilowatts (kW)

Pressure pounds/in.

2

(psi)

× 6.895

= kilopascal (kPa)

kilopascals (kPa)

× 0.145

= pounds/in.

2

(psi)

pounds/in.

2

(psi)

× 0.007

= megapascal (MPa)

megapascals (MPa)

× 145.04 = pounds/in.

2

(psi)

Temperature ( Fahrenheit 32)

× 0.56

= Celsius (C)

( Celsius × 1.8) +32

= Fahrenheit

Torque pound inches (lbf in.)

× 0.113

= Newton meter (N•m)

Newton meter (N•m)

× 8.851

= pound inches (lb f in.)

pound feet (lbf ft)

× 1.356

= Newton meter (N•m)

Newton meter (N•m)

× 0.738

= pound feet (lb f ft)

× 0.621

= miles/hour (mph)

× 0.061

= inches

3

(in. 3)

3

(in. 3)

Velocity miles/hour (mph)

× 1.609

= kilometer/hour (km/h) kilometer/hr (km/h)

Volume inches

3

3

3

3

(in. )

× 16.387

= centimeters

inches

3

(in. 3)

× 0.016

= liters (l)

liters (l)

× 61.024 = inches

quarts, U.S. (qt)

× 0.946

= liters (l)

liters (l)

× 1.057

= quarts, U.S. (qt)

quarts, U.S. (qt)

× 0.83

= quarts, Imp. (qt)

quarts, Imp. (qt)

× 1.205

= quarts, U.S. (qt)

gallons, U.S. (gal)

× 3.785

= liters (l)

liters (l)

× 0.264

= gallons, U.S. (gal)

gallons, U.S. (gal)

× 0.83

= gallons, Imp. (gal)

gallons, Imp. (gal)

× 1.205

= gallons, U.S. (gal)

ounces (oz)

× 29.57

= milliliters (ml)

milliliters (ml)

× 0.034

= ounces (oz)

(cm )

centimeters

3

(cm 3)

9

General

8000 SRM 231 Table 8. Cotter Pin Dimensional Data

Nominal Size A

Shank Diameter A

Head Dia. B

Length of Extended Prong C

Recommended Hole Size

max

min

min

max

min

min

max

1.00 mm (0.031 in.)

0.90 mm (0.035 in.)

0.70 mm (0.028 in.)

1.50 mm (0.060 in.)

1.52 mm (0.060 in.)

0.25 mm (0.01 in.)

0.91 mm (0.036 in.)

1.37 mm (0.054 in.)

1.60 mm (0.047 in.)

1.20 mm (0.048 in.)

0.90 mm (0.035 in.)

1.50 mm (0.060 in.)

2.54 mm (0.10 in.)

0.51 mm (0.02 in.)

1.50 mm (0.059 in.)

1.78 mm (0.070 in.)

2.00 mm (0.062 in.)

1.50 mm (0.060 in.)

1.30 mm (0.051 in.)

2.40 mm (0.094 in.)

2.54 mm (0.10 in.)

0.76 mm (0.03 in.)

1.90 mm (0.075 in.)

2.18 mm (0.086 in.)

2.50 mm (0.094 in.)

2.30 mm (0.091 in.)

2.10 mm (0.083 in.)

4.00 mm (0.158 in.)

2.54 mm (0.10 in.)

1.00 mm (0.04 in.)

2.41 mm (0.095 in.)

2.95 mm (0.116 in.)

3.20 mm (0.125 in.)

3.00 mm (0.120 in.)

2.70 mm (0.106 in.)

5.10 mm (0.201 in.)

3.30 mm (0.13 in.)

1.52 mm (0.06 in.)

3.12 mm (0.123 in.)

3.76 mm (0.148 in.)

4.00 mm (0.156 in.)

3.80 mm (0.150 in.)

3.50 mm (0.138 in.)

6.50 mm (0.256 in.)

4.06 mm (0.16 in.)

1.78 mm (0.07 in.)

3.94 mm (0.155 in.)

4.55 mm (0.179 in.)

5.00 mm (0.188 in.)

4.60 mm (0.181 in.)

4.40 mm (0.172 in.)

8.00 mm (0.315 in.)

4.06 mm (0.16 in.)

2.03 mm (0.08 in.)

4.93 mm (0.194 in.)

5.33 mm (0.210 in.)

6.30 mm (0.250 in.)

5.90 mm (0.232 in.)

5.60 mm (0.220 in.)

10.3 mm (0.406 in.)

4.06 mm (0.16 in.)

2.03 mm (0.08 in.)

6.22 mm (0.245 in.)

6.96 mm (0.274 in.)

8.00 mm (0.312 in.)

7.50 mm (0.295 in.)

7.00 mm (0.275 in.)

13.1 mm (0.516 in.)

4.06 mm (0.16 in.)

2.03 mm (0.08 in.)

7.85 mm (0.309 in.)

8.28 mm (0.326 in.)

9.50 mm (0.375 in.)

9.50 mm (0.374 in.)

8.40 mm (0.329 in.)

16.6 mm (0.654 in.)

6.35 mm (0.25 in.)

4.06 mm (0.16 in.)

9.45 mm (0.372 in.)

9.73 mm (0.383 in.)

13.0 mm (0.500 in.)

12.4 mm (0.488 in.)

11.9 mm (0.467 in.)

21.7 mm (0.854 in.)

6.35 mm (0.25 in.)

3.05 mm (0.12 in.)

12.62 mm (0.497 in.)

13.21 mm (0.520 in.)

16.0 mm (0.625 in.)

15.4 mm (0.606 in.)

15.0 mm (0.590 in.)

27.0 mm (1.063 in.)

8.89 mm (0.35 in.)

3.05 mm (0.12 in.)

15.80 mm (0.622 in.)

16.28 mm (0.641 in.)

10

8000 SRM 231

General Table 9. Cotter Pin Dimensional Data

Nominal Length L

Length Range

Nominal Size - Part Numbers 1.00 mm (0.031 in.)

1.60 mm (0.047 in.)

2.00 mm (0.062 in.)

2.50 mm (0.094 in.)

3.20 mm (0.125 in.)

5.50 mm (0.217 in.)

0221870

0221875

10.5 mm (0.413 in.)

8.80 mm (0.345 in.)

0221871

0221876

12.7 mm (0.500 in.)

13.5 mm (0.530 in.)

11.5 mm (0.453 in.)

0221872

0221877

0015200

0015211

0015221

19.05 mm (0.750 in.)

20.5 mm (0.807 in.)

18.3 mm (0.720 in.)

0221873

0221878

0015201

0015212

0015222

25.4 mm (1.000 in.)

26.9 mm (1.060 in.)

23.9 mm (0.940 in.)

0221874

0221879

0015202

0015213

0015223

31.75 mm (1.250 in.)

33.3 mm (1.310 in.)

29.2 mm (1.150 in.)

0015203

0015216

0015224

38.1 mm (1.500 in.)

40.9 mm (1.610 in.)

36.6 mm (1.440 in.)

0015204

0015217

0015225

44.45 mm (1.750 in.)

46.0 mm (1.810 in.)

42.9 mm (1.690 in.)

0015205

0015218

0015226

50.8 mm (2.000 in.)

52.3 mm (2.060 in.)

49.3 mm (1.940 in.)

0015206

0015219

0015227

57.15 mm (2.250 in.)

58.7 mm (2.310 in.)

55.1 mm (2.170 in.)

0015220

0056997

63.5 mm (2.500 in.)

65.0 mm (2.560 in.)

62.0 mm (2.440 in.)

0221894

0015229

69.85 mm (2.750 in.)

72.1 mm (2.840 in.)

68.3 mm (2.690 in.)

0015230

76.2 mm (3.000 in.)

81.3 mm (3.200 in.)

74.7 mm (2.940 in.)

0015279

88.9 mm (3.500 in.)

91.4 mm (3.600 in.)

87.4 mm (3.440 in.)

101.6 mm (4.000 in.)

113.3 mm (4.460 in.)

98.8 mm (3.890 in.)

max

min

6.35 mm (0.250 in.)

7.10 mm (0.280 in.)

9.525 mm (0.375 in.)

11

General

8000 SRM 231

Table 9. Cotter Pin Dimensional Data (Continued) Nominal Length L

Length Range max

min

127.0 mm (5.000 in.)

128.5 mm (5.060 in.)

123.7 mm (4.870 in.)

152.4 mm (6.000 in.)

153.9 mm (3.060 in.)

5.460 mm (138.7 in.)

Nominal Size - Part Numbers 1.00 mm (0.031 in.)

1.60 mm (0.047 in.)

2.00 mm (0.062 in.)

2.50 mm (0.094 in.)

3.20 mm (0.125 in.)

Table 10. Cotter Pin Dimensional Data Nominal Length L

Length Range 4.00 mm (0.156 in.)

5.00 mm (0.188 in.)

18.3 mm (0.720 in.)

0015232

0015241

23.9 mm (0.940 in.)

0015233

0015242

max

min

6.35 mm (0.250 in.)

7.10 mm (0.280 in.)

5.50 mm (0.217 in.)

9.525 mm (0.375 in.)

10.5 mm (0.413 in.)

8.80 mm (0.345 in.)

12.7 mm (0.500 in.)

13.5 mm (0.530 in.)

11.5 mm (0.453 in.)

19.05 mm (0.750 in.)

20.5 mm (0.807 in.)

25.4 mm (1.000 in.)

26.9 mm (1.060 in.)

12

Nominal Size - Part Numbers 6.30 mm (0.250 in.)

8.00 mm (0.312 in.)

0015251

0015261

9.52 mm (0.375 in.)

8000 SRM 231

General

Table 10. Cotter Pin Dimensional Data (Continued) Nominal Length L

Length Range

Nominal Size - Part Numbers 4.00 mm (0.156 in.)

5.00 mm (0.188 in.)

6.30 mm (0.250 in.)

8.00 mm (0.312 in.)

9.52 mm (0.375 in.)

29.2 mm (1.150 in.)

0015234

0015243

0015252

0015262

0221884

40.9 mm (1.610 in.)

36.6 mm (1.440 in.)

0015235

0015244

0015253

0015263

0221885

44.45 mm (1.750 in.)

46.0 mm (1.810 in.)

42.9 mm (1.690 in.)

0015236

0015245

0015254

0015264

0221886

50.8 mm (2.000 in.)

52.3 mm (2.060 in.)

49.3 mm (1.940 in.)

0015237

0015246

0015255

0015265

0015271

57.15 mm (2.250 in.)

58.7 mm (2.310 in.)

55.1 mm (2.170 in.)

0015238

0015247

0015256

0221880

0221887

63.5 mm (2.500 in.)

65.0 mm (2.560 in.)

62.0 mm (2.440 in.)

0015240

0015248

0015257

0221881

0015273

69.85 mm (2.750 in.)

72.1 mm (2.840 in.)

68.3 mm (2.690 in.)

0015280

0015249

0015258

0221882

0015286

76.2 mm (3.000 in.)

81.3 mm (3.200 in.)

74.7 mm (2.940 in.)

0015283

0015250

0015259

0015267

0015272

88.9 mm (3.500 in.)

91.4 mm (3.600 in.)

87.4 mm (3.440 in.)

0015239

0015284

0015266

0015274

101.6 mm (4.000 in.)

113.3 mm (4.460 in.)

98.8 mm (3.890 in.)

0015301

0015260

0128754

0015275

127.0 mm (5.000 in.)

128.5 mm (5.060 in.)

123.7 mm (4.870 in.)

0221883

0015277

152.4 mm (6.000 in.)

153.9 mm (3.060 in.)

5.460 mm (138.7 in.)

max

min

31.75 mm (1.250 in.)

33.3 mm (1.310 in.)

38.1 mm (1.500 in.)

0221888

13

General

8000 SRM 231 Table 11. Cotter Pin Dimensional Data

Nominal Length L

14

Length Range

Nominal Size - Part Numbers 13.0 mm (0.500 in.)

16.00 mm (0.625 in.)

max

min

19.05 mm (0.750 in.)

20.5 mm (0.807 in.)

18.3 mm (0.720 in.)

25.4 mm (1.00 in.)

26.9 mm (1.060 in.)

23.9 mm (0.940 in.)

31.75 mm (1.250 in.)

33.3 mm (1.310 in.)

29.2 mm (1.150 in.)

38.1 mm (1.500 in.)

40.9 mm (1.610 in.)

36.6 mm (1.440 in.)

44.45 mm (1.750 in.)

46.0 mm (1.810 in.)

42.9 mm (1.690 in.)

0221889

50.8 mm (2.000 in.)

52.3 mm (2.060 in.)

49.3 mm (1.940 in.)

0221890

57.15 mm (2.250 in.)

58.7 mm (2.310 in.)

55.1 mm (2.170 in.)

0221891

63.5 mm (2.500 in.)

65.0 mm (2.560 in.)

62.0 mm (2.440 in.)

0221892

69.85 mm (2.750 in.)

72.1 mm (2.840 in.)

68.3 mm (2.690 in.)

0221893

0221895

76.2 mm (3.000 in.)

81.3 mm (3.200 in.)

74.7 mm (2.940 in.)

0015291

0221896

88.9 mm (3.500 in.)

91.4 mm (3.600 in.)

87.4 mm (3.440 in.)

0015292

0221897

101.6 mm (4.000 in.)

113.3 mm (4.460 in.)

98.8 mm (3.890 in.)

0015293

0221898

8000 SRM 231

General

Table 11. Cotter Pin Dimensional Data (Continued) Nominal Length L

Length Range

Nominal Size - Part Numbers 13.0 mm (0.500 in.)

16.00 mm (0.625 in.)

123.7 mm (4.870 in.)

0015295

0221899

138.7 mm (5.460 in.)

0015297

0221900

max

min

127.0 mm (5.000 in.)

128.5 mm (5.060 in.)

152.4 mm (6.000 in.)

153.9 mm (3.060 in.)

15

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

16

PERIODIC MAINTENANCE W40Z [B218]; W45Z [C215]; W50Z [D215]

PART NO. 1499808

8000 SRM 1009

Periodic Maintenance

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

How to Move a Disabled Truck .....................................................................................................................

How to Tow the Lift Truck ........................................................................................................................

How to Put a Lift Truck on Blocks................................................................................................................

How to Raise Drive/Steer Tire ..................................................................................................................

How to Raise Load Wheels .......................................................................................................................

Welding Repairs.............................................................................................................................................

Battery Maintenance .........................................................................................................................................

How to Charge the Battery ...........................................................................................................................

Equalizing Charge.....................................................................................................................................

Normal Charge ..........................................................................................................................................

Maintenance-Free Battery Charger .........................................................................................................

Battery Charger (W40Z Only) ..................................................................................................................

How to Change the Battery...........................................................................................................................

Maintenance Schedule.......................................................................................................................................

Checks and Inspection Procedures ...............................................................................................................

Hydraulic System ......................................................................................................................................

Lifting Mechanism ....................................................................................................................................

Controls......................................................................................................................................................

Electrical and Battery ...............................................................................................................................

Wheels and Tires .......................................................................................................................................

Casters ...........................................................................................................................................................

Recommended Schedule of Maintenance..........................................................................................................

Lubrication Instructions....................................................................................................................................

Every 8 Hours or Daily..................................................................................................................................

Every 350 Hours or 6 Months .......................................................................................................................

Check Hydraulic Oil Level........................................................................................................................

Every 2000 Hours or 2 Years ........................................................................................................................

To Fill Hydraulic Reservoir.......................................................................................................................

1 1 1 2 3 3 3 4 4 4 4 5 5 5 6 6 7 8 8 9 10 10 11 16 16 16 16 17 17

This section is for the following models: W40Z [B218]; W45Z [C215]; W50Z [D215]

Š2007 HYSTER COMPANY

i

8000 SRM 1009

General

General WARNING DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so. Repairs and adjustments that are not correct 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 remove the key from the key switch.

This section contains the instructions for periodic maintenance and inspection and a Maintenance Schedule.

How to Tow the Lift Truck WARNING Never carry a disabled lift truck unless the lift truck MUST be moved. The lift truck used to lift the disabled lift truck MUST have a rated capacity equal to or greater than the weight of the disabled lift truck. The capacity must be for a load center equal to half the width of the disabled lift truck. See the capacity plate on the disabled lift truck for the approximate total weight. The forks must extend the full width of the disabled lift truck. Put the weight of the disabled lift truck at the center of the forks and be careful not to damage the under side of the disabled lift truck.

The Maintenance Schedule has time intervals for inspection, lubrication, and periodic maintenance. The time intervals are based on a normal operation. Normal operation is considered to be one eight hour shift per day in a relatively clean environment on an improved surface. Multiple shifts, dirty operating conditions, etc. will reduce the time intervals between services recommended in the Maintenance Schedule.

Make sure no one except the driver is near the lift trucks during towing. Both the tow truck and the disabled truck can cause personal injury during towing.

NOTE: The front end of the lift truck is the control handle end. Forward travel is movement with the forks trailing. Rear travel is movement in the direction of the forks. The right hand side of the lift truck is to the operator’s right hand, facing the truck from the control handle end in the position for operating the controls.

Until repairs are complete, keep a DO NOT OPERATE tag on the control handle. Remove the key.

Your Hyster® lift truck dealer has the trained personnel and equipment to do a complete program of inspection, lubrication, and maintenance. This complete program will help your lift truck operate better over a longer period of time.

Some users have service personnel and facilities to do the items listed in the Maintenance Schedule.

Service Manuals are available from your Hyster lift truck dealer to help users who do their own repairs.

HOW TO MOVE A DISABLED TRUCK This lift truck is not normally towed. If the traction system will not operate, make repairs at the location if possible. If the lift truck must be towed, refer to the Maintenance Manual.

Stay clear of the tow chain, towing vehicle, and the lift truck during the towing operation to prevent personal injury.

To avoid personal injury, use extra care when moving a lift truck during the following conditions: • Brake does not operate correctly.

• Steering does not operate correctly.

• Tire is damaged.

• Traction conditions are bad.

• The lift truck must be moved up a steep grade.

CAUTION Never tow the lift truck faster than the speed of a person walking. Steering can be difficult and motor damage can occur at higher speeds.

Always travel smoothly without sudden starts.

The electric brake must be released before the lift truck can be moved. If there is not sufficient battery power, placing the control handle in the operating position will not release the electric brake. Use the control handle to steer the lift truck while it is being towed. Use one hand and walk to one side of the lift

1

General

8000 SRM 1009

truck. DO NOT walk or stand between the towing vehicle and the lift truck.

1. Disconnect the battery, remove the hood, and fasten the chain to the lift truck. Make sure the tow chain has the capacity to tow the weight. Carefully fasten the tow chain completely around the motor and battery compartments on top of the forks. The chain must not cause damage to either lift truck.

2. The electric brake must be released before the lift truck can be towed. Disconnect connector 6 and plug in brake override connector. See Diagrams 8000 SRM 1011 or Diagrams 8000 SRM 1228.

NOTE: The brake override connector must be removed after repairs are completed before returning the truck to service. Otherwise the truck will not operate.

3. If there is not sufficient battery power, placing the control handle in the operating position will not release the electric brake.

4. Steer the lift truck with the control handle while it is being towed. Use one hand and walk to one side of the lift truck. DO NOT walk or stand between the towing vehicle and the lift truck.

5. Tow the lift truck slowly.

6. If another lift truck that has the drive wheels near the forks is used to tow the disabled lift truck, that lift truck must have weight added to the forks. The total weight of the lift truck and

load must be equal to or greater than the weight of the disabled lift truck. Install a load of approximately half the maximum capacity on the forks of the lift truck that is used for towing. This load will increase the traction of the lift truck. Keep the load on the forks lowered as much as possible.

If the lift truck used for towing has a master drive unit (MDU) or drive unit similar to this lift truck, DO NOT add weight to the forks. Additional weight on the forks may decrease the traction of the drive wheel(s). Make sure that the lift truck has a total weight equal to or greater than the weight of the disabled lift truck.

HOW TO PUT A LIFT TRUCK ON BLOCKS WARNING DO NOT put the lift truck on blocks if the surface is not solid, even, and level. Make sure that any blocks used to support the lift truck are solid, one-piece units. Put blocks in front and in back of the tires to prevent movement of the lift truck.

DO NOT raise the lift truck by attaching an overhead crane to areas that will be damaged.

Some of these points are not designed to support the weight of the lift truck. The lift truck can be damaged or it can fall causing serious personal injury. Attach the chain or sling to a support structure of the lift truck frame.

See Figure 1.

Figure 1. Putting Lift Truck on Blocks

2

8000 SRM 1009

How to Raise Drive/Steer Tire 1. Put blocks on each side (front and back) of the load wheels to prevent movement of the lift truck.

2. Use a special low clearance hydraulic jack, crane, or another lift truck to raise the drive tire. Make sure that the jack, crane, or other lift truck has the correct capacity rating. The capacity must equal to 2/3 the weight of the lift truck including the battery. See the capacity plate.

3. Raise the lift truck only enough to suspend the drive tire. Install additional blocks under the frame near the drive tire.

How to Raise Load Wheels WARNING Never raise the forks any higher than necessary to change the load wheels. Always raise both forks at the same time. Raising the forks too high can make the lift truck tip over and cause property damage or possible, personal injury.

1. Put blocks on both sides (front and back) of the drive tire to prevent movement of the lift truck.

2. Use an overhead crane and web sling under the forks to raise the load wheels. Another lift truck can also be used to raise the forks. Make sure that the crane and sling or other lift truck has a capacity of at least 2/3 the total weight of the lift truck as shown on the capacity plate.

General

WELDING REPAIRS WARNING Forklift truck frames and components may have polyurethane paint. Welding, burning, or other heat sufficient to cause thermal decomposition of the paint may release isocyanates.

These chemicals are allergic sensitizers to skin and respiratory tract and overexposure may occur without odor warning. Should work be performed, utilize good industrial hygiene practices including removal of all paint (prime and finish coats) to the metal around the area to be welded, local ventilation, and/or supplied-air respiratory protection.

Remove the battery before welding. Welding can cause a fire and or an explosion. Make sure there is no fuel, oil, or grease near the weld area. Make sure the area is well ventilated.

CAUTION When using an arc welder, always disconnect the battery connector to prevent damage to circuit components. Connect the welding ground clamp as close to the weld area as possible to prevent welding current from damaging bearings.

Observe previous WARNINGS and CAUTIONS before doing any welding.

3. Raise the forks only enough to suspend the wheels. Install blocks under the forks at the rear of the wheels to support the lift truck.

3

Battery Maintenance

8000 SRM 1009

Battery Maintenance HOW TO CHARGE THE BATTERY WARNING DO NOT put tools on the battery.

If the lift truck was operated with a low battery, check all contactors for welded contacts before a charged battery is connected.

Make sure the key switch is in the OFF position and the park brake is set before connecting the battery.

The acid in the electrolyte can cause injury.

If the electrolyte is spilled, use water to flush the area. Use a solution of sodium bicarbonate (soda) and water to make the acid neutral.

Acid in the eyes must be immediately flushed with water continuously for 15 minutes, then seek medical attention.

Batteries generate explosive fumes. Keep the vents in the caps clean. Keep sparks or open flames away from the battery area. DO NOT make a spark from the battery connections.

Disconnect the battery when doing maintenance.

CAUTION Never connect the battery charger plug to the plug of the lift truck. You can damage the electronic controller. Make sure the battery charger voltage is the correct voltage for the battery.

Correct use of the hydrometer and proper operation of the battery charger is important. Operate the battery charger according to the instructions of the charger manufacturer. Never let the battery discharge below the minimum value given by the battery manufacturer. A fully charged battery will have a specific gravity of 1.265 to 1.310 at 25 C (77 F). See Table 1. Never charge a battery at a rate that will raise the electrolyte temperature above 49 C (120 F). Never permit a battery to stay discharged for long periods.

4

Table 1. Specific Gravity Corrections Specific Gravity Reading

Electrolyte Temperature

Correction Points

Correct Value

1.210

31 C (88 F)

+0.003

1.213

1.210

27 C (81 F)

+0.001

1.211

1.210

25 C (77 F)

+0.000

1.210

1.210

18 C (64 F)

0.004

1.206

+0.001 for each 1.7 C (35 F) from the 25 C (77 F).

Base Value (Degrees C Ă— 1.8) + 32 = Degrees F.

Equalizing Charge This charge is at a low rate and balances the charge in all of the cells. The equalizing charge is normally given approximately once a month. It is a charge at a slow rate for 3 to 6 hours in addition to the regular charging cycle.

DO NOT give an equalizing charge more than once a week. The most accurate specific gravity measurement for a charged battery will be after an equalizing charge. If the difference in specific gravity is more than 0.020 between cells of a battery after an equalizing charge, there may be a cell that has a malfunction. Consult your battery dealer.

NOTE: Many customers have battery chargers that can follow a program to automatically charge a battery according to recommendations of the battery manufacturer. Use the recommendations of the battery manufacturer for charging the battery.

Use only battery chargers approved by the battery manufacturer or dealer.

Normal Charge This charge is normally given to a battery that is discharged from normal operation. Many customers charge the battery at regular intervals that depend on use. This procedure will keep the battery correctly charged if the battery is not discharged below the limit. Always use a hydrometer to check the battery if the battery is charged at regular intervals. Frequent charging of a battery that has a 2/3 or more charge can decrease the life of the battery.

8000 SRM 1009

Battery Maintenance

Maintenance-Free Battery Charger WARNING To reduce the risk of fire, use only on circuits provided with 5 amps branch circuit protection in accordance with the National Electrical Code, ANSI/NFPA 70.

For lift trucks equipped with maintenance-free batteries or industrial batteries, the battery connector must be disconnected from the truck and connected to a suitable battery charger. Refer to Operating Manual.

Battery Charger (W40Z Only) For lift trucks equipped with the standard battery pack and on-board charger, it is not required to disconnect the battery connector before charging the battery. Connect AC cord to a 120-volt AC outlet.

This will automatically charge the batteries. Refer to Operating Manual.

CAUTION If the lift truck was operated using a low battery, inspect for welded contacts BEFORE connecting a charged battery. The circuit will not reset and lift truck operation cannot be controlled if the contacts are welded. Prevent sideto-side movement of the battery by adjusting the brackets on each side of the battery and tighten the capscrews, lockwashers, and nuts to retain the batteries.

The replacement battery must fit the battery compartment. Make sure the battery cables have clearance to move during lifting and lowering of the forks. Make sure that the replacement battery is the correct voltage and weight as shown on the capacity plate. See Figure 2.

1. Turn the key switch to the OFF position. Disconnect the battery. Use a spreader bar and lifting device to remove the battery.

NOTE: The utility tray must remain open during charging to allow batteries proper ventilation.

HOW TO CHANGE THE BATTERY WARNING Make sure the capacity of the crane and spreader bar is greater than the weight of the battery. The weight of the battery is normally shown on the battery case. The spreader bar must NOT be made of metal or it must have insulated straps.

Batteries are heavy. Use care to avoid injury.

The replacement battery must fit the battery compartment correctly. Use spacers to prevent the battery from moving in the battery compartment.

Make sure the weight of the replacement battery is within the maximum and minimum weights shown on the nameplate.

Make sure the key switch is in the OFF position and the park brake is set before connecting the battery.

1.

2.

3.

4.

CRANE SPREADER BAR INSULATOR STRAPS BATTERY Figure 2. Changing the Battery

5

Maintenance Schedule

8000 SRM 1009

2. Position blocks under both sides of the truck in the area of the battery compartment.

3. Loosen and remove buckle and strap from around battery.

4. Lift the battery out of the truck. DO NOT allow the battery to shift from side to side. Make sure the battery cables have clearance.

5. Before installing a new battery, make sure the battery is the correct size and weight for the lift truck. Make sure the battery has clearance for installation. Check that the battery connector

can be attached to the lift truck connector without pulling during lifting and lowering operations. DO NOT damage the battery cables during installation. Install the battery.

6. Replace buckle and strap and tighten to prevent the battery from moving.

7. Remove the blocks from under the truck.

8. Connect the battery. Test the operation of the motorized hand truck before returning the truck to service.

Maintenance Schedule CHECKS AND INSPECTION PROCEDURES WARNING DO NOT make repairs or adjustments to the lift truck unless you been properly trained and specifically authorized to do so. Repairs and adjustments that are not performed correctly 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, put a DO NOT OPERATE tag on the control handle. Remove the key from the key switch.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations.

Trucks operating in non-standard or severe applications may require special optional environmental packages, additional maintenance procedures, more frequent service intervals and/or special lubricants.

6

The Recommended Schedule of Maintenance is located in this section. The Maintenance Schedule has the time intervals for inspection, lubrication, and maintenance. The Maintenance Schedule is based on normal operations. Severe or unusual operating conditions will require a reduction in the recommended time periods in the Maintenance Schedule.

Your HysterÂŽ dealer has the facilities and trained personnel to do complete lift truck maintenance.

A complete program of inspection, lubrication, and maintenance will help your lift truck perform efficiently and operate over a longer period of time.

Service manuals are available from your Hyster dealer to help users who do their own maintenance.

Put the lift truck on a level surface. Lower the forks, turn the key switch to the OFF position and disconnect the battery. Remove the hood. If repair is required, attach a DO NOT OPERATE tag to the control handle. DO NOT operate a lift truck until all repairs have been performed.

8000 SRM 1009

Hydraulic System WARNING Always wear the proper protective equipment including eye protection and petroleum-resistant gloves when handling hydraulic oil. Thoroughly wash oil from exposed areas of skin as soon as possible.

Completely lower forks to relieve hydraulic pressure before disassembling any part of the lift pump or disconnecting any hydraulic hoses.

Maintenance Schedule hydraulic pump assembly. The fluid level full mark is labeled on the hydraulic reservoir. The hydraulic reservoir fluid level can be seen through the reservoir. If levels do not meet necessary requirements, add hydraulic oil. DO NOT overfill. Oil will leak from the breather if too full. After filling, make sure to tighten the breather cap to prevent oil leaks. See Figure 3 and Figure 4.

Check the hydraulic system for leaks. Inspect all hydraulic hoses and fittings for leaks. Check for broken or defective clamping devices. Repair or replace any damaged components as necessary.

The hydraulic oil is hot at normal operating temperatures. Be careful when draining the oil.

Never check for leaks by putting hands on hydraulic lines or components under pressure.

Hydraulic oil under pressure can be injected into the skin.

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.

NOTE: There is no filter on this hydraulic system.

There is a screen on the pump inlet. The screen and the magnet in the bottom of the reservoir must be cleaned each time the reservoir is removed for repairs.

To check the hydraulic oil level, make sure the temperature of the oil is at least 32 C (90 F), and the forks are fully lowered. Remove the electrical compartment cover from the lift truck, and locate the

1. BREATHER CAP 2. HYDRAULIC OIL RESERVOIR Figure 3. 12-Volt Hydraulic Reservoir

7

Maintenance Schedule

8000 SRM 1009 1. Raise the forks slowly without a load. Check for smooth operation and mechanical interference.

Mechanical interference is caused by damaged or worn linkage or shafts, or by incorrect adjustment of the tension rods.

2. Check for damaged or worn linkage bushings or shafts.

3. Check for missing or loose shaft pins.

4. Check load wheels and support bearings, shafts, and shaft pins for wear, damage, or missing parts.

Controls WARNING If any function does not operate or operates incorrectly, report the faulty operation immediately. DO NOT operate the lift truck until the problem is corrected. Put a DO NOT OPERATE tag on the control handle. Remove the key and disconnect the battery.

Perform the following checks in an area that is clear of other personnel or equipment.

1. BREATHER CAP 2. HYDRAULIC OIL RESERVOIR Figure 4. 24-Volt Hydraulic Reservoir

Lifting Mechanism WARNING DO NOT put any part of your body in or through the lift mechanism unless the forks are completely lowered, the key is removed, and the battery is disconnected.

Always wear the proper protective equipment including eye protection and petroleum-resistant gloves when handling hydraulic oil. Thoroughly 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.

8

1. Check the operation of the key switch. Functions should not operate with the key switch in the OFF position, except the steering. Turn the key switch to the ON position. Lower the control handle to the operating position. The horn, hydraulic system, traction system, and brake should now be operational.

2. Check the operation of the brake switch. Release the control handle to allow it to return to the vertical position. Move the speed/direction control without lowering the control handle. The traction system must not operate.

3. Check the operation of the speed/direction control. Lower the control handle to release the brake. Slowly rotate the speed/direction control.

The lift truck must accelerate smoothly. Rotate the control in the opposite direction. The lift truck must stop smoothly and then change direction. The control must return to the OFF position when released.

4. Check the operation of the lift and lower functions. Push the lift button and then the lower button. Check that the forks raise and lower.

8000 SRM 1009 5. Check the operation of the traction reverse function. Slowly rotate the speed/direction control for slow travel in the control handle direction. Push the traction reverse button without changing the position of the speed/direction control. The lift truck must stop and then accelerate in the opposite direction. The horn will sound. Once the lift truck changes direction and moves with the control handle trailing, release the traction reverse button without releasing the speed/direction control. The lift truck should not accelerate in the control handle direction. (Once the traction reverse button has been pressed, the traction motor should not accelerate the lift truck toward the control handle.) Full direction control may be reestablished by rotating the speed/direction control to the OFF position or moving the control handle to a brake ON position.

6. Check the steering function. Move the control handle to the right and left. Check for smooth movement of the steer (drive) wheel in the same direction. Steering will be more difficult if the lift truck is stopped.

7. Check the operation of the optional creep speed button. The optional slow speed or "turtle" mode button enables the truck to be operated at a slow speed, with the control handle in the fully upright position. To operate, press and hold the slow speed button, and rotate the speed/direction control button in the direction of desired travel. Releasing the button will reapply the brake. If the control handle is lowered to the normal drive position while the slow speed button is depressed, the truck will continue to operate in the slow speed mode until the button is released. The truck should operate at only 1.6 km/h (1.0 mph).

Electrical and Battery WARNING DO NOT put tools on the battery.

The acid in the electrolyte can cause injury. If the electrolyte is spilled, use water to flush the

Maintenance Schedule area. Make the acid neutral with a solution of sodium bicarbonate (soda) and water. Acid in the eyes must be immediately flushed with water continuously for 15 minutes, then seek medical attention.

Batteries generate explosive fumes. Keep the vents in the caps clean. Keep sparks or open flames away from the battery area. DO NOT make a spark with the battery connections.

Disconnect the battery when doing maintenance.

The battery must fit the battery compartment so the battery restraint panels will operate correctly. Use spacers to prevent the battery from moving more than 13.0 mm (0.5 in.) in any direction.

Broken electrical connections, damaged wires or cables, and leakage or corrosion from the battery can cause the electrical controls of the lift truck to operate incorrectly.

Check for loose or broken electrical connections and damaged wires or cables. Examine the battery case for damage and leakage. See the battery dealer in the area to repair any damage to the battery or cables.

Keep the battery case, top cover, and battery areas clean and painted. Use a water and soda solution to clean the battery and the battery area (1 pound of baking or commercial soda ash to 1 gallon of water).

Keep the top of the battery clean, dry, and free of corrosion.

NOTE: The following electrolyte level and specific gravity checks are not necessary for low maintenance batteries.

Check that the vent caps are clear. Check the electrolyte level daily on a minimum of one cell and weekly on all cells. Fill to the correct level according to the battery manufacturer’s recommendations.

Add only distilled water. Use a hydrometer to check that the battery is not discharged below the minimum specific gravity given by the manufacturer and has enough charge to complete a work period.

9

Maintenance Schedule

Wheels and Tires CAUTION Whenever wheels have been installed, check all wheel nuts after 2 to 5 hours of operation.

Tighten the nuts in a cross pattern to the correct torque value shown in Capacities and Specifications 8000 SRM 1010. When the nuts stay tight after an 8-hour check, the interval for checking the torque can be extended to 350 hours.

8000 SRM 1009 carry more of the load. If the casters are not shimmed properly, the caster can reduce the load on the drive tire and reduce the ability of the drive tire to stop the truck.

1. Place the truck on a level surface. Lower the forks, turn the key switch to the OFF position and disconnect the battery.

2. Ensure the caster wheel is pointed toward the battery. See Figure 6.

Inspect the drive tire, caster, and load wheels for foreign material, cuts, and tears. Remove all foreign material and smooth any cuts or tears to prevent further damage. See Figure 5.

Figure 6. Caster Orientation 3. The caster should be in contact with the floor. If there is a gap between the floor and the bottom of the caster wheel, the gap should not exceed 1.50 mm (0.06 in.).

NOTE: DO NOT install too many shims.

4. If the gap is greater than 1.50 mm (0.06 in.), add shims to adjust the caster to the floor.

1. SMOOTH EDGES 2. REMOVE NAILS, GLASS, AND ALL METAL Figure 5. Tires NOTE: The load wheel bearings have lube fittings.

Under normal conditions, it is recommended that they be lubricated every 50 hours minimum or once per month. The load wheel bearings are cleaned and repacked every 1000 hours or once per year.

NOTE: Step 5 and Step 6 can be performed to check that the casters have not been over shimmed.

5. Look for a gap between the round bar and the frame of the caster wheel. See Figure 7.

Trucks equipped with the food processing package use sealed bearings, which do not require periodic maintenance. Inspect every 350 hours or 2 months.

CASTERS CAUTION In normal operation, the casters should be in contact with the floor. As the drive tire wears, the casters will move closer to the floor and will

10

1. ROUND BAR 2. CASTER WHEEL FRAME Figure 7. Caster Measurement

8000 SRM 1009

Recommended Schedule of Maintenance

6. The gap should be no greater than 4.50 mm (0.19 in.) with the caster touching the ground.

Remove excess shims if gap exceeds 4.50 mm (0.19 in.).

Recommended Schedule of Maintenance Although this Recommended Schedule of Maintenance is intended for use with all motorized hand lift truck models, not all models are equipped with all the items listed in this schedule. Be certain this schedule is read thoroughly and all operations are followed. If in doubt of any procedure or component to be inspected, adjusted, and lubricated, or if the truck is specially equipped and used for special applications, consult your nearest authorized HysterÂŽ Industrial Truck Dealer for assistance.

CAUTION Trucks operating in non-standard or severe applications may require special optional environmental packages, additional maintenance procedures, more frequent service intervals, and/or special lubricants.

NOTE: Some items on the following charts may not be applicable to your truck.

SAFETY AND OPERATIONAL CHECK (Prior to each shift) Only the 8-hour checks are to be performed by the operator. Have a qualified technician correct all problems in accordance with appropriate Hyster maintenance instructions.

A - Every 8 Hours B - Every 350 Hours C - Every 2000 Hours

X - Indicates Visual Inspection, Repair, or Replace as Required O - Indicates Drain and Fill

Component:

A

Leaks - Hydraulic Fluid

X

Tires - Condition (See Note 1)

X

Forks - Condition

X

Load Backrest - Cracks and Mounting

X

Hydraulic Hoses and Fittings - Inspect for Leaks and Damaged or Defective Components

X

Safety Warnings - Attached (Refer to Parts Manual for Location)

X

B

C

Internal Checks: Battery - Water/Electrolyte Level and Charge

X

Hydraulic Reservoir Fluid Level - Check Level

X

Operating Manual in Container

X

NOTES: 1. Tires - Condition affects stability, safety, and load capacity that can be handled safely.

2. Under Normal Conditions, it is recommended that the Load Wheel Bearings be lubricated every 200 hours, minimum. The load wheel bearings are cleaned and repacked every 2000 hours. For trucks equipped with the Food Processing Package or operate under Wet or Corrosive Conditions, it is recommended to lubricate the lift linkage every 50 hours. Load wheel bearings should be inspected every 350 hours.

3. See Capacities and Specifications 8000 SRM 1010 for all lubrication specifications.

4. The presence of hydraulic fluid on cylinder rods and fittings does not necessarily indicate a leak.

5.

Recycle all waste oils.

11

Recommended Schedule of Maintenance

8000 SRM 1009

SAFETY AND OPERATIONAL CHECK (Prior to each shift) Only the 8-hour checks are to be performed by the operator. Have a qualified technician correct all problems in accordance with appropriate Hyster maintenance instructions.

A - Every 8 Hours B - Every 350 Hours C - Every 2000 Hours

X - Indicates Visual Inspection, Repair, or Replace as Required O - Indicates Drain and Fill

Component:

A

Nameplate Attached - Information Matches Model, Serial Number, & Attachments

X

Battery Restraints in Place

X

B

C

Controls (Turn Truck On) Unusual Noises Must Be Investigated Immediately: Brake System - Functioning Smoothly

X

Directional/Speed Control - Functioning Smoothly

X

Lift and Lower Control - Functioning Smoothly

X

Gauges, Horn, and Fuses - Functioning

X

Steering Operation - Functioning Smoothly

X

NOTES: 1. Tires - Condition affects stability, safety, and load capacity that can be handled safely.

2. Under Normal Conditions, it is recommended that the Load Wheel Bearings be lubricated every 200 hours, minimum. The load wheel bearings are cleaned and repacked every 2000 hours. For trucks equipped with the Food Processing Package or operate under Wet or Corrosive Conditions, it is recommended to lubricate the lift linkage every 50 hours. Load wheel bearings should be inspected every 350 hours.

3. See Capacities and Specifications 8000 SRM 1010 for all lubrication specifications.

4. The presence of hydraulic fluid on cylinder rods and fittings does not necessarily indicate a leak.

5.

Recycle all waste oils.

NOTE: The following inspections and necessary corrections are the responsibility of the user.

12

8000 SRM 1009

Recommended Schedule of Maintenance

LUBRICATION CHECK Blow off, clean when necessary, and inspect for damage.

A - Every 8 Hours B - Every 350 Hours C - Every 2000 Hours

X - Indicates Visual Inspection, Repair, or Replace as Required O - Indicates Drain and Fill

Component:

A

B

Lubricate - Chassis (All Fittings)

X

All Linkage and Load Wheels (See Note 2)

X

C

X

Clean and Repack Load Wheel Bearings Hydraulic Reservoir Oil Level

X

Hydraulic Reservoir Breather

X

Caster Wheel Clearance

X

Drive Unit Oil Level (See Note 5)

X

O

O

NOTES: 1. Tires - Condition affects stability, safety, and load capacity that can be handled safely.

2. Under Normal Conditions, it is recommended that the Load Wheel Bearings be lubricated every 200 hours, minimum. The load wheel bearings are cleaned and repacked every 2000 hours. For trucks equipped with the Food Processing Package or operate under Wet or Corrosive Conditions, it is recommended to lubricate the lift linkage every 50 hours. Load wheel bearings should be inspected every 350 hours.

3. See Capacities and Specifications 8000 SRM 1010 for all lubrication specifications.

4. The presence of hydraulic fluid on cylinder rods and fittings does not necessarily indicate a leak.

5. Drain and refill drive unit gear oil after initial 350 hours of operation.

6.

Recycle all waste oils.

HYDRAULIC SYSTEM CHECK A - Every 8 Hours B - Every 350 Hours C - Every 2000 Hours Component:

X - Indicates Visual Inspection, Repair, or Replace as Required O - Indicates Drain and Fill A

B

Hydraulic Pump for Noise and Operation

X

Hydraulic Control Valve for Leaks and Operation

X

Relief Valve Settings

X

C

NOTES: 1. Tires - Condition affects stability, safety, and load capacity that can be handled safely.

2. Under Normal Conditions, it is recommended that the Load Wheel Bearings be lubricated every 200 hours, minimum. The load wheel bearings are cleaned and repacked every 2000 hours. For trucks equipped with the Food Processing Package or operate under Wet or Corrosive Conditions, it is recommended to lubricate the lift linkage every 50 hours. Load wheel bearings should be inspected every 350 hours.

3. See Capacities and Specifications 8000 SRM 1010 for all lubrication specifications.

4. The presence of hydraulic fluid on cylinder rods and fittings does not necessarily indicate a leak.

5.

Recycle all waste oils.

13

Recommended Schedule of Maintenance

8000 SRM 1009

HYDRAULIC SYSTEM CHECK A - Every 8 Hours B - Every 350 Hours C - Every 2000 Hours

X - Indicates Visual Inspection, Repair, or Replace as Required O - Indicates Drain and Fill

Component:

A

B

All Hydraulic Hoses and Fittings for Leaks, Wear, Kinks, Flattening, and Charring

X

For General Leaks

X

C

NOTES: 1. Tires - Condition affects stability, safety, and load capacity that can be handled safely.

2. Under Normal Conditions, it is recommended that the Load Wheel Bearings be lubricated every 200 hours, minimum. The load wheel bearings are cleaned and repacked every 2000 hours. For trucks equipped with the Food Processing Package or operate under Wet or Corrosive Conditions, it is recommended to lubricate the lift linkage every 50 hours. Load wheel bearings should be inspected every 350 hours.

3. See Capacities and Specifications 8000 SRM 1010 for all lubrication specifications.

4. The presence of hydraulic fluid on cylinder rods and fittings does not necessarily indicate a leak.

5.

Recycle all waste oils.

DRIVE UNIT CHECKS A - Every 8 Hours B - Every 350 Hours C - Every 2000 Hours Component:

X - Indicates Visual Inspection, Repair, or Replace as Required O - Indicates Drain and Fill A

B

Brake Wear and Adjustment

X

Electric Motor and Drive Unit Mounting Bolts

X

Wheel Bolts - Torque to Specifications

X

C

NOTES: 1. Tires - Condition affects stability, safety, and load capacity that can be handled safely.

2. Under Normal Conditions, it is recommended that the Load Wheel Bearings be lubricated every 200 hours, minimum. The load wheel bearings are cleaned and repacked every 2000 hours. For trucks equipped with the Food Processing Package or operate under Wet or Corrosive Conditions, it is recommended to lubricate the lift linkage every 50 hours. Load wheel bearings should be inspected every 350 hours.

3. See Capacities and Specifications 8000 SRM 1010 for all lubrication specifications.

4. The presence of hydraulic fluid on cylinder rods and fittings does not necessarily indicate a leak.

5.

14

Recycle all waste oils.

8000 SRM 1009

Recommended Schedule of Maintenance

ELECTRICAL SYSTEM CHECKS NOTE: DO NOT use Steam to Clean Electrical Parts A - Every 8 Hours B - Every 350 Hours C - Every 2000 Hours

X - Indicates Visual Inspection, Repair, or Replace as Required O - Indicates Drain and Fill

Component:

A

B

Clean all Controls

X

Interlock Switches - Functioning

X

All Motors - Clean with Compressed Air - Functioning

X

All Motors - Clean Power Wire Terminals - Functioning

X

Battery Box and Connectors - Neutralize and Clean

X X

Battery Condition - Physical and Electrical All Wire Connections - Tightness and Corrosion

C

X X X

Contactors - Tips and Wire Connections - Tightness and Corrosion

NOTES: 1. Tires - Condition affects stability, safety, and load capacity that can be handled safely.

2. Under Normal Conditions, it is recommended that the Load Wheel Bearings be lubricated every 200 hours, minimum. The load wheel bearings are cleaned and repacked every 2000 hours. For trucks equipped with the Food Processing Package or operate under Wet or Corrosive Conditions, it is recommended to lubricate the lift linkage every 50 hours. Load wheel bearings should be inspected every 350 hours.

3. See Capacities and Specifications 8000 SRM 1010 for all lubrication specifications.

4. The presence of hydraulic fluid on cylinder rods and fittings does not necessarily indicate a leak.

5.

Recycle all waste oils.

GENERAL CHECKS A - Every 8 Hours B - Every 350 Hours C - Every 2000 Hours Component: All Bolts, Nuts, Cotter Pins, Etc.

X - Indicates Visual Inspection, Repair, or Replace as Required O - Indicates Drain and Fill A

B

C X

NOTES: 1. Tires - Condition affects stability, safety, and load capacity that can be handled safely.

2. Under Normal Conditions, it is recommended that the Load Wheel Bearings be lubricated every 200 hours, minimum. The load wheel bearings are cleaned and repacked every 2000 hours. For trucks equipped with the Food Processing Package or operate under Wet or Corrosive Conditions, it is recommended to lubricate the lift linkage every 50 hours. Load wheel bearings should be inspected every 350 hours.

3. See Capacities and Specifications 8000 SRM 1010 for all lubrication specifications.

4. The presence of hydraulic fluid on cylinder rods and fittings does not necessarily indicate a leak.

5.

Recycle all waste oils.

15

Lubrication Instructions

8000 SRM 1009

ROAD AND LOAD TEST TRUCK The following items must be tested at initial installation of the truck and after every maintenance inspection or repair.

Test the rated load in a clear area. Report any questionable functions or unusual noises.

A - Every 8 Hours B - Every 350 Hours C - Every 2000 Hours

X - Indicates Visual Inspection, Repair, or Replace as Required O - Indicates Drain and Fill

Component:

As Required Steering System Brake System

Emergency Disconnect Switch

Test the unit for proper operation in a clear area with the rated load.

Test for proper operation

NOTES: 1. Tires - Condition affects stability, safety, and load capacity that can be handled safely.

2. Under Normal Conditions, it is recommended that the Load Wheel Bearings be lubricated every 200 hours, minimum. The load wheel bearings are cleaned and repacked every 2000 hours. For trucks equipped with the Food Processing Package or operate under Wet or Corrosive Conditions, it is recommended to lubricate the lift linkage every 50 hours. Load wheel bearings should be inspected every 350 hours.

3. See Capacities and Specifications 8000 SRM 1010 for all lubrication specifications.

4. The presence of hydraulic fluid on cylinder rods and fittings does not necessarily indicate a leak.

5.

Recycle all waste oils.

Lubrication Instructions THE OCCUPATIONAL SAFETY AND HEALTH ACT (OSHA) REQUIRES THAT THE USER EXAMINE THE TRUCK BEFORE EACH SHIFT TO BE SURE IT IS IN SAFE WORKING ORDER.

Refer to Capacities and Specifications 8000 SRM 1010 for proper specifications on lubrication requirements for the lubrication fittings. Clean the lubrication fittings before and after lubricating. See Figure 8.

EVERY 8 HOURS OR DAILY Perform all safety and operational checks as outlined in the Recommended Schedule of Maintenance found in this manual.

Check battery level and add water if necessary to maintain the level that is recommended by the manufacturer. A certain amount of water loss in battery cells is normal. Always replace water at the end of a charge. Use approved tap water or distilled water.

EVERY 350 HOURS OR 6 MONTHS NOTE: Freezer and other specialized applications may require specific greases and lubricant types other than that normally used. Refer to Capacities and Specifications 8000 SRM 1010.

16

Check Hydraulic Oil Level NOTE: Refer to Capacities and Specifications 8000 SRM 1010 for proper oil selections.

Hydraulic System Check - Check the hydraulic oil level when the oil is at normal operating temperature and forks are in the lowered position.

Remove drive unit cover. Remove breather cap from hydraulic pump and reservoir. Add hydraulic oil, if necessary, through the breather filler pipe until oil is at Full mark on reservoir. Install breather cap and tighten. DO NOT OVERFILL.

8000 SRM 1009 Hydraulic Reservoir Breather - Remove drive unit cover. Remove breather and clean with a suitable cleaning solution, blow dry with compressed air, and install. Replace breather if it cannot be cleaned or is damaged.

Drive Unit (Initial 350 hour check) - Keep truck level. Place a drip pan under front end of the truck and drain the oil. Remove drive unit cover. Remove drain and fill plugs to drain gear oil. Replace drain.

Add gear oil through fill plug until oil runs out. Replace fill plug. Drive unit capacity is 0.18 liter (6 oz).

DO NOT OVERFILL. Drive Unit - With the truck level, remove the fill plug and check the oil level, add gear oil until full.

DO NOT OVERFILL.

EVERY 2000 HOURS OR 2 YEARS WARNING Always wear the proper protective equipment including eye protection and petroleum resistant gloves when handling oil. Thoroughly 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.

Lubrication Instructions 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.

Disposal of lubricants and fluids must meet local environmental regulations.

Load Wheel Bearings - Disassemble, clean, and inspect for wear or damage. Pack the bearings with grease and assemble.

Drive Unit Gear Oil - Keep truck level. Place a drip pan under front end of the truck and drain the oil.

Remove drive unit cover. Remove drain and fill plugs to drain gear oil. Replace drain. Add gear oil through fill plug until oil runs out. Replace fill plug. Drive unit capacity is 0.18 liter (6 oz). DO NOT OVERFILL. Hydraulic System - Lower the forks. Remove the drive unit cover. Remove the reservoir. Empty hydraulic oil into a suitable container and discard in accordance with local regulations. Clean the hydraulic reservoir using a suitable cleaning solution and dry with compressed air. Clean and inspect the strainer.

Replace the strainer if clogged or damaged. Make sure reservoir is clean and dry. Install the reservoir.

To Fill Hydraulic Reservoir Lower the forks. Remove the breather filler cap. Add hydraulic oil through the breather filler pipe until at Max Mark on reservoir. Capacity is approximately 0.95 liter (1.0 qt). Install the breather cap and tighten. Raise and lower the forks, while bringing oil to normal operating temperature. Then recheck hydraulic oil level. DO NOT OVERFILL.

CAUTION Protect the hydraulic system from dirt and contaminants when servicing the hydraulic system.

17

Lubrication Instructions

8000 SRM 1009

Figure 8. Lubrication Locations

18

8000 SRM 1009

Lubrication Instructions Legend for Figure 8

Item

Location

No. of Fittings

1

Compression Rod

2 per rod

2

Load Link

2 per load link

3

Gear Oil

4

Load Wheel

5

Hydraulic Oil

6

Lower Link

4 per lower link

7

Steer Bearings

1

8

Upper Link

3

1 per load wheel

19

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

20

STEERING MECHANISM W20-25ZA [A495]; W25-30ZA 2 [B495]; W40Z [B218]; W45Z [C215]; W50Z [D215]

PART NO. 1511564

1600 SRM 1004

Steering Mechanism

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Special Precautions............................................................................................................................................

Control Handle Head .........................................................................................................................................

Control Handle...................................................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Gas Spring ..........................................................................................................................................................

Discharging the Gas Spring ..........................................................................................................................

Troubleshooting..................................................................................................................................................

1 1 2 2 2 3 5 5 6

This section is for the following models: W20-25ZA [A495]; W25-30ZA 2 [B495]; W40Z [B218]; W45Z [C215]; W50Z [D215]

©2008 HYSTER COMPANY

i

1600 SRM 1004

Special Precautions

General The control handle assembly is designed to perform several functions. The standard control handle includes the speed/direction control and buttons for the horn, traction reversing, and hydraulic functions.

The control handle is connected to the Master Drive Unit (MDU) and is used to steer the truck as it turns the MDU. Move the control handle left or right to turn the drive/steer tire and steer the truck. Controls mounted in the handle are linked to the control

panel by a wiring harness that passes through the center of the handle. The brake is applied when the handle is in the full up or down position.

A bottom-mounted control handle assembly is used on the W20-25ZA, W25-30ZA 2, and W40-45-50Z. The handle is designed to be used while the operator is walking beside the lift truck.

Special Precautions WARNING To avoid personal injury and prevent electrical shock, perform the following steps before troubleshooting or adjusting and before connecting or disconnecting a handset or personal computer.

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 controller terminal or motor terminal to the battery. Make sure to use the proper procedure when servicing the controller.

1. Turn the key switch to the OFF position and disconnect the battery.

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 with a screwdriver or jumper wire. See Figure 1 and Figure 2.

3. Remove the 200-ohm, 2-watt resistor before reconnecting the battery.

1.

2.

3.

4.

POSITIVE CONNECTION NEGATIVE CONNECTION INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR Figure 1. Discharging Controller - W40Z

1

Control Handle

1600 SRM 1004 Legend for Figure 2 1.

2.

3.

4.

NEGATIVE CONNECTION POSITIVE CONNECTION 200-OHM, 2-WATT RESISTOR INSULATED JUMPER WIRES

Figure 2. Discharging Controller - W20ZA, W25ZA, W25ZA 2, W30ZA 2, W45Z, and W50Z

Control Handle Head Refer to the section Electrical System 2200 SRM 1007 for instructions on removing and installing the control handle head from the control handle. The instructions for disassembly and assembly of the control handle head can be located in the same section.

Control Handle REMOVE WARNING The gas springs used on the control handle are installed under tension and can release with enough force to cause personal injury or property damage.

WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and

2

personal injury, discharge the capacitor before inspecting or repairing any component in the drive unit compartment. Wear safety glasses.

Make certain the battery has been disconnected. Refer to Figure 1 and Figure 2 in the Special Precautions section of this manual.

1. Move the lift truck to a safe, level area and block the wheels to prevent movement.

2. Turn the key switch to the OFF position and disconnect the battery.

1600 SRM 1004

Control Handle

3. Remove the drive unit compartment covers and MDU covers.

2. If previously removed, install the bushings into the support bracket pivot pin holes.

4. Discharge the capacitor in the controller by connecting a 200-ohm, 2 watt resistor between the B+ and B connectors on the controller.

NOTE: Install the switch to the bracket with wire to bottom of the bracket.

5. Disconnect the control handle wiring harness plug and the control handle arm prox switch plug located on top of the drive motor.

For the following instructions refer to Figure 3.

6. Remove the rubber bumper retaining screw and wire clamp.

7. If necessary, remove the control handle head. See the section Electrical System 2200 SRM 1007, Control Handle.

CAUTION Discharging the gas spring is a destructive operation.

8. Discharge and remove the gas spring. Refer to Gas Spring.

9. Remove both threaded control arm pivot pins and washers.

10. Remove the control arm from the support bracket.

11. Remove two screws from the support bracket and remove the control handle arm prox switch.

3. Install the control handle arm prox switch into the mounting bracket and mount onto the support bracket with retaining screws. Leave retaining screws loose until the control handle arm is installed.

4. Install the bumper and wire clamp with retaining screw and tighten to 10.5 N•m (93 lbf in).

5. If removed, install the control handle head. See the section Electrical System 2200 SRM 1007, Control Handle.

6. Install the control arm into the support bracket.

Apply Loctite® 242 to the threaded portion of the pivot pins and install pivot pins. Torque to 142 ±7 N•m (105 ±5 lbf ft).

7. Drive the pin through lower end of gas spring to secure to support bracket.

8. Adjust control handle arm prox switch. Refer to the section Electrical System 2200 SRM 1007, Control Handle Arm Prox Switch - Install.

9. Install the MDU covers and drive unit compartment covers.

10. Connect the battery and test the operation of the lift truck prior to returning to service.

12. If bushings are worn, remove the bushings from the support bracket pivot pin holes.

INSTALL 1. Install the new gas spring to the control handle arm. Refer to Gas Spring.

3

Control Handle

1600 SRM 1004

Figure 3. Control Handle Assembly

4

1600 SRM 1004

Gas Spring Legend for Figure 3

1.

2.

3.

4.

5.

6.

7.

8.

CONTROL HANDLE ARM PIVOT PIN WASHER BUSHING PIN GAS SPRING SCREW LOCKWASHER

9. FLAT WASHER 10. RUBBER BUMPER 11. CONTROL HANDLE ARM PROX SWITCH 12. MOUNTING BRACKET 13. SCREW 14. SCREW 15. CONTROL HANDLE HEAD

16.

17.

18.

19.

20.

21.

22.

SCREW LOCKWASHER FLAT WASHER SCREW LOCKWASHER WIRE CLAMP ALLEN HEAD SCREW

Gas Spring WARNING Disconnect the battery by separating the battery connector before opening the compartment cover and before inspecting or repairing the electrical system. DO NOT place tool on top of the battery. If a tool causes a short circuit, the high-current flow from the battery can cause personal injury or property damage.

WARNING The capacitor in the traction motor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component.

Make certain the battery has been disconnected and always wear safety glasses. See Special Precautions in this section. DO NOT attempt to discharge the capacitors by shorting the controller.

CAUTION The control handle return spring is charged with pressurized gas and contains a hydraulic oil lubricant.

NOTE: This process is a destructive operation to the gas spring. A new gas spring must be used during reassembly.

1. Check that the handle return spring is installed and properly secure the control handle arm in the full upright position. Remove the plastic plugs to increase visibility of the gas spring.

CAUTION DO NOT damage the control handle wiring harness inside the control handle arm.

2. Locate and drill a 7 mm (0.25 in.) access hole through the center of the control handle tube, approximately 50 mm (2 in.) below the existing access hole.

WARNING WARNING

The gas spring used on the control handle is installed under tension and can release with enough force to cause personal injury or property damage.

Contents are under pressure. This process may eject metal chips and oil.

Review the following procedures before removing the gas spring.

3. Locate the gas spring inside the control handle through the newly drilled access hole and drill a 3 mm (0.125 in.) hole into the gas spring cylinder shell to relieve pressure.

DISCHARGING THE GAS SPRING WARNING

4. Clean up any discharged oil and dispose of in accordance with local regulations.

Goggles and a face shield must be worn for personal protection as metal chips and hydraulic lubricant may be ejected from the drill operation due to the high internal pressure.

5

Troubleshooting

1600 SRM 1004

Troubleshooting PROBLEM Steering is rough or difficult.

Steering handle does not return to the vertical position.

6

POSSIBLE CAUSE

PROCEDURE OR ACTION

Damaged, worn, or defective steering handle swivel bearing(s).

Replace bearings.

Steering handle swivel bearing(s) need lubrication.

Lubricate or repack bearings.

Bearing retaining nut torque incorrect.

Loosen retaining nut and tighten to correct torque. See the section Master Drive Unit 630 SRM 1003.

Drive unit housing bearing (steer) damaged.

Replace drive unit housing bearing (steer).

Gas spring is weak or broken.

Replace gas spring.

Gas spring ball stud broken or loose.

Retighten or replace gas spring ball stud.

WALKIE HYDRAULIC SYSTEMS W40Z [B218]; W45Z [C215]; W50Z [D215]

PART NO. 1518954

1900 SRM 1018

Walkie Hydraulic Systems

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Operation............................................................................................................................................................

Lifting a Load.................................................................................................................................................

Lowering a Load ............................................................................................................................................

Hydraulic Lines .............................................................................................................................................

Hydraulic Oil .................................................................................................................................................

Cleanliness .....................................................................................................................................................

Sound Level....................................................................................................................................................

Hydraulic Unit ...................................................................................................................................................

Remove ...........................................................................................................................................................

Special Precautions .......................................................................................................................................

Install .............................................................................................................................................................

Hydraulic Pump .................................................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Hydraulic Pump Reservoir ................................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Hydraulic Cylinder ............................................................................................................................................

Remove ...........................................................................................................................................................

Repacking.......................................................................................................................................................

Install .............................................................................................................................................................

Relief Valve Adjustment ....................................................................................................................................

Relief Valve Pressure Check .........................................................................................................................

Relief Valve Adjust ........................................................................................................................................

Troubleshooting..................................................................................................................................................

Lift Assemblies ..............................................................................................................................................

Hydraulic Cylinders ......................................................................................................................................

Hydraulic Pump.............................................................................................................................................

1 1 1 1 1 2 2 3 4 4 4 5 5 5 5 7 7 7 8 8 8 9 10 10 11 12 12 13 14

This section is for the following models: W40Z [B218]; W45Z [C215]; W50Z [D215]

Š2007 HYSTER COMPANY

i

1900 SRM 1018

Operation

General The hydraulic system provides the force required to lift the loads on all motorized lift trucks.

The hydraulic system on the motorized lift truck consists of the following individual components: • Pump Motor Assembly • Hydraulic Pump Assembly • Solenoid Lowering Valve • Pilot Relief Valve • Lift Cylinder • Reservoir

The hydraulic pump and motor assemblies are mechanically joined together as a compact unit, combining the reservoir, pump, and motor together as a single assembly. The pump is located inside of the hydraulic tank and coupled to the motor by an adapter plate, coupler drive, and four capscrews.

Hydraulic unit servicing is best performed by removing the unit from the truck to a clean work area.

Operation LIFTING A LOAD To raise a load, the lift button must be depressed.

Depressing this switch will activate the pump motor.

This torque is transferred to the pump from the motor through the motor shaft and shaft coupling.

Hydraulic oil is pumped through the system as the pump begins to operate. A vacuum created inside of the pump draws oil out of the reservoir through the suction line. Air which is drawn into the reservoir through the breather displaces the pumped oil, allowing it to be sent through the system. See Figure 1, Figure 2, and Figure 3. If the breather is clogged or blocked the ability of the system to lift a load will be greatly reduced.

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 pressure acting against it is high enough to overcome the weight of the load at rest on the forks/platform.

When the piston is fully extended to the end of its stroke or if the load is too heavy, pressure will continue to build until the rated pressure needed to operate 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 valve pressure is reached, hydraulic oil will continue to be diverted from the lift cylinder to the reservoir until the lift button is released 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 cylinder back to the reservoir.

HYDRAULIC LINES 1. All hydraulic lines must be thoroughly cleaned before installation.

Figure 1. Hydraulic Schematic

1

Operation

1900 SRM 1018

2. When making repairs, use the least number of fittings and connections to minimize flow resistance and the possibility of leakage.

a problem exists with the battery or hydraulic system.

CLEANLINESS 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. Refer to the Lubrication Charts for the recommended hydraulic oil to be used.

Adhere to the following precautionary steps to ensure that the hydraulic system remains clean.

1. Flush the entire system when a failure is encountered to make sure all paint, metal chips, welding shot, and debris are removed.

Check the reservoir level when troubleshooting lifting problems. Low oil levels will make it appear that

2. Filter each change of oil to prevent the introduction of contaminants into the system.

1. HYDRAULIC POWER UNIT 2. CAPSCREW 3. WASHER 4. LOCKWASHER 5. CAPSCREW 6. FITTING

7.

8.

9.

10.

11.

12.

13.

HOSE TUBE FITTING ADAPTER FITTING LIFT CYLINDER SPACER PLATE

Figure 2. Hydraulic System - 12 Volt

2

1900 SRM 1018

Operation

3. Provide continuous protection from airborne contamination by keeping the breather clean and serviceable.

SOUND LEVEL Hydraulic system noise is caused by both improperly selected oil and loose or damaged system components. • Hydraulic oil with high or moderately high viscosities - At startup, temperatures can cause pump

1.

2.

3.

4.

5.

6.

HYDRAULIC POWER UNIT CAPSCREW WASHER LOCKWASHER CAPSCREW FITTING

noises due to cavitation and also impedes the release of trapped air. Air does not have sufficient time to purge itself from the fluid while in the reservoir before recycling through the system. • Aerated Hydraulic Oil - Results in system noise that is similar to cavitation. Aerated oil is caused by the ingestion of air through the pipe joints of the inlet lines and high velocity discharge lines, as well as cylinder rod packing. Aeration can also be caused by oil discharging above the fluid level.

7.

8.

9.

10.

11.

12.

HOSE TUBE FITTING ADAPTER FITTING LIFT CYLINDER

Figure 3. Hydraulic System - 24 Volt

3

Hydraulic Unit

1900 SRM 1018

Hydraulic Unit REMOVE WARNING Batteries are heavy and can cause personal injury. Use care to avoid injury. DO NOT put hands, arms, feet, and/or legs between the battery and a solid object. Make sure the capacity of the crane and spreader bar is greater than the weight of the battery. The weight of the battery is normally shown on the battery case.

The maximum battery weight is shown on the lift truck nameplate. The spreader bar must NOT be made of metal or it must have insulated straps.

WARNING Put blocks under each side of the truck under the drive unit frame. Position blocks on both sides of the load wheels. The blocks must prevent the lift truck from falling and causing personal injury or property damage.

WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component in the drive unit compartment. Wear safety glasses. Make certain the battery has been disconnected. Refer to the section Steering Mechanism 1600 SRM 1004.

CAUTION Make certain the hydraulic cylinder is fully collapsed.

1. Remove the drive unit compartment cover.

5. Tag and disconnect all of the electrical wires from the hydraulic unit.

6. Remove the hydraulic lines from the hydraulic unit.

7. Loosen and remove the three capscrews attaching the hydraulic unit to the frame. Remove the hydraulic unit and place in a clean work area.

SPECIAL PRECAUTIONS WARNING To avoid personal injury and prevent electrical shock, perform the following steps before performing any troubleshooting and/or adjustments, and connecting or disconnecting a handset or PC.

CAUTION To avoid controller damage always disconnect the battery. Discharge the capacitor, and never put power to the controller with any power wire disconnected. Never short any controller terminal or motor terminal to battery. Make sure to use proper procedure when servicing the controller. Refer to the section Steering Mechanism 1600 SRM 1004.

1. Block the lift truck so that the drive wheels are off the floor. See the section Periodic Maintenance 8000 SRM 1009, How to Put a Lift Truck on Blocks.

2. Turn the key switch to the OFF position and unplug the battery.

3. After key-off, the capacitors in the unit remain charged for several minutes. To discharge the capacitors, connect a 200-ohm, 2-3W resistor between +BATT and BATT on the controller. Hold for 5 seconds.

2. Disconnect the battery. Use a spreader bar and lifting device to remove the battery. DO NOT allow the battery move from side to side. Make sure the battery cables have clearance.

4. Tag and disconnect all electrical wires to the hydraulic unit.

3. Raise the drive wheel off the floor and put blocks under both sides of the drive unit frame.

5. Disassemble and plug the hydraulic lines to the hydraulic unit.

4. Drain the hydraulic oil from the hydraulic unit into an appropriate container.

4

1900 SRM 1018

Hydraulic Pump

INSTALL 1. Align the hydraulic unit with the mounting holes in the frame and install the three capscrews. Tighten the hydraulic unit mounting capscrews to 49 N•m (36 lbf ft).

2. Install the hydraulic lines to the hydraulic unit.

3. Connect all the electrical wires to the hydraulic unit.

4. Remove the blocks and lower the lift truck to the floor.

5. Remove the breather and add the recommended hydraulic oil until the oil level reaches the full level mark. Replace the breather. If too much hydraulic oil is added, the oil will leak from the breather during operation.

6. Install the battery and connect the battery. Operate the lift truck until the hydraulic oil reaches operating temperature. Add additional oil if necessary. Check for hydraulic oil leaks.

7. Install the drive unit compartment cover. Test the operation of the lift truck prior to returning the truck to service.

Hydraulic Pump REMOVE 1. Remove the hydraulic unit from the lift truck.

Refer to the Hydraulic Unit in this section.

2. Clean the reservoir and pump area to prevent contaminants from entering the hydraulic system.

3. Remove the capscrews retaining the reservoir to the hydraulic unit. Tap around the perimeter to break the seal and separate the reservoir from the motor assembly.

4. Remove the spring retaining screw from the suction tube.

5. Remove the suction tube and strainer by pulling down and out.

6. Remove the four capscrews retaining the pump to the drive motor.

7. Disassemble the pump assembly and coupling from the adapter.

INSTALL NOTE: The hydraulic unit includes four separate kits as shown in Figure 4.

1. Clean and lubricate all components using clean hydraulic oil.

2. Replace all O-rings and seals within the unit.

3. Grease the coupler and coupler cavity with the motor resting with the adapter plate up. Align the pump mounting holes with the holes in the motor. Ensure that the tank is seated into the motor.

4. Install the four capscrews and tighten to 13.6 to 16.3 N•m (10 to 12 lbf ft).

5. Install the O-rings into the pump cavities. Apply grease to the return tubes. Insert tubes into pump cavities and O-rings. Grease the suction tube and insert into locking device with hole. Install and tighten the spring retaining screw to secure the suction tube.

6. Remove the retainer and replace the O-ring.

Lightly grease the O-ring before installation.

7. Align the reservoir so the hose connections will be in the same position as they were prior to removal. Install the four capscrews to retain the reservoir.

8. Install the hydraulic unit. Refer to Hydraulic Unit, Install in this manual.

9. Remove the breather and fill the reservoir with the recommended oil. See the section Capacities and Specifications 8000 SRM 1010. Add oil until the oil is up to the full mark. If too much oil is added, the oil will leak from the breather during operation. If too much oil has been added, drain the excess or use a suction device to remove some of the oil.

5

Hydraulic Pump

1900 SRM 1018

Figure 4. Hydraulic Unit

6

1900 SRM 1018

Hydraulic Pump Reservoir Legend for Figure 4 3. HYDRAULIC SUB UNIT 4. FILLER TANK

1. MOTOR 2. ELECTRO-POPPET VALVE 10. Run the pump for 5 seconds and energize the lowering valve at the same time so that oil gets through the pump body and valve at 0.0 psi. Operate the forks up and down three or four times to remove air from the system. Operate the lift truck until the hydraulic oil reaches operating temperature. Remove the breather and check

the hydraulic oil level. Add additional oil if necessary. Check for hydraulic oil leaks.

11. Install the drive unit compartment cover. Test the operation of the motorized hand truck before returning the truck to service.

Hydraulic Pump Reservoir REMOVE The reservoir of the hydraulic pump unit can be removed without removing the complete hydraulic unit. The motor will also come loose, with one set of screws holding the reservoir to the subunit to the motor.

WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component in the drive unit compartment. Wear safety glasses. Make certain the battery has been disconnected. Refer to the section Steering Mechanism 1600 SRM 1004.

CAUTION Make certain the hydraulic cylinder is fully collapsed.

NOTE: The reservoir must be lowered below the suction tube before attempting to move the reservoir away from the lift truck. Remember the reservoir may contain hydraulic oil. Dispose of all used oil in accordance with local regulations.

1. Move the key to the OFF position. Disconnect the battery.

2. Remove the drive unit compartment cover.

3. Discharge the capacitor in the transistor controller.

4. Disassemble and plug the hydraulic lines to the hydraulic unit.

5. Remove the four capscrews retaining the reservoir to the hydraulic unit. Carefully remove the reservoir.

6. Clean the reservoir and the suction screen. Inspect the screen for damage and replace if necessary.

NOTE: On 24-volt trucks, the capscrews that hold the reservoir to the subunit also hold the motor to the subunit. When the capscrews are removed, the motor will be resting on the subunit. When reinserting the capscrews, ensure that the motor is located correctly and the coupler is seated properly.

INSTALL 1. Lubricate a new O-ring using clean hydraulic oil and install into the pump body.

2. Align the reservoir in the proper position and install the four capscrews to retain the reservoir to the hydraulic unit.

3. Install the hydraulic lines to the hydraulic unit.

4. Remove the blocks and lower the lift truck to the floor.

5. Remove the breather and add the recommended hydraulic oil until it reaches the full mark. Replace the breather. If too much hydraulic oil is added, the oil will leak from the breather during operation. If too much oil has been added, drain or use a suction device to remove excess oil.

7

Hydraulic Cylinder

1900 SRM 1018

6. Connect the battery. Run the pump for 5 seconds and energize the lowering valve at the same time so that oil gets through the pump body and valve at 0.0 psi. Operate the forks up and down three or four times to remove air from the system. Operate the lift truck until the hydraulic oil reaches operating temperature. Remove the

breather and check the hydraulic oil level. Add additional oil if necessary. Check for hydraulic oil leaks.

7. Install the drive unit compartment cover. Test the operation of the lift truck prior to returning the truck to service.

Hydraulic Cylinder REMOVE WARNING Put blocks under each fork. Position blocks on both sides of the drive wheel. The blocks must prevent the lift truck from falling and causing personal injury or damage.

WARNING Be careful when removing or installing snap rings. The snap rings can come loose during removal or installation with enough force to cause a personal injury. Always use the correct snap ring pliers, and wear eye and face protection during removal and installation.

1. Raise the motorized lift truck forks/platform to one half its maximum height.

2. Place blocks under the forks. Block the drive wheel. See the section Periodic Maintenance 8000 SRM 1009, How to Put a Lift Truck on Blocks.

3. Remove the drive unit compartment cover.

4. Separate the frames. Refer to the section Frame 100 SRM 1015.

5. Manually collapse the piston into the cylinder while depressing the lower switch.

6. Relieve pressure from the hydraulic cylinder. See Figure 5.

7. Drive the roll pin retaining the top clevis pin out of the frame and clevis pin. Remove the top clevis pin.

8. Remove the roll pin retaining the bottom clevis pin. Remove the bottom clevis pin and the hydraulic cylinder.

8

REPACKING CAUTION Lubricate the seals, packing, and O-rings with clean hydraulic oil before assembling. Make certain to install spacers, if any were removed.

CAUTION Make certain that none of the sealant gets into the cylinder. Allowing sealant to get into the hydraulic system may cause damage to the components within the hydraulic system.

1. Move the cylinder toward the rear of the truck.

Loosen the gland nut. Extract the piston, gland nut, and rod from the cylinder.

2. Disassemble the nut and piston from the cylinder rod. Remove the spacers, if used, and slide the rod out of the gland nut.

3. Replace all seals, packing, and O-rings.

4. Install the seals, packing, and O-rings as necessary into the gland and piston after coating them with clean hydraulic oil.

5. Carefully install the rod through the gland nut.

Install the piston, spacer (if necessary), and the lock nut. Tighten the lock nut (lubricated) to 150 N•m (110 lbf ft).

6. Carefully install the rod assembly into the cylinder. Apply Loctite® 242 or equivalent to the threads of the gland nut. Tighten the gland nut to 27 N•m (20 lbf ft).

1900 SRM 1018

1.

2.

3.

4.

5.

ROD SEAL RING SEAL SEAL

Hydraulic Cylinder

6.

7.

8.

9.

10.

11. NUT 12. BEARING 13. RING

GLAND SEAL BARREL PISTON SEAL

Figure 5. Hydraulic Cylinder

INSTALL WARNING Be careful when removing or installing snap rings. The snap rings can come loose during removal or installation with enough force to cause a personal injury. Always use the correct snap ring pliers and wear eye and face protection during removal and installation.

1. Align the bottom of the cylinder with the frame and install the bottom clevis pin.

2. Install the roll pin to retain the clevis pin.

3. Align the top of the cylinder rod with the frame and install the top clevis pin. Install the roll pin to retain the clevis pin.

4. Assemble the frames.

Frame 100 SRM 1015.

Refer to the section

5. Remove the blocks and lower the lift truck to the floor.

6. Remove the breather and add the recommended hydraulic oil until the oil is up to the full mark.

Replace the breather. If too much hydraulic oil is added, the oil will leak from the breather during operation. If too much oil has been added, drain the excess or use a suction device to remove some of the oil.

7. Run the pump for 5 seconds and energize the lowering valve at the same time so that oil gets through the pump body and valve at 0.0 psi. Operate the forks up and down three or four times to remove air from the system. Operate the lift truck until the hydraulic oil reaches operating

9

Relief Valve Adjustment

1900 SRM 1018

temperature. Check the hydraulic oil level. If necessary add additional oil. Check for hydraulic oil leaks.

8. Install the drive unit compartment cover. Test the operation of the lift truck prior to returning the truck to service.

Relief Valve Adjustment RELIEF VALVE PRESSURE CHECK 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 repair. Report the problem to your supervisor immediately. If repairs are necessary, turn the key switch to the OFF position, attach a DO NOT OPERATE tag to the control handle, and disconnect the battery.

Always wear the proper protective equipment including eye protection and petroleum resistant gloves when servicing hydraulic components. Thoroughly wash oil from exposed areas of skin as soon as possible.

Completely lower all lift components and relieve pressure before disassembling any part of the lift pump or disconnecting any hydraulic hoses.

2. Lower the forks completely to relieve pressure from hydraulic circuit.

3. Turn key to the OFF position and disconnect the battery.

4. Block load wheels to prevent lift truck from moving.

5. Remove the drive unit compartment covers.

6. Discharge the capacitor. tions.

See Special Precau-

7. Clean any buildup of dirt from around the lift pump and motor assembly.

WARNING Hydraulic oil hoses and lines may be under pressure. Slowly loosen the hydraulic connections to ensure pressure has been relieved.

8. Disconnect the hydraulic hose at the pump.

9. Install a tee fitting and a pressure gauge of at least 24.8 MPa (3600 psi).

The hydraulic oil is hot at normal operating temperatures. Be careful when draining the oil.

10. Verify the oil is at an operating temperature of 43 to 49 C (110 to 120 F).

Never put your hands on pressurized hydraulic components. Pressurized hydraulic oil escaping through pin-hole leaks can be injected into the skin.

11. Raise the forks completely and continue to hold the lift button. Read the pressure gauge while the pump is in relief. See Table 1 for correct pressures.

CAUTION DO NOT OVERFILL. Oil will leak from the breather/filler cap if too full.

NOTE: Check the hydraulic oil level in the reservoir when oil is at room temperature. Remove breather cap and add recommended hydraulic oil to proper level, as required. See Hydraulic Pump Reservoir.

1. Operate lift truck until hydraulic oil reaches operating temperature (43 to 49 C (110 to 120 F)).

10

NOTE: The pump will stop after a short period of time. Release the lower button then press and hold again to continue.

12. If the relief pressure is incorrect, refer to Relief Valve Adjust.

13. After the proper relief pressure is obtained, lower the forks completely to relieve pressure from hydraulic circuit.

14. Turn key switch to OFF position. Disconnect the battery.

1900 SRM 1018

Relief Valve Adjustment

Table 1. Relief Valve Settings Model

Relief Setting*

4000 lb

16.9 MPa (2450 psi)

4500 lb 12 Volt

19.3 MPa (2800 psi)

4500 lb 24 Volt

18.6 MPa (2700 psi)

5000 lb

22.0 MPa (3200 psi)

* +0.6

2. Remove the hydraulic reservoir. See Hydraulic Pump Reservoir.

3. Loosen the locking nut on the relief valve. See Figure 6.

4. Adjust the relief valve screw in small increments.

Turn the adjustment screw clockwise to increase pressure. Turn the adjustment screw counterclockwise to decrease pressure.

5. Tighten the lock nut and torque to 15 N•m (11 lbf ft).

0.0 MPa (+87 0 psi)@ 21 C (70 F) Oil Temperature Full Flow

15. Discharge the capacitor. tions.

See Special Precau-

16. Remove the pressure gauge and tee.

17. Reconnect the hydraulic hose to pump.

18. Connect the battery and turn the key switch to ON position.

19. Operate the hydraulic functions several times to purge the air from the hydraulic circuit.

20. Remove blocks from wheels.

21. Test the lift truck by lifting and lowering a load several times. Visually check for leaks.

CAUTION DO NOT OVERFILL RESERVOIR. Oil will leak from the breather/filler cap during operation if reservoir is over filled.

22. Check the hydraulic oil level in the reservoir.

Remove breather cap and add recommended hydraulic oil to proper level, as required. See Hydraulic Pump Reservoir.

23. Install the drive unit compartment covers.

RELIEF VALVE ADJUST Refer to Relief Valve Pressure Check to determine if adjustment is necessary.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

LIFT MOTOR PUMP HOUSING TUBE CLAMP INLET ADAPTER SCREEN SNAP RING ADJUSTMENT SCREW LOCK NUT RELIEF VALVE ASSEMBLY Figure 6. Relief Valve Adjust

1. Verify the key switch is in the OFF position and the battery is disconnected.

11

Troubleshooting

1900 SRM 1018

6. Install the hydraulic reservoir as removed.

Connect the battery and turn key to ON position.

7. Recheck the relief pressure.

Pressure Check.

See Relief Valve

8. Repeat as necessary, until the correct relief pressure is measured.

9. Perform Step 13 through Step 23 in Relief Valve Pressure Check to complete procedure.

Troubleshooting LIFT ASSEMBLIES PROBLEM

POSSIBLE CAUSE

Forks fail to elevate.

Faulty hydraulic equipment.

See Pumps and Hydraulic Cylinders below.

Deformed lifting components.

Disassemble and replace damaged parts.

Faulty hydraulic equipment.

See Pumps and Hydraulic Cylinders below.

Deformed lifting components.

Disassemble and replace damaged parts.

Deformed forks.

Disassemble, repair, or replace.

Deformed lifting components.

Disassemble, repair, or replace.

Bent hydraulic cylinder piston rod.

See Hydraulic Cylinders below.

Slow lifting speed and insufficient handling capacity.

Forks fail to lower.

12

PROCEDURE OR ACTION

1900 SRM 1018

Troubleshooting

HYDRAULIC CYLINDERS PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

Foreign matter on packing.

Replace packing.

Score on piston rod.

Remove any foreign matter. Smooth rod surface with an oil stone. If oil still leaks, disassemble and repack cylinder.

Scores on wiper ring lip.

Replace wiper ring.

Unusual distortion of wiper ring.

Replace wiper ring.

Chrome plating is stripped.

Replace piston rod or renew chrome plating.

Oil leaks from welded portion.

Cylinder tube damaged.

Replace cylinder tube.

Rod spontaneously retracts.

Scores on inner surface of tube.

Smooth surface with an oil stone.

Score on tube.

Replace cylinder tube.

Score on piston ring.

Replace piston ring.

Foreign matter on packing ring.

Replace packing.

Considerable score on lip of packing ring.

Replace packing.

Unusual distortion of packing ring.

Replace packing.

Excessive clearance between cylinder tube and wear ring.

Replace wear ring (included in packing kit).

Oil leaks from cylinder gland around piston rod (An oil ring appears on the piston rod).

Wear limit (clearance between cylinder tube and wear ring).

13

Troubleshooting

1900 SRM 1018

HYDRAULIC PUMP PROBLEM Pump not delivering oil.

Pump pressure fails to rise.

Pump produces noise.

14

POSSIBLE CAUSE

PROCEDURE OR ACTION

Pump does not draw oil.

Check pump, piping, and valves for leaks.

Low oil level in reservoir.

Check fluid level.

Clogged screen at pump inlet.

Change oil and clean screen.

Improperly adjusted relief valve.

Increase to specified pressure using a pressure gauge.

Relief valve clogged.

Disassemble and clean with fresh oil.

Interfering relief valve or broken relief spring.

Disassemble spring.

Air suction.

Check piping on suction side for leaks.

Add oil to reservoir.

Check pump seals.

Cavitation caused by collapsed suction hose or clogged screen.

Drain and clean system.

Faulty oil suction.

Add oil to specified level.

Air suction through loose connections on suction side.

Tighten all hose connections on suction side.

Air suction from pump oil seal.

Disassemble pump and replace oil seals.

Breather clogged.

Clean or replace breather.

Cavitation caused by high oil viscosity.

Change to recommended oil and operate pump in recommended temperature ranges.

valve

and

replace

1900 SRM 1018

PROBLEM Abnormal temperature rise of hydraulic oil.

Pump case or drive gear broken.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

Overwork.

Adjust workload to fall within pump’s operating range.

Improper viscosity or contaminated oil.

Drain and replace oil with recommended oil.

Incorrect pressure setting.

Check for excessive resistance in hydraulic circuit. Make certain relief pressure is properly adjusted and valve is working properly.

15

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

16

ZAPIâ„¢ CONTROLLERS W45Z [C215]; W50Z [D215]

PART NO. 1540377

2200 SRM 1067

ZAPI™ Controllers

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Description .........................................................................................................................................................

ZAPI™ Transistor Motor Controller.............................................................................................................

Principles of Operation..................................................................................................................................

Controller Safety ................................................................................................................................................

Controller Adjustments .....................................................................................................................................

Modes of Operation ............................................................................................................................................

User-Selectable Operating Modes ................................................................................................................

Programming......................................................................................................................................................

Custom Performance Mode ...........................................................................................................................

Controller Parameters...................................................................................................................................

Tester Menu ...................................................................................................................................................

Set Option Menu............................................................................................................................................

ZAPI™ Handset.............................................................................................................................................

Troubleshooting..................................................................................................................................................

ZAPI™ PC Interface ..........................................................................................................................................

Connecting PC to ZAPI™ Controller............................................................................................................

File Menu .......................................................................................................................................................

Open File....................................................................................................................................................

TX From File .............................................................................................................................................

Save File ....................................................................................................................................................

Print Settings ............................................................................................................................................

Exit.............................................................................................................................................................

Connection Menu ...........................................................................................................................................

Function Menu...............................................................................................................................................

Parameter ..................................................................................................................................................

Memory Menu............................................................................................................................................

Set Options ................................................................................................................................................

Tester..........................................................................................................................................................

Data Logger ...............................................................................................................................................

Alarm Logbook ..........................................................................................................................................

Alarms........................................................................................................................................................

Repair .................................................................................................................................................................

Remove ...........................................................................................................................................................

Brass Stud Replacement ...............................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Install .............................................................................................................................................................

Repair .............................................................................................................................................................

1 2 2 3 3 4 4 4 5 5 5 6 6 7 10 33 33 36 36 37 39 41 42 43 43 44 48 49 51 53 56 57 58 58 58 58 58 58 58

This section is for the following models: W45Z [C215]; W50Z [D215]

©2007 HYSTER COMPANY

i

2200 SRM 1067

General

General This section describes the ZAPI™ transistor motor controller. Procedures are outlined for controller

safety, adjustments, troubleshooting, and repairs.

See Figure 2.

Figure 1. Controller W40Z

1

Description

2200 SRM 1067

Figure 2. Controller W45Z and W50Z

Description ZAPI™ TRANSISTOR MOTOR CONTROLLER The ZAPI™ controller is a solid-state DC motor controller utilizing SEM technology. It controls the traction motor, brake, and hydraulic system. The controller receives inputs from the control handle by serial communication, and direct inputs from the key switch and control handle arm position switch. The controller directly controls the traction motor, lift pump motor, lift valve, proportional lowering valve, brake, and main contactor. Additional hydraulic functions, such as reach, sideshift, and tilt are controlled through an auxiliary relay board mounted to the front of the controller. Jumpers are used to configure the basic controller and the controller with auxiliary relay board for different truck models.

The controller software provides self diagnostics which are accessed by means of a ZAPI™ handset or a PC with specialized ZAPI™ software. The controller software features a Test Menu for monitoring

2

controller inputs and outputs, a Diagnostic Menu for viewing fault code information, and a Programming Menu for customizing the truck performance.

The self diagnostics monitor the traction motor, brake coil, lowering valve coil, contactor coil, control handle serial communications, controller temperature, and internal logic functions. The controllers on standard trucks come equipped with a red LED fault indicator located at the bottom of the controller. In the event of a fault, the LED flashes a numeric code.

Troubleshoot the fault using a ZAPI™ handset or a properly configured IBM compatible PC. On trucks equipped with the optional dash display, the dash wiring harness plugs into the controller in place of the LED. The display also has a red LED, however, it does not flash codes. If a fault occurs, the red LED blinks, the wrench LCD is shown, and "AL" followed by the fault number is displayed.

2200 SRM 1067

Controller Safety

PRINCIPLES OF OPERATION The ZAPI™ transistor motor controller uses a sophisticated microprocessor to control the logic and operation of the controller, eliminating the need for forward and reverse contactors. The SEM motor controller operates on the principle of controlling the motor field circuit and the motor armature circuit independently. The controller has many programmable features, including maximum speed,

acceleration rate, release braking, and braking current limit. The SEM controller includes a full range of features, as well as diagnostic and setup capability.

NOTE: There are no user-serviceable parts in the ZAPI™ controller. No attempt should be made to open, repair, or otherwise modify the controller.

Doing so may damage the controller and will void the warranty.

Controller Safety WARNING The ZAPI™ controllers can hold an electrical charge for several minutes after the key switch has been turned OFF. To prevent injury, discharge the controllers by connecting a 200-ohm, 2-watt resistor between the battery positive connector and battery negative connector on the controller and hold there for 5 seconds.

See Figure 3.

1.

2.

3.

4.

NEGATIVE CONNECTION POSITIVE CONNECTION 200-OHM, 2-WATT RESISTOR INSULATED JUMPER WIRES

Figure 3. Discharging Controller W45Z and W45Z

3

Modes of Operation

2200 SRM 1067

Controller Adjustments The ZAPI™ transistor motor controller can store and display Error Codes (Alarms). It is also possible to modify the controller Setup for individual preferences. Communication with the controller is possible by four methods:

3. ZAPI™ Handset - A diagnostic handset is available through your Hyster dealer. The handset makes it possible to diagnose faults and modify controller settings. See Programming, in this section.

1. LED - An LED may be installed in trucks that do not use a display. The LED can flash error codes to the technician for diagnosis. The LED would be installed on the bottom of the ZAPI™ controller. On the W45Z and W50Z, connector port D is used. See Figure 2.

4. Personal Computer - The controller can also be connected to a personal computer (PC) equipped with special software and cables. The PC can read, store, and change settings on the controller.

2. Dash Display - Some trucks are equipped with an optional dash display or MDI. Error codes are shown on the LCD (liquid crystal display) when the wrench symbol and red light are lit. The format is AL XX where XX is the error code.

Proper use of these four methods and a list of diagnostic codes are explained in Troubleshooting, in this section.

Modes of Operation It is possible to adjust the operating characteristics of the lift truck. There are two basic ways to do this: User-Selectable and Non-User-Selectable Operating Modes.

USER-SELECTABLE OPERATING MODES The operator has a choice of three performance modes that are selectable through the control handle. The mode selection is made at startup or key ON. Performance parameters that vary are acceleration, deceleration, regenerative (neutral) braking, and top travel speed.

The three operator-selectable performance modes are factory programmed per the following: • Mode 1 - Economy mode (battery saver) - soft acceleration, reduced top speed with regenerative (neutral) braking.

• Mode 2 - Performance with regenerative (neutral) braking - medium acceleration, reduced top travel speed with regenerative (neutral) braking.

• Mode 3 - Performance without regenerative (neutral) braking - maximum acceleration, maximum top travel speed with coast at throttle release.

The following procedure is used to access the userselectable operating modes: 1. The controller drive modes parameter must be ON. This is the factory setting.

4

NOTE: You must use the handset or PC interface to change this setting. Using the ZAPI™ handset or PC connection, it is possible to set the drive mode parameters to ON or OFF. In the ON mode, the user-selectable rules are enabled. In the OFF mode, the lift truck will only operate using the settings selected.

The procedure to alter or modify these settings is given in Programming in this section.

2. Control handle must be in the full, upright position, brake ON. 3. Press and hold the horn button while turning the key switch to the ON position.

4. Release the horn button when the horn sounds.

5. Toggle through the modes by pressing the lift or lower buttons to the desired mode.

6. The horn provides an audible indication as to the mode selected. One beep indicates Mode 1, two beeps indicate Mode 2, and three beeps indicate Mode 3.

7. Lower the control handle to the operating position, brake OFF, and begin operation.

8. The selected mode is maintained until the procedure is repeated.

9. Turning the key OFF before lowering the control handle will cancel the mode change.

2200 SRM 1067

Programming

Programming CUSTOM PERFORMANCE MODE In some instances, it may be preferable to disable the Drive Modes and use a custom setting. This controller has adjustable parameters that may be modified to suit specific customer needs. There are two methods used to adjust these parameters: the ZAPI™ handset or the personal computer (PC) interface.

Figure 4. ZAPI™ Handset

CONTROLLER PARAMETERS Parameters are controller settings that can be adjusted to alter the performance characteristics of the truck.

7. Press buttons 1 and 5 simultaneously.

To adjust parameters and install custom drive settings, Drive Modes must be OFF. To set Drive Modes to OFF, use the following procedure:

9. Scroll through the menus using button 1 or 2 to the SET OPTIONS menu.

1. Turn key switch OFF.

11. Press button 5 or 6 to set Drive Modes to OFF.

2. Remove drive unit compartment cover.

12. Press button 4 to exit this menu.

3. Connect adapter harness to handset.

13. The handset will prompt, "Are you sure?"

NOTE: It may be necessary to remove the MDI harness connector from the controller to install the adapter harness.

14. Press ENTER (button 3) to retain settings.

NOTE: Connect and disconnect the handset only with the key switch in the OFF position.

16. Turn the key switch OFF to save the drive modes OFF parameter change.

4. Connect adapter harness to controller.

17. Turn the key switch ON to enter the MAIN MENU and change the parameters outlined in Table 1.

5. Turn key switch ON.

8. The screen will display CONFIG MENU.

10. Enter this menu by pressing button 3.

15. Press OUT (button 4) to discard settings.

6. The handset will turn ON. See Figure 4.

Table 1. Parameters Parameter

Description

Value and Affect

ACCELERATION DELAY

Adjusts truck acceleration.

0 = short or rapid acceleration 9 = long or slow acceleration

DECELERATION DELAY

Adjusts truck deceleration according to throttle position.

0 = short or rapid deceleration 9 = long or slow deceleration

RELEASE BRAKING

Adjusts motor braking strength or regenerative braking when throttle is released. This determines coast distance.

0 = soft braking 9 = strong braking

INVERSE BRAKING

Adjusts plugging rate.

0 = long or soft plugging 9 = short or rapid plugging

5

Programming

2200 SRM 1067

Table 1. Parameters (Continued) Parameter

Description

Value and Affect

MAX SPEED FORW

Adjusts maximum speed in forward direction, forks trailing.

0 = minimum 9 = maximum

MAX SPEED BACK

Adjusts maximum speed in reverse direction, forks leading.

0 = minimum 9 = maximum

TESTER MENU The most important input or output signals can be measured in real time using the TESTER function of the handset. The handset acts as a multimeter to read voltage, current, temperature, switch state, and other functions.

1. BATTERY VOLTAGE = battery voltage, nominal value = 24V, V. 2. MOTOR VOLTAGE = motor voltage obtained VBATT - VMN, V. 3. MOTOR CURRENT = armature current during traction (positive value) or braking (negative value).

4. FIELD CURRENT = field current in the selected traction direction.

5. TEMPERATURE = controller temperature, C. 6. ACCELERATOR = traction potentiometer value received from control handle.

7. LIFTING CONTROL = lifting/lowering potentiometer value received from control handle.

8. CONTROL HANDLE SWITCH = control handle switch input, ON/OFF. 9. FORWARD SWITCH = forward direction request from control handle card, ON/OFF. 10. BACKWARD SWITCH = backward direction request from control handle card, ON/OFF. 11. CUTBACK SWITCH 1 = speed reduction switch input, ON/OFF (closed switch = OFF = no speed reduction).

12. LIFTING SWITCH = lifting function request from control handle card, ON/OFF.

6

13. LOWERING SWITCH = lowering function request from control handle card, ON/OFF. 14. FORK LIFT SWITCH = i - lift request from control handle card, ON/OFF. 15. FORK LOW SWITCH = i - lift request from control handle card, ON/OFF. 16. BELLY SWITCH = belly input switch to the controller or belly request from control handle card, ON/OFF. 17. HARD & SOFT = snail request from control handle card allows machine to drive with control handle up, ON/OFF. 18. HORN SWITCH = horn request from control handle card, ON/OFF. 19. LIFTING BLOCK = lifting block input switch, ON/OFF (with LIFTING BLOCK option programmed OFF).

20. BATTERY MODEL = battery-type of input switch, ON/OFF. ON = flooded battery (input closed), OFF = sealed battery (input open).

21. BATTERY CHARGE = battery charge indication, %.

SET OPTION MENU DRIVE MODES

ON

The truck has three performance modes, each with a fixed set of parameters.

This function is enabled by setting DRIVE MODES = ON.

OFF

DRIVE MODES disabled.

2200 SRM 1067

Programming

ZAPI™ HANDSET The ZAPI™ handset must be connected to the controller before turning on the key. The handset must have an adapter harness to connect to the controller.

The handset and adapter harness are available from your Hyster dealer. Connect the handset to plug B. The handset can remain connected to the controller while running, and the parameters can be changed in real time. In this case, it is necessary to go in a standby condition (truck at rest) before switching OFF the controller in order to store the new values in the EEPROM. This section describes the ZAPI™ handset functions.

Six buttons provide the capability of changing or reading the parameters.

1

Roll-Up

Push to scroll up.

2

Roll-Down

Push to scroll down.

3

Enter

Push to enter a submenu or to confirm a change.

4

Out

Push to exit a selected menu or to refuse a change.

5

Set-Up

Push to increase a parameter value.

6

Set-Down

Push to decrease a parameter value.

NOTE: After a modification, save the new values by pushing out, then enter to confirm. (Screen prompts will guide the user.)

To navigate the menu options, numbers inside the triangles in the following map correspond to the same number on the handset keyboard buttons. The orientation of the triangle indicates the way to the next function. See Figure 4.

NOTE: Connect and disconnect the handset only with the key switch in the OFF position.

For additional handset description, see Figure 5.

7

Programming

8

2200 SRM 1067

2200 SRM 1067

Programming

Figure 5. ZAPIâ„¢ Handset Instructions

9

Troubleshooting

2200 SRM 1067

Troubleshooting Dash Display

Controller LED

Handset or PC

LCD display

Red LED

Red LED Fault Indicator

Located at base of motor controller.

Error codes stored under Main Menu Alarms

(Trucks equipped with optional dash display)

(Trucks without dash display)

Message displayed on Handset or PC CORRESPONDING SCHEMATIC SHOWING CIRCUITS TO BE CHECKED

CONDITION

OR

TRUCK RESPONSE

AFFECTED COMPONENT

POSSIBLE CAUSES AND TEST PROCEDURES

LOGIC

NOTE: General error code information is provided by the Dash Display and Red LED at the base of the controller. In most instances, it will be necessary to use a handset or a PC to further define the possible causes and test procedures.

10

2200 SRM 1067

Troubleshooting

Dash Display

Controller LED

Handset or PC - 12V

No LEDs or LCDs illuminated

LED OFF

Handset does not operate

CONDITION Dash display, controller LED, and truck inoperative.

TRUCK RESPONSE Travel and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • B+ and/or B missing at controller.

Confirm battery is connected and of proper voltage.

Verify key switch is ON. Verify brake override circuit is connected in run position.

Verify continuity between batteries negative (at battery) and B power wire connection (at controller).

If no continuity, check: Power wiring between battery and controller.

Verify continuity between battery positive (at battery) and B-1 and B-12 connection (at controller).

If no continuity, check: Fuse 2 for open.

Key switch continuity in ON position.

Wiring battery + to main contactor to fuse 2 to key switch, to controller A-6 connection.

• Defective battery charger.

Disconnect wires 2D and 12 from leads to battery charger.

Use test lead to connect 2D and 12.

If truck operates, check charger fuses, repair or replace battery charger.

• Defective motor controller.

Check for battery voltage between A-6 and B power wire connection at controller.

If correct battery voltage, replace controller.

LOGIC Occurs when there is no power to the controller or the controller is defective.

11

Troubleshooting

2200 SRM 1067

Dash Display

Controller LED

Handset or PC - 24V

No LEDs or LCDs illuminated

LED OFF

Handset does not operate

CONDITION Dash display, controller LED, and truck inoperative.

TRUCK RESPONSE Travel and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • B+ and/or B missing at controller.

Confirm battery is connected and of proper voltage.

Verify key switch is ON. Verify brake override circuit is connected in run position.

Verify continuity between batteries negative (at battery) and B power wire connection (at controller).

If no continuity, check: Power wiring between battery and controller.

Verify continuity between battery positive (at battery) and B-1 and B-12 connection (at controller).

If no continuity, check: Fuse 2 for open.

Key switch continuity in ON position.

Wiring battery + to main contactor to fuse 2 to key switch, to controller A-6 connection.

• Defective battery charger.

Disconnect wires 2D and 12 from leads to battery charger.

Use test lead to connect 2D and 12.

If truck operates, check charger fuses, repair or replace battery charger.

• Defective motor controller.

Check for battery voltage between A-6 and B power wire connection at controller.

If correct battery voltage, replace controller.

12

LOGIC Occurs when there is no power to the controller or the controller is defective.

2200 SRM 1067

Troubleshooting

Dash Display

Controller LED

Handset or PC

No LEDs or LCDs illuminated

LED OFF

No error codes present

CONDITION Dash display and/or controller LED inoperative.

TRUCK RESPONSE Travel and hydraulic functions normal.

POSSIBLE CAUSES AND TEST PROCEDURES • Open connection between dash display and controller.

Verify harness connections at MDI and connector D on controller.

Verify continuity of wires between MDI and controller.

• Defective dash display.

Connect handset to controller and confirm communication to handset.

If handset operates correctly, replace MDI. • Defective LED. Disconnect LED and connect handset. If handset works, replace LED.

LOGIC Occurs when the MDI or LED receives no signal, or MDI or LED are damaged.

Dash Display

Controller LED

Handset or PC

No LEDs or LCDs illuminated

LED OFF

NO COMMUNICATION

CONDITION Dash display and/or controller LED inoperative.

TRUCK RESPONSE Travel and hydraulic functions normal.

POSSIBLE CAUSES AND TEST PROCEDURES • Defective controller.

Connect handset to controller and confirm communication to handset.

If handset will not communicate with controller, replace controller.

LOGIC Occurs when controller does not send a signal to the MDI or LED.

13

Troubleshooting

2200 SRM 1067

Dash Display

Controller LED

Handset or PC

No Alarm

LED OFF - No Flashes

INCORRECT START

CONDITION Improper startup sequence by operator.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Throttle or hydraulic function selected at key ON. Steer handle in run position at key ON. Return steer handle to full upright position. Return throttle to neutral. Release all hydraulic function controls.

If fault remains, attach handset and go to test menu.

• Check brake switch, it should be off. If steer handle is in vertical position and reading is not OFF, check brake switch for damage, interference, or shorts.

• Check accelerator - Should be 0 volts at neutral. If not, repeat control card calibration. If this does not correct the problem, replace control card.

• Check hydraulic inputs – Should be 0 volts. If not, recalibrate tiller card. Follow auto-learn procedure listed in steering. If this does not clear fault, check buttons for damage or interference. Replace damaged or faulty buttons.

14

LOGIC Fault occurs when controller receives input that has not followed the proper operational sequence.

2200 SRM 1067

Troubleshooting

Dash Display

Controller LED

Handset or PC

AL66

Continuous Flashing

BATTERY LOW

CONDITION Battery discharged and requires charging.

TRUCK RESPONSE Hydraulic lift function disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Battery voltage is low.

Charge or replace battery.

• Controller voltage calibration is incorrect.

Install handset. Go to test menu and select Battery Voltage. Compare tester voltage to voltage measured by an accurate digital voltmeter between B+ and B terminals. Pull down tiller handle to engage contactor for this measurement. If these two voltages are more than 1.5 volts difference, replace controller.

LOGIC Controller measures low battery voltage over multiple checks during traction or hydraulic operation.

Dash Display

Controller LED

Handset or PC

AL99

Continuous Flash

BATTERY KO

CONDITION Improper battery connection or defective battery.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Incorrect battery selected.

Verify correct battery voltage for truck.

• Damaged or extremely discharged battery.

Disconnect battery and check voltage at connector. Inspect battery for correct water level and damage. Repair or replace battery.

• Defective or damaged connection to battery.

Inspect cable crimps and cables from battery to connector.

Inspect cable crimps and cables from battery contactor to controller and contactor.

LOGIC Battery voltage is much less than allowable.

15

Troubleshooting

2200 SRM 1067

Dash Display

Controller LED

Handset or PC

AL01

1 Flash

VACC NOT OK

CONDITION Connection/communication error between tiller card and traction controller.

TRUCK RESPONSE Traction and hoist functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Control card throttle calibration is out of range.

Install handset. Go to tester function of handset.

If accelerator output is >1V (20%) and the enable switch is open, recalibrate control card.

• Control card throttle damaged or defective.

If card cannot be recalibrated, replace card.

LOGIC Occurs when accelerator voltage from serial control card is higher than 1V (20%) before neutral switch is closed.

Dash Display

Controller LED

Handset or PC

AL01

1 Flash

PUMP VACC NOT OK

CONDITION Connection/communication error between control card and traction controller.

TRUCK RESPONSE Traction and hoist functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • A lift/lower switch is damaged or defective.

Install handset. Go to tester function. Check lifting control and EVP voltage. Check on/off switches and proportional switches for smooth, linear operation. Replace damaged switches.

• Control card lift/lower switch calibration is out of range.

Install handset. Go to tester function. Check lifting control and EVP voltage. Output of proportional hydraulic controls should be less than 1V (20%) at neutral.

Recalibrate control card.

• Control card is damaged or defective.

Replace card.

16

LOGIC Occurs if the output of one on the hydraulic controls is higher than 1V (20%) at start.

2200 SRM 1067

Troubleshooting

Dash Display

Controller LED

Handset or PC

AL01

1 Flash

FORW + BACK

CONDITION Connection/communication error between control card and traction controller.

TRUCK RESPONSE Traction and hoist functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Control card throttle device is damaged or defective.

Install handset. Go to tester function. If forward switch and backward switch are both on at the same time, card is damaged.

Replace control card.

LOGIC Occurs if controller receives signal for forward and reverse directions simultaneously.

Dash Display

Controller LED

Handset or PC

AL01

1 Flash

SERIAL ERROR #1

CONDITION Connection/communication error between control card and traction controller.

TRUCK RESPONSE Traction and hoist functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Loose or damaged electrical connection between control card and controller.

Verify connection at controller.

Verify wire harness connection at base of steer handle.

Verify connection at control card.

• Damaged or defective control card.

Measure voltage at pin 5, connector C, on the controller. With control card disconnected, this should be about 12V; with the card connected, it should be about 5V. 0V or 12V with the card connected means that the card is damaged.

Replace control card.

LOGIC No information or incorrect information has been sent from the control card to controller.

17

Troubleshooting

2200 SRM 1067

Dash Display

Controller LED

Handset or PC

AL01

1 Flash

INPUT ERROR #1

CONDITION Connection/communication error between control card and traction controller.

TRUCK RESPONSE Traction and hoist functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Traction reversing switch is not connected.

Install handset. Go to tester function. Check for operation of traction reversing switch.

Verify that traction reversing switch cover is making contact with switch on control card.

Check wires in control handle arm are secure.

• Damaged or defective control card.

Replace control card.

LOGIC Control card is not sending digital signal for the traction-reversing switch.

Dash Display

Controller LED

Handset or PC

AL01

1 Flash

INPUT ERROR #2

CONDITION Connection/communication error between control card and traction controller.

TRUCK RESPONSE Traction and hoist functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Traction reversing switch is not connected.

Install handset. Go to tester function. Check for operation of traction reversing switch.

Verify that traction reversing switch cover is making contact with switch on control card.

• Damaged or defective cable.

Check steer handle control cable for loose connections or broken wires.

• Damaged or defective tiller card.

Replace control card.

LOGIC Control card is not sending hard-wired signal from traction-reversing switch to controller.

18

2200 SRM 1067

Troubleshooting

Dash Display

Controller LED

Handset or PC

AL01

1 Flash

BATTERY CHARGING

CONDITION Controller waits in standby mode while a battery charger is connected.

TRUCK RESPONSE Traction and hoist functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • A battery charger is connected.

Disconnect or shut down battery changer.

• Controller is damaged.

Install handset. Go to tester function. Look at SW7 while installing and removing connector E. This input should cycle between ON and OFF. If this does not occur, replace controller.

LOGIC Controller inputs indicate a battery charger is connected.

Dash Display

Controller LED

Handset or PC - 12V

AL02

2 Flashes

CONTACTOR CLOSED

CONDITION Main contactor circuit is damaged.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Main contactor tips are welded closed.

Disconnect power leads at contactor. Use meter to confirm open circuit across power terminals.

If short circuit is measured, replace contactor.

• Problem in motor field circuit.

Verify electrical connections between motor field and controller.

Check motor field for shorts to chassis.

• Controller is damaged.

Replace controller.

LOGIC Occurs when the controller detects a short in the main contactor circuit.

19

Troubleshooting

2200 SRM 1067

Dash Display

Controller LED

Handset or PC - 24V

AL02

2 Flashes

CONTACTOR CLOSED

CONDITION Main contactor circuit is damaged.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Main contactor tips are welded closed.

Disconnect power leads at contactor. Use meter to confirm open circuit across power terminals.

If short circuit is measured, replace contactor.

• Problem in motor field circuit.

Verify electrical connections between motor field and controller.

Check motor field for shorts to chassis.

• Controller is damaged.

Replace controller.

LOGIC Occurs when the controller detects a short in the main contactor circuit.

Dash Display

Controller LED

Handset or PC

AL4

4 Flashes

EVP NOT OK

CONDITION Lowering valve will not operate correctly.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Damaged or loose electrical connection to lowering valve.

Verify electrical connections between valve coil and controller.

• Lowering coil damaged.

Check lowering valve coil for correct resistance.

Coil resistance should be approximately 33 ohms.

Replace coil if damaged.

• Lowering valve cartridge is damaged.

Replace lowering valve cartridge.

LOGIC Occurs if electro-proportional valve is open before circuit is energized. Valve does not follow the supplied signal from controller.

20

2200 SRM 1067

Troubleshooting

Dash Display

Controller LED

Handset or PC

AL5

5 Flashes

EB DRIVER KO

CONDITION Electric brake does not release or remains released at all times.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Damaged or loose electrical connection to brake.

Verify electrical connection between electric brake and controller.

• Check brake coil for correct coil resistance.

Disconnect brake. Measure brake coil resistance in both directions. Coil resistance should be between 28-32 ohms.

• Damaged fly-back diode at brake.

Check coil resistance. Short circuit measured at brake connector may indicate a damaged diode.

Cut one lead of diode and check with meter. If damaged, replace diode.

• Damaged controller.

Activate the brake switch. Use voltmeter to measure voltage on wire 2C and 17 with brake connected in circuit. If both measurements are 24V and the alarm is displayed, then controller is damaged.

LOGIC Occurs when brake driver circuit is shorted or open circuit.

21

Troubleshooting

2200 SRM 1067

Dash Display

Controller LED

Handset or PC

AL6

6 Flashes

VFIELD NOT OK

CONDITION Voltage measured at field connections is not correct.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Cable connection to motor field is loose or damaged.

Verify connection of field wires to motor and controller.

• Check condition of crimps on wires connecting to F1 and F2.

LOGIC This fault occurs when the voltage measured at the field connections is not the expected value.

Dash Display

Controller LED

Handset or PC

AL6

6 Flashes

I = 0 EVER

CONDITION Motor current levels do not exceed a preset minimum value while driving.

TRUCK RESPONSE Traction and hydraulic function disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Damaged or loose electrical connections to traction motor.

Verify electrical connections between traction motor and controller.

• Traction motor armature resistance is too low.

Check traction motor armature for shorts.

• Controller is damaged.

Cycle key switch. Place steer handle in drive position and select throttle. If the truck starts to drive but then stops and presents code AL6, replace controller.

LOGIC Occurs if while driving, the motor current does not exceed a preset minimum value.

22

2200 SRM 1067

Troubleshooting

Dash Display

Controller LED

Handset or PC

AL6

6 Flashes

HIGH FIELD CURR, BW HIGH FLD CURR, FW HIGH FLD CURR

CONDITION High field current values measured by controller.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Field wires are loose, damaged, or shorted.

Verify connection of field wires to motor and controller.

• Motor field winding is shorted or too low.

Check motor field for correct resistance and continuity. It should measure approximately 0.5 ohms.

• Failure of current sensor in controller.

Replace controller.

• Failure of field current driver in controller.

Replace controller.

LOGIC Measured field current is too high.

23

Troubleshooting

2200 SRM 1067

Dash Display

Controller LED

Handset or PC

AL6

6 Flashes

NO FIELD CURR

CONDITION Low field current values measured by controller.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Cable connection to motor field is loose or damaged.

Verify connection of field wires to motor and controller.

• Motor field winding is open or too high.

Check motor field for correct resistance and continuity. It should measure approximately 0.5 ohms.

• Field current sensor in controller has failed.

Replace controller.

• Main contactor circuit damaged or disconnected.

Verify electrical connection between controller and contactor.

Check contactor coil for correct resistance of 22.0 ohms.

• Field current drivers in controller are damaged.

Replace controller.

LOGIC Measured field current is too low.

Dash Display

Controller LED

Handset or PC

AL6

6 Flashes

STBY I HIGH

CONDITION Controller detects motor current during standby mode.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Damaged controller.

Replace controller.

LOGIC Occurs if controller detects motor currents during standby mode.

24

2200 SRM 1067

Troubleshooting

Dash Display

Controller LED

Handset or PC

AL7

7 Flashes

THERMAL PROTECTION

CONDITION Controller temperature is out of operating range.

TRUCK RESPONSE Traction functions reduced below 10 C (14 F) and above 75 C (167 F). Traction and hydraulic functions disabled above 90 C (194 F).

POSSIBLE CAUSES AND TEST PROCEDURES • Controller temperature is too hot/cold.

Move truck to cooler or warmer location and allow controller to return to operating temperature.

• Controller temperature miscalibrated.

Install handset. Go to tester function and check temperature. Controller and vehicle temperature should be same as room temperature at initial startup. If these temperatures differ, replace controller.

• Controller temperature sensor damaged.

Replace controller.

• Controller damaged.

Replace controller.

LOGIC This alarm is generated when the controller temperature outside is 10 to 75 C (14 to 167 F).

25

Troubleshooting

2200 SRM 1067

Dash Display

Controller LED

Handset or PC

AL8

8 Flashes

POWER FAILURE #1

CONDITION Short circuit in device connected to controller.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Overcurrent detected in driven component.

Check main harness for damaged or shorted connections to main contactor, brake, and electric valve coils.

Check main contactor, brake, and electric valve coils for correct resistance values.

Check contactor coil for correct resistance of 22.0 ohms.

Check the brake coil for the correct resistance.

Resistance should be between 27.36 and 30.24 ohms.

Check the electric valve coils for correct resistance of 17.7 ohms.

LOGIC Occurs when controller detects short circuit in component driven by controller.

Value should be within ±10% at room temperature.

Dash Display

Controller LED

Handset or PC

AL10

LED ON (No Flashing)

EEPROM KO

CONDITION Fault in the memory area where parameters are stored.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Controller damaged.

Cycle key switch OFF and ON. If fault remains, replace controller.

LOGIC Occurs if controller discovers fault in the area of memory where parameters are stored.

26

2200 SRM 1067

Troubleshooting

Dash Display

Controller LED

Handset or PC

AL10

LED ON (No Flashing)

CAPACITOR CHARGE

CONDITION Main controller capacitors did not charge within 500 ms of key ON. TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Loose or damaged wire connection.

Inspect and confirm wire connections at contactor, pump motor, and traction motor.

• Short circuit in harness.

Disconnect main harness and check for shorts.

• Short circuit in component coil.

Disconnect battery. Disconnect all drive motor, pump motor, solenoid, brake, and coil connections at the component end of the harness. Tape or secure the wire ends to prevent shorts.

Discharge controller by placing 200 ohm, 2W resistor across B+ and B terminals. Reconnect battery and turn key ON. Use voltmeter to observe voltage across B+ and B . If there is no voltage increase, replace controller. If there is a steady voltage increase to battery voltage, connect each accessory one at a time until the fault occurs to identify damaged component.

• Damaged controller.

Replace controller.

LOGIC Occurs when an internal or external short or open prevents the main capacitors from charging at key ON.

27

Troubleshooting

2200 SRM 1067

Dash Display

Controller LED

Handset or PC - 12V

AL10

LED ON (No Flashing)

VMN NOT OK

CONDITION Measured voltage at traction motor inputs does not match battery voltage.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Loose or damaged cable connections to motor.

Verify motor armature cables and connections.

• Ground between motor windings and chassis.

Check for grounds between motor chassis and terminals.

• Damaged controller.

Voltage at –T terminal on controller should be the same as the +B terminal.

Replace controller.

LOGIC Occurs when controller observes differences between battery voltage and voltage supplied to the traction motor.

28

2200 SRM 1067

Troubleshooting

Dash Display

Controller LED

Handset or PC - 24V

AL10

LED ON (No Flashing)

VMN NOT OK

CONDITION Measured voltage at traction motor inputs does not match battery voltage.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Loose or damaged cable connections to motor.

Verify motor armature cables and connections.

• Ground between motor windings and chassis.

Check for grounds between motor chassis and terminals.

• Damaged controller.

Voltage at –T terminal on controller should be the same as the +B terminal.

Replace controller.

LOGIC Occurs when controller observes differences between battery voltage and voltage supplied to the traction motor.

29

Troubleshooting

2200 SRM 1067

Dash Display

Controller LED

Handset or PC

AL10

LED ON (No Flashing)

VFIELD NOT OK

CONDITION Voltage measured at field connections is not correct.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Cable connection to motor field is loose or damaged.

Verify connection of field wires to motor and controller.

• Motor field winding is shorted to chassis.

Check motor field for shorts to chassis.

Measure motor field resistance. Motor field should be approximately 0.5 ohms.

• Field current driver circuit has failed.

Use a voltmeter to measure between F1 and B and F2 and B with battery connected and key ON. Voltage should measure 1/2 the voltage between B+ and B .

Replace controller.

• Field current drivers in controller are damaged.

Replace controller. Verify motor field cable connections.

LOGIC This fault occurs when the voltage measured at the field connections is not the expected value.

Dash Display

Controller LED

Handset or PC

AL10

LED ON (No Flashing)

WATCHDOG

CONDITION Watchdog hardware circuit is not OK. TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Watchdog hardware circuit is damaged.

Cycle key switch OFF then ON. If alarm returns, replace controller.

LOGIC Occurs if the watchdog hardware circuit is damaged.

30

2200 SRM 1067

Troubleshooting

Dash Display

Controller LED

Handset or PC

AL10

LED ON (No Flashing)

Driver Shorted

CONDITION Voltage measured at field connections is not correct.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Cable connection to motor field is loose or damaged.

Verify connection of field wires to motor and controller.

• Motor field winding is shorted to chassis.

Check motor field for shorts to chassis.

Measure motor field resistance. Motor field should be approximately 0.5 ohms.

• Main contactor coil shorted/open.

Check contactor coil for correct resistance of 22.0 ohms.

• Field current driver circuit has failed.

Use a voltmeter to measure between F1 and B and F2 and B with battery connected and key ON. Voltage should measure 1/2 the voltage between B+ and B .

Replace controller.

• Field current drivers in controller are damaged.

Replace controller. Verify motor field cable connections.

LOGIC This fault occurs when the voltage measured at the field connections is not the expected value.

31

Troubleshooting

2200 SRM 1067

Dash Display

Controller LED

Handset or PC

AL94

OFF

NONE

CONDITION Controller is installing hourmeter memory from MDI display if controller has been replaced.

TRUCK RESPONSE Traction and hydraulic functions disabled for 1 minute.

POSSIBLE CAUSES AND TEST PROCEDURES • No fault is occurring.

Controller will send hourmeter data to MDI and truck will operate as soon as transfer is complete.

Wait approximately 60 seconds.

LOGIC Synchronize hourmeter data between MDI and controller.

32

2200 SRM 1067

ZAPI™ PC Interface

ZAPI™ PC Interface CONNECTING PC TO ZAPI™ CONTROLLER

4. Connect the interface cable to the controller and the PC. See Figure 8 and Figure 9.

NOTE: Values used on the following figures are for example only. For the correct values for your truck, see Controller Parameters in this section.

1. Turn the key switch to the OFF position.

2. Remove the drive unit compartment cover to access the controller.

3. Locate the communications port on the controller. (The port will have either a diagnostic LED, as in Figure 6, or a connector for the display, as in Figure 7.)

Figure 8. Controller Connection

Figure 6. Diagnostic LED Figure 9. PC Connection 5. Locate the icon for the ZAPI™ software on the PC and double-click on it. See Figure 10.

Figure 7. Display Connection

Figure 10. ZAPI™ Icon

33

ZAPI™ PC Interface

2200 SRM 1067

6. You should now see a screen as shown in Figure 11.

Figure 11. ZAPI™ Software Screen 7. Click on the START button first and then turn the key switch to ON. See Figure 12.

Figure 12. Start Button

34

2200 SRM 1067

ZAPI™ PC Interface

8. If the connection was successful, you should now see the screen shown in Figure 13. If you get an error message, go back to Step 7 and try again.

Explanation of Screen Connected To:

MPB NA V1.01

This tells the current software revision.

Nominal Voltage:

24V

Voltage of the controller installed.

Nominal Current:

180A

Maximum operating current of the controller.

Hour:

0h

Internal hourmeter of the controller.

Alarm:

Connection Status:

If there is a current "live" error in the controller, the alarm code will appear here.

CONNECTED

Indicates if the software is communicating with the PC.

Figure 13. ZAPI™ Software Version Screen

35

ZAPI™ PC Interface

2200 SRM 1067

FILE MENU Open File When you select this function, you will be able to open a previously saved file that contains parameter settings for the controller. See Figure 14.

Figure 14. File - Open

36

2200 SRM 1067

ZAPI™ PC Interface

Note that the previously saved file has the .csv extension, and observe how the file name was used. See

the Save File section of this manual for proper file saving techniques. See Figure 15.

Figure 15. Look In:

TX From File This selection in the file menu is similar to the File Open selection. See Figure 16.

Figure 16. File - TX From File

37

ZAPIâ„¢ PC Interface

2200 SRM 1067

Notice the CONNECTION STATUS while the file is downloaded into the controller. See Figure 17.

Figure 17. Connection Status

38

2200 SRM 1067

ZAPI™ PC Interface

Save File The ZAPI™ PC software can save configurations for up to 500 controllers. When saving a configuration

to the PC, the following steps should be followed to help track which file goes with each controller. See Figure 18.

Figure 18. File - Save 1. Try to use the actual truck serial number and put the word "settings" after it. (This is to keep the

controller settings file separate from the tester function Save file.) See Figure 19.

Figure 19. Save: In

39

ZAPIâ„¢ PC Interface

2200 SRM 1067

2. Once you select a file name and click on Save, you will see the screen shown in Figure 20.

3. Under the Enter a Comment box, you can either describe what is different with the settings or enter a customer name.

Here is what a saved parameter file looks like: [Info] Chopper_Name=MPB NA V1.01 User_Comment=modified mode 4 to lower speed and coast more Save_Date=Thu Apr 04 15:58:15 2002

0;ACCELER.DELAY;0;0;0;LEVEL=0 5;DECELER.DELAY;1;0;9;LEVEL=9 11;RELEASE BRAKING;2;0;0;LEVEL=9 12;INVERS.BRAKING;3;0;9;LEVEL=9 30;MAX SPEED FORW;4;0;9;LEVEL=9 31;MAX SPEED BACK;5;0;9;LEVEL=9 248;DRIVE MODES ;01;1;ON [End] [Validation] Code=FFDA [Stop]

[Code;Name;Position;Menu;Value;Scaled Value]

Figure 20. Enter a Comment

40

2200 SRM 1067

ZAPI™ PC Interface

Print Settings This selection allows you to print out your current parameter settings in the controller. See Figure 21.

Figure 21. File - Print

41

ZAPI™ PC Interface

2200 SRM 1067

Exit This selection will exit the ZAPI™ PC console software. See Figure 22.

Figure 22. File - Exit

42

2200 SRM 1067

ZAPI™ PC Interface

CONNECTION MENU There are two selections under this menu: 1. Start - Starts the connection between the controller and PC (operates the same as the main Start button on the right-hand side of the display screen).

2. Stop - Stops the connection between the controller and PC (operates the same as the main Stop button on the right-hand side of the display screen).

See Figure 23.

Figure 23. Connection Menu

FUNCTION MENU There are seven selections under this menu: 1. Parameter - Allows the performance and configuration of the controller to be adjusted. Refer to Parameter, in this section.

2. Tester - Allows the testing of various inputs and operations of the controller. Refer to Tester, in this section.

3. Alarm Logbook - Stores alarms that the controller detects. Refer to Alarm Logbook, in this section.

4. Program VACC - Not Used.

5. Motor Data - Not Used.

6. Ram Function - Only Factory Use. 7. EEPROM Function - Only Factory Use.

43

ZAPI™ PC Interface

2200 SRM 1067

Parameter When you first activate this selection, the screen will look as indicated in Figure 24. In order to see the parameters of the controller, you have to download them to the PC. This can be done by 1 of 2 ways.

1. Receive menu - This will only download the current selected tab.

2. Receive - This will download all parameters and configurations to the PC so you can adjust them.

Figure 24. Parameter You will now see a screen like Figure 25, while the data are being downloaded.

Figure 25. Downloading Screen

44

2200 SRM 1067

ZAPI™ PC Interface

Now that the parameters have downloaded, you should see a screen as indicated in Figure 26.

Please note that the current drive mode the lift truck was in will be displayed. (There are three modes that cannot be adjusted.) In order to make any changes to the parameters, you must turn on Mode 4, which is covered in Set Options, in this section.

Adjustments can be made by first highlighting the parameter to be modified and then using the scroll bar on the right side of the screen to adjust it.

You will also notice that there are six tabs along the top to choose from: 1. Parameter Change - Allows the performance of the truck to be adjusted.

2. Set Options - Allows the technician to turn on or off mode 4 for personalized performance settings.

See Set Options.

3. Set Model - Not Used.

4. Adjustment - Not Used.

5. Special Adjust - Not Used.

6. Hardware settings - Not Used.

Figure 26. Drive Mode

45

ZAPI™ PC Interface

2200 SRM 1067

There are six parameters that can be adjusted to affect the performance of the lift truck. See Figure 27.

1. ACCELER. DELAY - Amount of ramp-up to full speed.

• Level 0 - Large acceleration curve, up to full speed.

• Level 9 - Short acceleration curve, up to full speed.

2. DECELER. DELAY - Amount of ramp-down to a lower speed.

• Level 0 - Large deceleration curve, to a lower speed (coasting).

• Level 9 - Short deceleration curve, to a lower speed (aggressive).

• Level 0 - Minimum braking (coasting).

• Level 9 - Maximum braking (aggressive).

4. INVERSE BRAKING - Amount of braking when the lift truck is "plugged."

• Level 0 - Minimum braking.

• Level 9 - Maximum braking.

5. MAX SPEED FORW - Maximum speed of the lift truck in the handle direction.

• Level 0 - Minimum speed.

• Level 9 - Maximum speed.

6. MAX SPEED BACK - Maximum speed of the lift truck in the forks direction.

• Level 0 - Minimum speed.

• Level 9 - Maximum speed.

3. RELEASE BRAKING - Amount of braking when the accelerator is released.

Figure 27. Adjustable Parameters

46

2200 SRM 1067

ZAPI™ PC Interface

Notice that the ACCELER. DELAY function has been adjusted. The parameter settings are "live," which means as they are being adjusted. The lift truck will react to the setting. Once the lift truck is performing as wanted, the Store button is pressed to save the settings into the controller. See Figure 28.

NOTE: If the Store button is not pressed before turning off the lift truck, then all changed parameters will be lost.

Figure 28. Store Button

47

ZAPI™ PC Interface

2200 SRM 1067

Memory Menu If you wish to start all over with your adjustments prior to pressing the Store button, then you can select the Memory menu to see the screen in Figure 29.

2. Store - Same as Store button.

3. Restore - Will revert the parameter settings to what they were before adjustments were made.

Note this will not work if the settings were stored before using this function.

This menu has three selections: 1. Receive - Same as Receive menu and Receive button.

Figure 29. Memory Menu

48

2200 SRM 1067

ZAPI™ PC Interface

Set Options This selection will allow Mode 4 to be activated, so that the performance parameters can be adjusted for a custom configuration. See Figure 30.

Figure 30. Set Options

49

ZAPI™ PC Interface

2200 SRM 1067

Highlight Drive Modes and then click on the scroll bar to the right and select OFF. See Figure 31.

Do the following steps once this has been done: 1. Press the Store button to save the change into the controller.

2. Press the Close button to go to the main screen of the ZAPI™ PC software.

3. Press the Stop button to disconnect the communication between the PC and the controller.

4. Turn the key switch on the lift truck to OFF; then do the reconnect procedure.

5. Now the parameters in the Function Menu can be adjusted to a custom configuration (Mode 4).

Figure 31. Turn Off Drive Modes

50

2200 SRM 1067

ZAPI™ PC Interface

Tester This selection allows the technician to monitor up to four items at a time to help troubleshoot problems.

See Figure 32.

The Tester function also features a data-logging capability to further assist the technician and the factory with problems.

Figure 32. Tester

51

ZAPI™ PC Interface

2200 SRM 1067

The PC software can test the following (four selections at a time). See Figure 33.

1. Battery Voltage - voltage across the battery.

2. Motor Voltage - voltage across the traction motor.

3. Motor Current - current through the traction motor.

4. Field Current - current through the fields in the traction motor.

5. Temperature - current temperature of the controller.

6. Accelerator - voltage and percent of "throw" from the traction thumbwheel.

7. Lifting Control 8. Tiller Switch - position of tiller handle.

9. Forward Switch - directional input.

10. Backward Switch - directional input.

11. Lifting Switch - refers to switch on right side of tiller head.

12. Lowering Switch - refers to switch on right side of tiller head.

13. Fork Lift Switch - refers to switch on left side of tiller head.

14. Fork Lower Switch - refers to switch on left side of tiller head.

15. Belly Switch 16. Snail Switch 17. Horn Switch 18. Cutback Switch 19. Lifting Block 20. Battery Model 21. Battery Charge - remaining charge on the battery.

Figure 33. Test Name

52

2200 SRM 1067

ZAPI™ PC Interface

Data Logger

1. Advanced - Allows the user to select sample rates and length of recording.

2. Start Rec. - Starts the data logger.

3. Stop Rec. - Stops the data logger.

4. Save Rec. - Saves the log to a file.

In addition to "live testing" of the controller, the ZAPI™ PC software also includes a data-logging capability. See Figure 34. There are four buttons associated with this, as listed below.

Figure 34. Data Logger The Advanced button allows the user to select time increments and the number of samples. See Figure 35.

Figure 35. Tester Advanced

53

ZAPI™ PC Interface

2200 SRM 1067

As the data logger is running, the screen will look like what is shown in Figure 36. During the logging

process, you will still be able to see the values changing in the display menu.

Figure 36. Logging Process

54

2200 SRM 1067

ZAPIâ„¢ PC Interface

Once the data logger is done, you can save the log using the Save Rec. button. See Figure 37.

Once the log file has been saved, the user can either analyze the data him/herself or e-mail the file to the factory for analysis.

Figure 37. Save As The raw data file looks like this (see Figure 38): [Info] Chopper_Name=CS P20 V1.00 Save_Date=Thu Apr 04 13:32:24 2002 TIME;MOTOR CURRENT;ACCELERATOR;BATTERY CHARGE ;FIELD CURRENT; 0;0;0.00

0;80;0.0;

10;0;0.00

0;80;0.0;

20;0;0.00

0;80;0.0;

30;0;0.00

0;80;0.0;

40;0;0.00

0;80;0.0;

50;0;0.00

0;80;7.2;

60;3;0.00

0;80;7.2;

70;3;0.27

10;80;7.2;

80;3;0.27

10;80;12.7;

90;8;0.53

16;80;12.7;

Figure 38. Test Data

55

ZAPI™ PC Interface

2200 SRM 1067

Alarm Logbook The ZAPI™ controller can record up to five unique alarms and store them in a logbook that the PC can access. See Figure 39.

Figure 39. Alarm Logbook

56

2200 SRM 1067

ZAPIâ„¢ PC Interface

The display screen (Figure 40) will display any current "live" alarms. Note the display ACTUAL ALARM that indicates a current "live" alarm condition.

The PC software will provide the alarm name and the number of times it has occurred, the temperature of the controller when the alarm occurred, and the hourmeter reading (internal to the controller) of when the alarm occurred.

The user can check for new alarms by pressing the Update key or clear out the alarm log by pressing the Clear key.

The following list consists of possible alarms.

Alarms 1.

2.

3.

4.

EVP NOT OK BRAKE DRIVER KO VFIELD NOT OK PUMP VACC NOT OK

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

SERIAL ERROR #1 WATCHDOG EEPROM KO FORW + BACK VMN NOT OK CONTACTOR CLOSED I=0 EVER STBY I HIGH HIGH FIELD CURRENT NO FIELD CURRENT CAPACITOR CHARGE LOW BATTERY THERMAL PROTECTION CHARGING BATTERY POWER FAILURE #1 DRIVER SHORTED CONTACTOR DRIVER VACC NOT OK INCORRECT START INPUT ERROR #2 INPUT ERROR #1

Figure 40. Actual Alarm

57

Repair

2200 SRM 1067

Repair REMOVE

2. Remove brass stud from controller.

1. Park lift truck in a safe, level area.

Install

2. Block drive wheel to prevent lift truck from moving.

The stud must be installed in the correct orientation with regard to the relief groove.

3. Connect handset or PC and download parameters, if possible.

1. Install brass stud onto controller and tighten to 10 to 11 N•m (92 to 97 lbf in).

4. Turn key to OFF.

2. Install brass washer, power fuse, brass washer, flat washer, lockwasher, and M8 nut to brass stud. Tighten M8 nut to 10 to 11 N•m (92 to 97 lbf in).

5. Disconnect battery.

6. Remove cover.

WARNING The capacitors in the controller remain charged for several minutes after operation.

To prevent personal injury and/or damage to equipment, the controller should be discharged. To discharge the controller, connect a 200-ohm, 2- to 3-watt resistor between the battery positive and negative terminals on the controller for at least 5 seconds. Refer to Figure 2 in the General section of this manual.

7. Discharge controller.

8. Identify and tag all power cables and wires connected to controller for later installation.

INSTALL 1. Align controller to plate and capscrews. Tighten capscrews.

2. Connect all power cables and wires connected to controller.

3. Connect battery.

4. Connect handset or PC. 5. Turn key to ON. 6. Upload parameters.

7. Remove blocks from drive wheel.

9. Remove all power cables and wires connected to controller.

8. Test lift truck in a safe, level area away from other personnel and equipment.

10. Loosen both capscrews retaining controller to plate.

9. Install cover.

REPAIR 11. Remove controller.

1. Replace fuses.

BRASS STUD REPLACEMENT Remove 1. Remove M8 nut, lockwasher, flat washer, brass washer, power fuse, and brass washer from brass stud.

58

2. Replace controllers by following the remove and install procedures listed above.

ZAPIâ„¢ CONTROLLERS W40Z [B218]

PART NO. 1511612

2200 SRM 1006

ZAPI™ Controllers

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Description .........................................................................................................................................................

ZAPI™ Transistor Motor Controller.............................................................................................................

Principles of Operation..................................................................................................................................

Controller Safety ................................................................................................................................................

Controller Adjustments .....................................................................................................................................

Modes of Operation ............................................................................................................................................

User-Selectable Operating Modes ................................................................................................................

Programming......................................................................................................................................................

Custom Performance Mode ...........................................................................................................................

Controller Parameters...................................................................................................................................

Tester Menu ...................................................................................................................................................

Set Option Menu............................................................................................................................................

ZAPI™ Handset.............................................................................................................................................

Troubleshooting..................................................................................................................................................

ZAPI™ PC Interface ..........................................................................................................................................

Connecting PC to ZAPI™ Controller............................................................................................................

File Menu .......................................................................................................................................................

Open File....................................................................................................................................................

TX From File .............................................................................................................................................

Save File ....................................................................................................................................................

Print Settings ............................................................................................................................................

Exit.............................................................................................................................................................

Connection Menu ...........................................................................................................................................

Function Menu...............................................................................................................................................

Parameter ..................................................................................................................................................

Memory Menu............................................................................................................................................

Set Options ................................................................................................................................................

Tester..........................................................................................................................................................

Data Logger ...............................................................................................................................................

Alarm Logbook ..........................................................................................................................................

Alarms........................................................................................................................................................

Repair .................................................................................................................................................................

Remove ...........................................................................................................................................................

Brass Stud Replacement ...............................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Install .............................................................................................................................................................

Repair .............................................................................................................................................................

1 2 2 2 3 3 4 4 4 4 4 5 6 6 10 30 30 33 33 34 36 38 39 40 40 41 45 46 48 50 53 54 55 55 55 55 55 55 55

This section is for the following models: W40Z [B218]

©2007 HYSTER COMPANY

i

2200 SRM 1006

General

General This section describes the ZAPI™ transistor motor controller. Procedures are outlined for controller

safety, adjustments, troubleshooting, and repairs.

See Figure 1.

Figure 1. Controller W40Z

1

Description

2200 SRM 1006

Description ZAPI™ TRANSISTOR MOTOR CONTROLLER The ZAPI™ controller is a solid state DC motor controller utilizing SEM technology. It controls the traction motor, brake, and hydraulic system. The controller receives inputs from the control handle by serial communication, and direct inputs from the key switch and control handle arm position switch.

The controller directly controls the traction motor, lift pump motor, lowering valve, brake, and main contactor. Jumpers are used to configure the basic controller.

The controller software provides self diagnostics which are accessed by means of a ZAPI™ handset or a PC with specialized ZAPI™ software. The controller software features a Test Menu for monitoring controller inputs and outputs, a Diagnostic Menu for viewing fault code information, and a Programming Menu for customizing the truck performance.

The self diagnostics monitor the traction motor, brake coil, lowering valve coil, contactor coil, control handle serial communications, controller temperature, and internal logic functions. The controllers on standard trucks come equipped with a red LED fault indicator located at the bottom of the controller. In the event of a fault, the LED flashes a numeric code.

2

Troubleshoot the fault using a ZAPI™ handset or a properly configured IBM compatible PC. On trucks equipped with the optional dash display, the dash wiring harness plugs into the controller in place of the LED. The display also has a red LED, however it does not flash codes. If a fault occurs, the red LED blinks, the wrench LCD is shown and "AL" followed by the fault number is displayed.

PRINCIPLES OF OPERATION The ZAPI™ Transistor Motor Controller uses a sophisticated microprocessor to control the logic and operation of the controller, eliminating the need for forward and reverse contactors. The SEM motor controller operates on the principle of controlling the motor field circuit and the motor armature circuit independently. The controller has many programmable features, including maximum speed, acceleration rate, release braking, and braking current limit. The SEM controller includes a full range of features, as well as diagnostic and setup capability.

NOTE: There are no user-serviceable parts in the ZAPI™ controller. No attempt should be made to open, repair, or otherwise modify the controller.

Doing so may damage the controller and will void the warranty.

2200 SRM 1006

Controller Adjustments

Controller Safety WARNING The ZAPI™ controllers can hold an electrical charge for several minutes after the key switch has been turned OFF. To prevent injury, discharge the controllers by connecting a 200-ohm, 2-watt resistor between the battery positive connector and battery negative connector on the controller and hold there for 5 seconds.

See Figure 2.

1.

2.

3.

4.

POSITIVE CONNECTION NEGATIVE CONNECTION INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR Figure 2. Discharging Controller W40Z

Controller Adjustments The ZAPI™ transistor motor controller can store and display Error Codes (Alarms). It is also possible to modify the controller Setup for individual preferences. Communication with the controller is possible by four methods:

3. ZAPI™ Handset - A diagnostic handset is available through your Hyster dealer. The handset makes it possible to diagnose faults and modify controller settings. See Programming, in this section.

1. LED - An LED may be installed in trucks that do not use a dash display. The LED flashes error codes to the technician for diagnosis. The LED would be installed on the bottom of the ZAPI™ controller. The LED is installed in connector port B. See Figure 1.

4. Personal Computer - The controller can also be connected to a personal computer (PC) equipped with special software and cables. The PC can read, store, and change settings on the controller.

2. Dash Display - Some trucks are equipped with an optional dash display or MDI. Error codes are shown on the LCD (liquid crystal display) when the wrench symbol and red light are lit. The format is AL XX where XX is the error code.

Proper use of these four methods and a list of diagnostic codes are explained in Troubleshooting, in this section.

3

Programming

2200 SRM 1006

Modes of Operation It is possible to adjust the operating characteristics of the lift truck. There are two basic ways to do this: User-Selectable and Non-User-Selectable Operating Modes.

USER-SELECTABLE OPERATING MODES The operator has a choice of three performance modes that are selectable through the control handle. The mode selection is made at startup or key ON. Performance parameters that vary are acceleration, deceleration, regenerative (neutral) braking, and top travel speed.

The three operator-selectable performance modes are factory programmed per the following: • Mode 1 - Economy mode (battery saver) - soft acceleration, reduced top speed with regenerative (neutral) braking.

• Mode 2 - Performance with regenerative (neutral) braking - medium acceleration, reduced top travel speed with regenerative (neutral) braking.

• Mode 3 - Performance without regenerative (neutral) braking - maximum acceleration, maximum top travel speed with coast at throttle release.

The following procedure is used to access the userselectable operating modes: 1. The controller drive modes parameter must be ON. This is the factory setting.

connection, it is possible to set the drive mode parameters to ON or OFF. In the ON mode, the user-selectable rules are enabled. In the OFF mode, the lift truck will only operate using the settings selected.

The procedure to alter or modify these settings is given in Programming in this section.

2. Control handle must be in the full, upright position, brake ON. 3. Press and hold the horn button while turning the key switch to the ON position.

4. Release the horn button when the horn sounds.

5. Toggle through the modes by pressing the lift or lower buttons to the desired mode.

6. The horn provides an audible indication as to the mode selected. One beep indicates Mode 1, two beeps indicate Mode 2, and three beeps indicate Mode 3.

7. Lower the control handle to the operating position, brake OFF, and begin operation.

8. The selected mode is maintained until the procedure is repeated.

9. Turning the key OFF before lowering the control handle will cancel the mode change.

NOTE: You must use the handset or PC interface to change this setting. Using the ZAPI™ handset or PC

Programming CUSTOM PERFORMANCE MODE In some instances, it may be preferable to disable the Drive Modes and use a custom setting. This controller has adjustable parameters that may be modified to suit specific customer needs. There are two methods used to adjust these parameters: the ZAPI™ handset or the personal computer (PC) interface.

CONTROLLER PARAMETERS Parameters are controller settings that can be adjusted to alter the performance characteristics of the truck.

4

To adjust parameters and install custom drive settings, Drive Modes must be OFF. To set Drive Modes to OFF, use the following procedure: 1. Turn key switch OFF. 2. Remove drive unit compartment cover.

3. Connect adapter harness to handset.

NOTE: It may be necessary to remove the MDI harness connector from the controller to install the adapter harness.

NOTE: Connect and disconnect the handset only with the key switch in the OFF position.

2200 SRM 1006

Programming

4. Connect adapter harness to controller.

9. Scroll through the menus using button 1 or 2 to the SET OPTIONS menu.

5. Turn key switch ON.

10. Enter this menu by pressing button 3.

6. The handset will turn ON. See Figure 3.

11. Press button 5 or 6 to set Drive Modes to OFF.

7. Press buttons 1 and 5 simultaneously.

12. Press button 4 to exit this menu.

8. The screen will display CONFIG MENU.

13. The handset will prompt, "Are you sure?"

14. Press ENTER (button 3) to retain settings.

15. Press OUT (button 4) to discard settings.

16. Turn the key switch OFF to save the drive modes OFF parameter change.

17. Turn the key switch ON to enter the MAIN MENU and change the parameters outlined in Table 1.

Figure 3. ZAPI™ Handset

Table 1. Parameters Parameter

Description

Value and Affect

ACCELERATION DELAY

Adjusts truck acceleration.

0 = short or rapid acceleration 9 = long or slow acceleration

DECELERATION DELAY

Adjusts truck deceleration according to throttle position.

0 = short or rapid deceleration 9 = long or slow deceleration

RELEASE BRAKING

Adjusts motor braking strength or regenerative braking when throttle is released. This determines coast distance.

0 = soft braking 9 = strong braking

INVERSE BRAKING

Adjusts plugging rate.

0 = long or soft plugging 9 = short or rapid plugging

MAX SPEED FORW

Adjusts maximum speed in forward direction, forks trailing.

0 = minimum 9 = maximum

MAX SPEED BACK

Adjusts maximum speed in reverse direction, forks leading.

0 = minimum 9 = maximum

TESTER MENU The most important input or output signals can be measured in real time using the TESTER function of the handset. The handset acts as a multimeter to read voltage, current, temperature, switch state, and other functions.

1. BATTERY VOLTAGE = battery voltage, nominal value = 24V, V.

3. MOTOR CURRENT = armature current during traction (positive value) or braking (negative value).

4. FIELD CURRENT = field current in the selected traction direction.

5. TEMPERATURE = controller temperature, C. 6. ACCELERATOR = traction potentiometer value received from control handle.

2. MOTOR VOLTAGE = motor voltage obtained VBATT - VMN, V.

5

Programming 7. LIFTING CONTROL = lifting/lowering potentiometer value received from control handle.

8. CONTROL HANDLE SWITCH = control handle switch input, ON/OFF.

2200 SRM 1006

SET OPTION MENU DRIVE MODES

9. FORWARD SWITCH = forward direction request from control handle card, ON/OFF. 10. BACKWARD SWITCH = backward direction request from control handle card, ON/OFF. 11. CUTBACK SWITCH 1 = speed reduction switch input, ON/OFF (closed switch = OFF = no speed reduction).

12. LIFTING SWITCH = lifting function request from control handle card, ON/OFF. 13. LOWERING SWITCH = lowering function request from control handle card, ON/OFF. 14. FORK LIFT SWITCH = i - lift request from control handle card, ON/OFF. 15. FORK LOW SWITCH = i - lift request from control handle card, ON/OFF. 16. BELLY SWITCH = belly input switch to the controller or belly request from control handle card, ON/OFF. 17. HARD & SOFT = snail request from control handle card allows machine to drive with control handle up, ON/OFF. 18. HORN SWITCH = horn request from control handle card, ON/OFF. 19. LIFTING BLOCK = lifting block input switch, ON/OFF (with LIFTING BLOCK option programmed OFF).

20. BATTERY MODEL = battery-type of input switch, ON/OFF. ON = flooded battery (input closed), OFF = sealed battery (input open).

21. BATTERY CHARGE = battery charge indication, %.

ON

The truck has three performance modes, each with a fixed set of parameters.

This function is enabled by setting DRIVE MODES = ON.

OFF

DRIVE MODES disabled.

ZAPI™ HANDSET The ZAPI™ handset must be connected to the controller before turning on the key. The handset must have an adapter harness to connect to the controller.

The handset and adapter harness are available from your Hyster dealer. Connect the handset to plug B. The handset can remain connected to the controller while running, and the parameters can be changed in real time. In this case, it is necessary to go in a standby condition (truck at rest) before switching OFF the controller in order to store the new values in the EEPROM. This section describes the ZAPI™ handset functions.

Six buttons provide the capability of changing or reading the parameters.

1

Roll-Up

Push to scroll up.

2

Roll-Down

Push to scroll down.

3

Enter

Push to enter a submenu or to confirm a change.

4

Out

Push to exit a selected menu or to refuse a change.

5

Set-Up

Push to increase a parameter value.

6

Set-Down

Push to decrease a parameter value.

NOTE: After a modification, save the new values by pushing out, then enter to confirm. (Screen prompts will guide the user.)

To navigate the menu options, numbers inside the triangles in the following map correspond to the same number on the handset keyboard buttons. The orientation of the triangle indicates the way to the next function. See Figure 3.

NOTE: Connect and disconnect the handset only with the key switch in the OFF position.

For additional handset description, see Figure 4.

6

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

7

Programming

8

2200 SRM 1006

2200 SRM 1006

Programming

Figure 4. ZAPIâ„¢ Handset Instructions

9

Troubleshooting

2200 SRM 1006

Troubleshooting Dash Display

Controller LED

Handset or PC

LCD display

Red LED

Red LED Fault Indicator

Located at base of motor controller.

Error codes stored under Main Menu Alarms

(Trucks equipped with optional dash display)

(Trucks without dash display)

Message displayed on Handset or PC CORRESPONDING SCHEMATIC SHOWING CIRCUITS TO BE CHECKED

CONDITION

OR

TRUCK RESPONSE

AFFECTED COMPONENT

POSSIBLE CAUSES AND TEST PROCEDURES

LOGIC

NOTE: General error code information is provided by the Dash Display and Red LED at the base of the controller. In most instances, it will be necessary to use a handset or a PC to further define the possible causes and test procedures.

10

2200 SRM 1006

Troubleshooting

Dash Display

Controller LED

Handset or PC

No LEDs or LCDs illuminated

LED OFF

Handset does not operate

CONDITION Dash display, controller LED, and truck inoperative.

TRUCK RESPONSE Travel and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • B+ and/or B missing at controller.

Confirm battery is connected and of proper voltage.

Verify key switch is ON. Verify brake override circuit is connected in run position.

Verify continuity between batteries negative (at battery) and B power wire connection (at controller).

If no continuity, check: Power wiring between battery and controller.

Check for +24V at D-4, A-3, and A-6.

If no continuity, check: Fuse 2 for open.

Key switch continuity in ON position.

Wiring battery + to main contactor to fuse 2 to key switch, to controller A-6 connection.

• Defective battery charger.

Disconnect wires 2D and 12 from leads to battery charger.

Use test lead to connect 2D and 12.

If truck operates, check charger fuses, repair or replace battery charger.

• Defective motor controller.

Check for battery voltage between A-6 and B power wire connection at controller.

If correct battery voltage, replace controller.

LOGIC Occurs when there is no power to the controller or the controller is defective.

11

Troubleshooting

2200 SRM 1006

Dash Display

Controller LED

Handset or PC

No LEDs or LCDs illuminated

LED OFF

No error codes present

CONDITION Dash display and/or controller LED inoperative.

TRUCK RESPONSE Travel and hydraulic functions normal.

POSSIBLE CAUSES AND TEST PROCEDURES • Open connection between dash display and controller.

Verify harness connections at MDI and connector B on controller.

Verify continuity of wires between MDI and controller.

• Defective dash display.

Connect handset to controller and confirm communication to handset.

If handset operates correctly, replace MDI. • Defective LED. Disconnect LED and connect handset. If handset works, replace LED.

LOGIC Occurs when the MDI or LED receives no signal, or MDI or LED are damaged.

Dash Display

Controller LED

Handset or PC

No LEDs or LCDs illuminated

LED OFF

NO COMMUNICATION

CONDITION Dash display and/or controller LED inoperative.

TRUCK RESPONSE Travel and hydraulic functions normal.

POSSIBLE CAUSES AND TEST PROCEDURES • Defective controller.

Connect handset to controller and confirm communication to handset.

If handset will not communicate with controller, replace controller.

LOGIC Occurs when controller does not send a signal to the MDI or LED.

12

2200 SRM 1006

Troubleshooting

Dash Display

Controller LED

Handset or PC

No Alarm

LED OFF - No Flashes

INCORRECT START

CONDITION Improper startup sequence by operator.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Throttle or hydraulic function selected at key ON. Steer handle in run position at key ON. Return steer handle to full upright position. Return throttle to neutral. Release all hydraulic function controls.

If fault remains, attach handset and go to test menu.

• Check brake switch, it should be off. If steer handle is in vertical position and reading is not OFF, check brake switch for damage, interference, or shorts.

• Check accelerator - Should be 0 volts at neutral. If not, repeat control card calibration. If this does not correct the problem, replace control card.

• Check hydraulic inputs – Should be 0 volts. If not, recalibrate tiller card. Follow auto-learn procedure listed in steering. If this does not clear fault, check buttons for damage or interference. Replace damaged or faulty buttons.

LOGIC Fault occurs when controller receives input that has not followed the proper operational sequence.

Dash Display

Controller LED

Handset or PC

AL66

Continuous Flashing

BATTERY LOW

CONDITION Battery discharged and requires charging.

TRUCK RESPONSE Hydraulic lift function disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Battery voltage is low.

Charge or replace battery.

• Controller voltage calibration is incorrect.

Install handset. Go to test menu and select Battery Voltage. Compare tester voltage to voltage measured by an accurate digital voltmeter between B+ and B terminals. Pull down tiller handle to engage contactor for this measurement. If these two voltages are more than 1.5 volts difference, replace controller.

LOGIC Controller measures low battery voltage over multiple checks during traction or hydraulic operation.

13

Troubleshooting

2200 SRM 1006

Dash Display

Controller LED

Handset or PC

AL99

Continuous Flash

BATTERY KO

CONDITION Improper battery connection or defective battery.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Incorrect battery selected.

Verify correct battery voltage for truck.

• Damaged or extremely discharged battery.

Disconnect battery and check voltage at connector. Inspect battery for correct water level and damage. Repair or replace battery.

• Defective or damaged connection to battery.

Inspect cable crimps and cables from battery to connector.

Inspect cable crimps and cables from battery contactor to controller and contactor.

LOGIC Battery voltage is much less than allowable.

Dash Display

Controller LED

Handset or PC

AL01

1 Flash

VACC NOT OK

CONDITION Connection/communication error between tiller card and traction controller.

TRUCK RESPONSE Traction and hoist functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Control card throttle calibration is out of range.

Install handset. Go to tester function of handset.

If accelerator output is >1V (20%) and the enable switch is open, recalibrate control card.

• Control card throttle damaged or defective.

If card cannot be recalibrated, replace card.

14

LOGIC Occurs when accelerator voltage from serial control card is higher than 1V (20%) before neutral switch is closed.

2200 SRM 1006

Troubleshooting

Dash Display

Controller LED

Handset or PC

AL01

1 Flash

PUMP VACC NOT OK

CONDITION Connection/communication error between control card and traction controller.

TRUCK RESPONSE Traction and hoist functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • A lift/lower switch is damaged or defective.

Install handset. Go to tester function. Check lifting control and EVP voltage. Check on/off switches and for smooth, linear operation. Replace damaged switches.

• Control card lift/lower switch calibration is out of range.

Install handset. Go to tester function. Check lifting control and EVP voltage. Output of hydraulic controls should be less than 1V (20%) at neutral.

Recalibrate control card.

• Control card is damaged or defective.

Replace card.

LOGIC Occurs if the output of one on the hydraulic controls is higher than 1V (20%) at start.

Dash Display

Controller LED

Handset or PC

AL01

1 Flash

FORW + BACK

CONDITION Connection/communication error between control card and traction controller.

TRUCK RESPONSE Traction and hoist functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Control card throttle device is damaged or defective.

Install handset. Go to tester function. If forward switch and backward switch are both on at the same time, card is damaged.

Replace control card.

LOGIC Occurs if controller receives signal for forward and reverse directions simultaneously.

15

Troubleshooting

2200 SRM 1006

Dash Display

Controller LED

Handset or PC

AL01

1 Flash

SERIAL ERROR #1

CONDITION Connection/communication error between control card and traction controller.

TRUCK RESPONSE Traction and hoist functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Loose or damaged electrical connection between control card and controller.

Verify connection at controller.

Verify wire harness connection at base of steer handle.

Verify connection at control card.

• Damaged or defective control card.

Measure voltage at pin 5, connector C, on the controller. With control card disconnected, this should be about 12V; with the card connected, it should be about 5V. 0V or 12V with the card connected means that the card is damaged.

Replace control card.

LOGIC No information or incorrect information has been sent from the control card to controller.

Dash Display

Controller LED

Handset or PC

AL01

1 Flash

INPUT ERROR #1

CONDITION Connection/communication error between control card and traction controller.

TRUCK RESPONSE Traction and hoist functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Traction reversing switch is not connected.

Install handset. Go to tester function. Check for operation of traction reversing switch.

Verify that traction reversing switch cover is making contact with switch on control card.

Check wires in control handle arm are secure.

• Damaged or defective control card.

Replace control card.

16

LOGIC Traction reversing switch data signal is not present and hardwire signal is present.

2200 SRM 1006

Troubleshooting

Dash Display

Controller LED

Handset or PC

AL01

1 Flash

INPUT ERROR #2

CONDITION Connection/communication error between control card and traction controller.

TRUCK RESPONSE Traction and hoist functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Traction reversing switch is not connected.

Install handset. Go to tester function. Check for operation of traction reversing switch.

Verify that traction reversing switch cover is making contact with switch on control card.

• Damaged or defective cable.

Check steer handle control cable for loose connections or broken wires.

• Damaged or defective tiller card.

Replace control card.

LOGIC Control card is not sending hard-wired signal from traction-reversing switch to controller.

Dash Display

Controller LED

Handset or PC

AL02

2 Flashes

CONTACTOR CLOSED

CONDITION Main contactor circuit is damaged.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Main contactor tips are welded closed.

Disconnect power leads at contactor. Use meter to confirm open circuit across power terminals.

If short circuit is measured, replace contactor.

• Problem in motor field circuit.

Verify electrical connections between motor field and controller.

Check motor field for shorts to chassis.

• Controller is damaged.

Replace controller.

LOGIC Occurs when the controller detects a short in the main contactor circuit.

17

Troubleshooting

2200 SRM 1006

Dash Display

Controller LED

Handset or PC

AL4

4 Flashes

EVP NOT OK

CONDITION Lowering valve will not operate correctly.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Damaged or loose electrical connection to lowering valve.

Verify electrical connections between valve coil LOGIC and controller.

• Lowering coil damaged.

Occurs if electro-proporCheck lowering valve coil for correct resistance. tional valve is open before circuit is energized. Valve Coil resistance should be approximately 33 ohms. does not follow the supplied signal from controller.

Replace coil if damaged.

• Lowering valve cartridge is damaged.

Replace lowering valve cartridge.

Dash Display

Controller LED

Handset or PC

AL5

5 Flashes

EB DRIVER KO

CONDITION Electric brake does not release or remains released at all times.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Damaged or loose electrical connection to brake.

Verify electrical connection between electric brake and controller.

• Check brake coil for correct coil resistance.

Disconnect brake. Measure brake coil resistance in both directions. Coil resistance should be between 27.36 and 30.24 ohms.

• Damaged controller.

Activate the brake switch. Use voltmeter to measure voltage on wire 2C and 17 with brake connected in circuit. If both measurements are 24V and the alarm is displayed, then controller is damaged.

18

LOGIC Occurs when brake driver circuit is shorted or open circuit.

2200 SRM 1006

Troubleshooting

Dash Display

Controller LED

Handset or PC

AL6

6 Flashes

VFIELD NOT OK

CONDITION Voltage measured at field connections is not correct.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Cable connection to motor field is loose or damaged.

Verify connection of field wires to motor and controller.

• Check condition of crimps on wires connecting to F1 and F2.

LOGIC This fault occurs when the voltage measured at the field connections is not the expected value.

19

Troubleshooting

2200 SRM 1006

Dash Display

Controller LED

Handset or PC

AL6

6 Flashes

I = 0 EVER

CONDITION Motor current levels do not exceed a preset minimum value while driving.

TRUCK RESPONSE Traction and hydraulic function disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Damaged or loose electrical connections to traction motor.

Verify electrical connections between traction motor and controller.

• Traction motor armature resistance is too low.

Check traction motor armature for shorts.

• Controller is damaged.

Cycle key switch. Place steer handle in drive position and select throttle. If the truck starts to drive but then stops and presents code AL6, replace controller.

LOGIC Occurs if while driving, the motor current does not exceed a preset minimum value.

20

2200 SRM 1006

Troubleshooting

Dash Display

Controller LED

Handset or PC

AL6

6 Flashes

HIGH FIELD CURR, BW HIGH FLD CURR, FW HIGH FLD CURR

CONDITION High field current values measured by controller.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Field wires are loose, damaged, or shorted.

Verify connection of field wires to motor and controller.

• Motor field winding is shorted or too low.

Check motor field for correct resistance and continuity. It should measure approximately 0.5 ohms.

• Failure of current sensor in controller.

Replace controller.

• Failure of field current driver in controller.

Replace controller.

LOGIC Measured field current is too high.

21

Troubleshooting

2200 SRM 1006

Dash Display

Controller LED

Handset or PC

AL6

6 Flashes

NO FIELD CURR

CONDITION Low field current values measured by controller.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Cable connection to motor field is loose or damaged.

Verify connection of field wires to motor and controller.

• Motor field winding is open or too high.

Check motor field for correct resistance and continuity. It should measure approximately 0.5 ohms.

• Field current sensor in controller has failed.

Replace controller.

• Main contactor circuit damaged or disconnected.

Verify electrical connection between controller and contactor.

Check contactor coil for correct resistance of 53.4 ohms.

• Field current drivers in controller are damaged.

Replace controller.

LOGIC Measured field current is too low.

Dash Display

Controller LED

Handset or PC

AL6

6 Flashes

STBY I HIGH

CONDITION Controller detects motor current during standby mode.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Damaged controller.

Replace controller.

LOGIC Occurs if controller detects motor currents during standby mode.

22

2200 SRM 1006

Troubleshooting

Dash Display

Controller LED

Handset or PC

AL7

7 Flashes

THERMAL PROTECTION

CONDITION Controller temperature is out of operating range.

TRUCK RESPONSE Traction functions reduced below 10 C (14 F) and above 75 C (167 F). Traction and hydraulic functions disabled above 90 C (194 F).

POSSIBLE CAUSES AND TEST PROCEDURES • Controller temperature is too hot/cold.

Move truck to cooler or warmer location and allow controller to return to operating temperature.

• Controller temperature miscalibrated.

Install handset. Go to tester function and check temperature. Controller and vehicle temperature should be same as room temperature at initial startup. If these temperatures differ, replace controller.

• Controller temperature sensor damaged.

Replace controller.

• Controller damaged.

Replace controller.

LOGIC This alarm is generated when the controller temperature outside is 10 to 75 C (14 to 167 F).

23

Troubleshooting

2200 SRM 1006

Dash Display

Controller LED

Handset or PC

AL8

8 Flashes

POWER FAILURE #1

CONDITION Short circuit in device connected to controller.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Overcurrent detected in driven component.

Check main harness for damaged or shorted connections to main contactor, brake, and electric valve coils.

Check main contactor, brake, and electric valve coils for correct resistance values.

Check contactor coil for correct resistance of 53.4 ohms.

Check the brake coil for the correct resistance.

Resistance should be between 27.36 and 30.24 ohms.

Check the electric valve coils for correct resistance of 17.7 ohms.

LOGIC Occurs when controller detects short circuit in component driven by controller.

Value should be within ±10% at room temperature.

Dash Display

Controller LED

Handset or PC

AL10

LED ON (No Flashing)

EEPROM KO

CONDITION Fault in the memory area where parameters are stored.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Controller damaged.

Cycle key switch OFF and ON. If fault remains, replace controller.

LOGIC Occurs if controller discovers fault in the area of memory where parameters are stored.

24

2200 SRM 1006

Troubleshooting

Dash Display

Controller LED

Handset or PC

AL10

LED ON (No Flashing)

CAPACITOR CHARGE

CONDITION Main controller capacitors did not charge within 500 ms of key ON. TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Loose or damaged wire connection.

Inspect and confirm wire connections at contactor, pump motor, and traction motor.

• Short circuit in harness.

Disconnect main harness and check for shorts.

• Short circuit in component coil.

Disconnect battery. Disconnect all drive motor, pump motor, solenoid, brake, and coil connections at the component end of the harness. Tape or secure the wire ends to prevent shorts.

Discharge controller by placing 200 ohm, 2W resistor across B+ and B terminals. Reconnect battery and turn key ON. Use voltmeter to observe voltage across B+ and B . If there is no voltage increase, replace controller. If there is a steady voltage increase to battery voltage, connect each accessory one at a time until the fault occurs to identify damaged component.

• Damaged controller.

Replace controller.

LOGIC Occurs when an internal or external short or open prevents the main capacitors from charging at key ON.

25

Troubleshooting

2200 SRM 1006

Dash Display

Controller LED

Handset or PC

AL10

LED ON (No Flashing)

VMN NOT OK

CONDITION Measured voltage at traction motor inputs does not match battery voltage.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Loose or damaged cable connections to motor.

Verify motor armature cables and connections.

• Ground between motor windings and chassis.

Check for grounds between motor chassis and terminals.

• Damaged controller.

Voltage at –T terminal on controller should be the same as the +B terminal.

Replace controller.

LOGIC Occurs when controller observes differences between battery voltage and voltage supplied to the traction motor.

26

2200 SRM 1006

Troubleshooting

Dash Display

Controller LED

Handset or PC

AL10

LED ON (No Flashing)

VFIELD NOT OK

CONDITION Voltage measured at field connections is not correct.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Cable connection to motor field is loose or damaged.

Verify connection of field wires to motor and controller.

• Motor field winding is shorted to chassis.

Check motor field for shorts to chassis.

Measure motor field resistance. Motor field should be approximately 0.5 ohms.

• Field current driver circuit has failed.

Use a voltmeter to measure between F1 and B and F2 and B with battery connected and key ON. Voltage should measure 1/2 the voltage between B+ and B .

Replace controller.

• Field current drivers in controller are damaged.

Replace controller. Verify motor field cable connections.

LOGIC This fault occurs when the voltage measured at the field connections is not the expected value.

Dash Display

Controller LED

Handset or PC

AL10

LED ON (No Flashing)

WATCHDOG

CONDITION Watchdog hardware circuit is not OK. TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Watchdog hardware circuit is damaged.

Cycle key switch OFF then ON. If alarm returns, replace controller.

LOGIC Occurs if the watchdog hardware circuit is damaged.

27

Troubleshooting

2200 SRM 1006

Dash Display

Controller LED

Handset or PC

AL10

LED ON (No Flashing)

Driver Shorted

CONDITION Voltage measured at field connections is not correct.

TRUCK RESPONSE Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES • Cable connection to motor field is loose or damaged.

Verify connection of field wires to motor and controller.

• Motor field winding is shorted to chassis.

Check motor field for shorts to chassis.

Measure motor field resistance. Motor field should be approximately 0.5 ohms.

• Main contactor coil shorted/open.

Check contactor coil for correct resistance of 53.4 ohms.

• Field current driver circuit has failed.

Use a voltmeter to measure between F1 and B and F2 and B with battery connected and key ON. Voltage should measure 1/2 the voltage between B+ and B .

Replace controller.

• Field current drivers in controller are damaged.

Replace controller. Verify motor field cable connections.

28

LOGIC This fault occurs when the voltage measured at the field connections is not the expected value.

2200 SRM 1006

Troubleshooting

Dash Display

Controller LED

Handset or PC

AL94

OFF

NONE

CONDITION Controller is installing hourmeter memory from MDI display if controller has been replaced.

TRUCK RESPONSE Traction and hydraulic functions disabled for 1 minute.

POSSIBLE CAUSES AND TEST PROCEDURES • No fault is occurring.

Controller will send hourmeter data to MDI and truck will operate as soon as transfer is complete.

Wait approximately 60 seconds.

LOGIC Synchronize hourmeter data between MDI and controller.

29

ZAPI™ PC Interface

2200 SRM 1006

ZAPI™ PC Interface CONNECTING PC TO ZAPI™ CONTROLLER NOTE: Values used on the following figures are for example only. For the correct values for your truck, see Controller Parameters in this section.

1. Turn the key switch to the OFF position.

2. Remove the drive unit compartment cover to access the controller.

3. Locate the communications port on the controller. (The port will have either a diagnostic LED, as in Figure 5, or a connector for the display, as in Figure 6.)

Figure 7. Controller Connection

Figure 8. PC Connection Figure 5. Diagnostic LED

5. Locate the icon for the ZAPI™ software on the PC and double-click on it. See Figure 9.

Figure 9. ZAPI™ Icon

Figure 6. Display Connection 4. Connect the interface cable to the controller and the PC. See Figure 7 and Figure 8.

30

6. You should now see a screen as shown in Figure 10.

2200 SRM 1006

ZAPI™ PC Interface

Figure 10. ZAPI™ Software Screen 7. Click on the START button first and then turn the key switch to ON. See Figure 11.

Figure 11. Start Button

31

ZAPI™ PC Interface

2200 SRM 1006

8. If the connection was successful, you should now see the screen shown in Figure 12. If you get an error message, go back to Step 7 and try again.

Explanation of Screen Connected To:

MPB NA V1.01

This tells the current software revision.

Nominal Voltage:

24V

Voltage of the controller installed.

Nominal Current:

180A

Maximum operating current of the controller.

Hour:

0h

Internal hourmeter of the controller.

Alarm: Connection Status:

If there is a current "live" error in the controller, the alarm code will appear here.

CONNECTED

Indicates if the software is communicating with the PC.

Figure 12. ZAPI™ Software Version Screen

32

2200 SRM 1006

ZAPI™ PC Interface

FILE MENU Open File When you select this function, you will be able to open a previously saved file that contains parameter settings for the controller. See Figure 13.

Figure 13. File - Open

33

ZAPI™ PC Interface

2200 SRM 1006

Note that the previously saved file has the .csv extension, and observe how the file name was used. See

the Save File section of this manual for proper file saving techniques. See Figure 14.

Figure 14. Look In:

TX From File This selection in the file menu is similar to the File Open selection. See Figure 15.

Figure 15. File - TX From File

34

2200 SRM 1006

ZAPIâ„¢ PC Interface

Notice the CONNECTION STATUS while the file is downloaded into the controller. See Figure 16.

Figure 16. Connection Status

35

ZAPI™ PC Interface

2200 SRM 1006

Save File The ZAPI™ PC software can save configurations for up to 500 controllers. When saving a configuration

to the PC, the following steps should be followed to help track which file goes with each controller. See Figure 17.

Figure 17. File - Save 1. Try to use the actual truck serial number and put the word "settings" after it. (This is to keep the

controller settings file separate from the tester function Save file.) See Figure 18.

Figure 18. Save: In

36

2200 SRM 1006

ZAPIâ„¢ PC Interface

2. Once you select a file name and click on Save, you will see the screen shown in Figure 19.

3. Under the Enter a Comment box, you can either describe what is different with the settings or enter a customer name.

Here is what a saved parameter file looks like: [Info] Chopper_Name=MPB NA V1.01 User_Comment=modified mode 4 to lower speed and coast more Save_Date=Thu Apr 04 15:58:15 2002

0;ACCELER.DELAY;0;0;0;LEVEL=0 5;DECELER.DELAY;1;0;9;LEVEL=9 11;RELEASE BRAKING;2;0;0;LEVEL=9 12;INVERS.BRAKING;3;0;9;LEVEL=9 30;MAX SPEED FORW;4;0;9;LEVEL=9 31;MAX SPEED BACK;5;0;9;LEVEL=9 248;DRIVE MODES ;01;1;ON [End] [Validation] Code=FFDA [Stop]

[Code;Name;Position;Menu;Value;Scaled Value]

Figure 19. Enter a Comment

37

ZAPI™ PC Interface

2200 SRM 1006

Print Settings This selection allows you to print out your current parameter settings in the controller. See Figure 20.

Figure 20. File - Print

38

2200 SRM 1006

ZAPI™ PC Interface

Exit This selection will exit the ZAPI™ PC console software. See Figure 21.

Figure 21. File - Exit

39

ZAPI™ PC Interface

2200 SRM 1006

CONNECTION MENU There are two selections under this menu: 1. Start - Starts the connection between the controller and PC (operates the same as the main Start button on the right-hand side of the display screen).

2. Stop - Stops the connection between the controller and PC (operates the same as the main Stop button on the right-hand side of the display screen).

See Figure 22.

Figure 22. Connection Menu

FUNCTION MENU There are seven selections under this menu: 1. Parameter - Allows the performance and configuration of the controller to be adjusted. Refer to Parameter, in this section.

2. Tester - Allows the testing of various inputs and operations of the controller. Refer to Tester, in this section.

40

3. Alarm Logbook - Stores alarms that the controller detects. Refer to Alarm Logbook, in this section.

4. Program VACC - Not Used.

5. Motor Data - Not Used.

6. Ram Function - Only Factory Use. 7. EEPROM Function - Only Factory Use.

2200 SRM 1006

ZAPI™ PC Interface

Parameter When you first activate this selection, the screen will look as indicated in Figure 23. In order to see the parameters of the controller, you have to download them to the PC. This can be done by 1 of 2 ways.

1. Receive menu - This will only download the current selected tab.

2. Receive - This will download all parameters and configurations to the PC so you can adjust them.

Figure 23. Parameter You will now see a screen like Figure 24, while the data are being downloaded.

Figure 24. Downloading Screen

41

ZAPI™ PC Interface

2200 SRM 1006

Now that the parameters have downloaded, you should see a screen as indicated in Figure 25.

Please note that the current drive mode the lift truck was in will be displayed. (There are three modes that cannot be adjusted.) In order to make any changes to the parameters, you must turn on Mode 4, which is covered in Set Options, in this section.

Adjustments can be made by first highlighting the parameter to be modified and then using the scroll bar on the right side of the screen to adjust it.

You will also notice that there are six tabs along the top to choose from: 1. Parameter Change - Allows the performance of the truck to be adjusted.

2. Set Options - Allows the technician to turn on or off mode 4 for personalized performance settings.

See Set Options.

3. Set Model - Not Used.

4. Adjustment - Not Used.

5. Special Adjust - Not Used.

6. Hardware settings - Not Used.

Figure 25. Drive Mode

42

2200 SRM 1006

ZAPI™ PC Interface

There are six parameters that can be adjusted to affect the performance of the lift truck. See Figure 26.

1. ACCELER. DELAY - Amount of ramp-up to full speed.

• Level 0 - Large acceleration curve, up to full speed.

• Level 9 - Short acceleration curve, up to full speed.

2. DECELER. DELAY - Amount of ramp-down to a lower speed.

• Level 0 - Large deceleration curve, to a lower speed (coasting).

• Level 9 - Short deceleration curve, to a lower speed (aggressive).

• Level 0 - Minimum braking (coasting).

• Level 9 - Maximum braking (aggressive).

4. INVERSE BRAKING - Amount of braking when the lift truck is "plugged."

• Level 0 - Minimum braking.

• Level 9 - Maximum braking.

5. MAX SPEED FORW - Maximum speed of the lift truck in the handle direction.

• Level 0 - Minimum speed.

• Level 9 - Maximum speed.

6. MAX SPEED BACK - Maximum speed of the lift truck in the forks direction.

• Level 0 - Minimum speed.

• Level 9 - Maximum speed.

3. RELEASE BRAKING - Amount of braking when the accelerator is released.

Figure 26. Adjustable Parameters

43

ZAPI™ PC Interface

2200 SRM 1006

Notice that the ACCELER. DELAY function has been adjusted. The parameter settings are "live," which means as they are being adjusted. The lift truck will react to the setting. Once the lift truck is performing as wanted, the Store button is pressed to save the settings into the controller. See Figure 27.

NOTE: If the Store button is not pressed before turning off the lift truck, then all changed parameters will be lost.

Figure 27. Store Button

44

2200 SRM 1006

ZAPI™ PC Interface

Memory Menu If you wish to start all over with your adjustments prior to pressing the Store button, then you can select the Memory menu to see the screen in Figure 28.

2. Store - Same as Store button.

3. Restore - Will revert the parameter settings to what they were before adjustments were made.

Note this will not work if the settings were stored before using this function.

This menu has three selections: 1. Receive - Same as Receive menu and Receive button.

Figure 28. Memory Menu

45

ZAPI™ PC Interface

2200 SRM 1006

Set Options This selection will allow Mode 4 to be activated, so that the performance parameters can be adjusted for a custom configuration. See Figure 29.

Figure 29. Set Options

46

2200 SRM 1006

ZAPI™ PC Interface

Highlight Drive Modes and then click on the scroll bar to the right and select OFF. See Figure 30.

Do the following steps once this has been done: 1. Press the Store button to save the change into the controller.

2. Press the Close button to go to the main screen of the ZAPI™ PC software.

3. Press the Stop button to disconnect the communication between the PC and the controller.

4. Turn the key switch on the lift truck to OFF; then do the reconnect procedure.

5. Now the parameters in the Function Menu can be adjusted to a custom configuration (Mode 4).

Figure 30. Turn Off Drive Modes

47

ZAPI™ PC Interface

2200 SRM 1006

Tester This selection allows the technician to monitor up to four items at a time to help troubleshoot problems.

See Figure 31.

The Tester function also features a data-logging capability to further assist the technician and the factory with problems.

Figure 31. Tester

48

2200 SRM 1006

ZAPI™ PC Interface

The PC software can test the following (four selections at a time). See Figure 32.

1. Battery Voltage - voltage across the battery.

2. Motor Voltage - voltage across the traction motor.

3. Motor Current - current through the traction motor.

4. Field Current - current through the fields in the traction motor.

5. Temperature - current temperature of the controller.

6. Accelerator - voltage and percent of "throw" from the traction thumbwheel.

7. Lifting Control 8. Tiller Switch - position of tiller handle.

9. Forward Switch - directional input.

10. Backward Switch - directional input.

11. Lifting Switch - refers to switch on right side of tiller head.

12. Lowering Switch - refers to switch on right side of tiller head.

13. Fork Lift Switch - refers to switch on left side of tiller head.

14. Fork Lower Switch - refers to switch on left side of tiller head.

15. Belly Switch 16. Snail Switch 17. Horn Switch 18. Cutback Switch 19. Lifting Block 20. Battery Model 21. Battery Charge - remaining charge on the battery.

Figure 32. Test Name

49

ZAPI™ PC Interface

2200 SRM 1006

Data Logger In addition to "live testing" of the controller, the ZAPI™ PC software also includes a data-logging capability. See Figure 33. There are four buttons associated with this, as listed below.

1. Advanced - Allows the user to select sample rates and length of recording.

2. Start Rec. - Starts the data logger.

3. Stop Rec. - Stops the data logger.

4. Save Rec. - Saves the log to a file.

Figure 33. Data Logger The Advanced button allows the user to select time increments and the number of samples. See Figure 34.

Figure 34. Tester Advanced

50

2200 SRM 1006

ZAPI™ PC Interface

As the data logger is running, the screen will look like what is shown in Figure 35. During the logging

process, you will still be able to see the values changing in the display menu.

Figure 35. Logging Process

51

ZAPIâ„¢ PC Interface

2200 SRM 1006

Once the data logger is done, you can save the log using the Save Rec. button. See Figure 36.

Figure 36. Save As Once the log file has been saved, the user can either analyze the data him/herself or e-mail the file to the factory for analysis.

The raw data file looks like this (see Figure 37): [Info] Chopper_Name=CS P20 V1.00 Save_Date=Thu Apr 04 13:32:24 2002 TIME;MOTOR CURRENT;ACCELERATOR;BATTERY CHARGE ;FIELD CURRENT; 0;0;0.00

0;80;0.0;

10;0;0.00

0;80;0.0;

20;0;0.00

0;80;0.0;

30;0;0.00

0;80;0.0;

40;0;0.00

0;80;0.0;

50;0;0.00

0;80;7.2;

60;3;0.00

0;80;7.2;

70;3;0.27

10;80;7.2;

80;3;0.27

10;80;12.7;

90;8;0.53

16;80;12.7;

Figure 37. Test Data

52

2200 SRM 1006

ZAPI™ PC Interface

Alarm Logbook The ZAPI™ controller can record up to five unique alarms and store them in a logbook that the PC can access. See Figure 38.

Figure 38. Alarm Logbook

53

ZAPIâ„¢ PC Interface

2200 SRM 1006

The display screen (Figure 39) will display any current "live" alarms. Note the display ACTUAL ALARM that indicates a current "live" alarm condition.

The PC software will provide the alarm name and the number of times it has occurred, the temperature of the controller when the alarm occurred, and the hourmeter reading (internal to the controller) of when the alarm occurred.

The user can check for new alarms by pressing the Update key or clear out the alarm log by pressing the Clear key.

The following list consists of possible alarms.

Alarms 1.

2.

3.

4.

EVP NOT OK BRAKE DRIVER KO VFIELD NOT OK PUMP VACC NOT OK

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

SERIAL ERROR #1 WATCHDOG EEPROM KO FORW + BACK VMN NOT OK CONTACTOR CLOSED I=0 EVER STBY I HIGH HIGH FIELD CURRENT NO FIELD CURRENT CAPACITOR CHARGE LOW BATTERY THERMAL PROTECTION CHARGING BATTERY POWER FAILURE #1 DRIVER SHORTED CONTACTOR DRIVER VACC NOT OK INCORRECT START INPUT ERROR #2 INPUT ERROR #1

Figure 39. Actual Alarm

54

2200 SRM 1006

Repair

Repair REMOVE

2. Remove brass stud from controller.

1. Park lift truck in a safe, level area.

Install

2. Block drive wheel to prevent lift truck from moving.

The stud must be installed in the correct orientation with regard to the relief groove.

3. Connect handset or PC and download parameters, if possible.

1. Install brass stud onto controller and tighten to 10 to 11 N•m (92 to 97 lbf in).

4. Turn key to OFF.

2. Install brass washer, power fuse, brass washer, flat washer, lockwasher, and M8 nut to brass stud. Tighten M8 nut to 10 to 11 N•m (92 to 97 lbf in).

5. Disconnect battery.

6. Remove cover.

WARNING The capacitors in the controller remain charged for several minutes after operation.

To prevent personal injury and/or damage to equipment, the controller should be discharged. To discharge the controller, connect a 200-ohm, 2- to 3-watt resistor between the battery positive and negative terminals on the controller for at least 5 seconds. Refer to Figure 1 in the General section of this manual.

7. Discharge controller.

8. Identify and tag all power cables and wires connected to controller for later installation.

INSTALL 1. Align controller to plate and capscrews. Tighten capscrews.

2. Connect all power cables and wires connected to controller.

3. Connect battery.

4. Connect handset or PC. 5. Turn key to ON. 6. Upload parameters.

7. Remove blocks from drive wheel.

9. Remove all power cables and wires connected to controller.

8. Test lift truck in a safe, level area away from other personnel and equipment.

10. Loosen both capscrews retaining controller to plate.

9. Install cover.

REPAIR 11. Remove controller.

1. Replace fuses.

BRASS STUD REPLACEMENT Remove

2. Replace controllers by following the remove and install procedures listed above.

1. Remove M8 nut, lockwasher, flat washer, brass washer, power fuse, and brass washer from brass stud.

55

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

56