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Electrical System Checks

  WARNING 

Disconnect  the  battery  before  opening  the  com-
partment cover or inspecting or repairing the elec-
trical  system.  If  a  tool  causes  a  short  circuit,  the
high current flow from the battery can cause per-
sonal injury or property damage.

The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted.  To  prevent  electrical  shock  and  personal  in-
jury, discharge the capacitor before inspecting or
repairing  any  component  in  the  drive  unit  com-
partment.  Wear  safety  glasses.  Make  certain  the
battery has been disconnected.

All checks, adjustments, and repairs in the drive unit com-
partment  are  done  with  the  compartment  cover  removed.
Remove the drive unit compartment cover for access to the
electrical components.

SAFETY PRECAUTIONS

  WARNING 

Some  checks  require  the  battery  to  be  reconnec-
ted.  DO  NOT  connect  the  battery  until  the  proce-
dure tells you to do so. Make sure the drive wheel
is raised to prevent truck movement and possible
injury.  Raise  the  drive  wheel.  The  blocks  must
prevent the lift truck from falling and causing per-
sonal injury or property damage.

  CAUTION

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

1. 

Block  lift  truck  so  the  drive  tire  is  raised  slightly  off
the floor to prevent unexpected movement when mak-
ing checks.

  WARNING 

DO  NOT  put  the  lift  truck  on  blocks  unless  the
surface is solid, even, and level. Make sure that all
blocks  used  to  support  the  lift  truck  are  solid,

one-piece  units.  Put  a  block  in  front  and  back  of
the tire or wheels touching the ground to prevent
unexpected movement of the lift truck.

  WARNING 

DO  NOT  raise  the  lift  truck  by  attaching  an  over-
head  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 dam-
aged  or  it  can  fall,  causing  serious  injury.  Attach
the chain or sling to a support structure of the lift
truck frame.

  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
or  unevenly  can  cause  the  lift  truck  tip  over  and
cause personal injury or property damage.

2. 

Use a crane or jack to raise the forks or motor compart-
ment assembly. Put blocks under the forks or the edge
plates  of  the  motor  compartment  assembly.  See  Fig-
ure 5. 
Make sure the lifting device has a capacity of at
least two-thirds (2/3) of the combined weight of the lift
truck and the battery as listed on the nameplate.

3. 

Turn  the  key  switch  to  the 

OFF

  position  and  discon-

nect the battery.

4. 

Discharge  the  capacitors.  See  Special  Precautions  in
this section.

NOTE:  

These checks require a volt-ohmmeter with a me-

ter  movement.  Most  digital  meters  will  not  operate  cor-
rectly for some of these checks. Specific checks require ad-
ditional equipment.

NOTE:   

The  correct  meter  polarity  is  necessary  for  the

checks. The voltage checks are made between the point in-
dicated in Table 1 and battery negative. Connect the meter
negative to battery negative.

NOTE:  

The battery does not have to be removed to check

the specific gravity.

5. 

Using  a  hydrometer,  check  the  specific  gravity  of  the
battery.  If  the  specific  gravity  is  less  than  1.260,  the
battery  is  not  fully  charged  or  is  damaged.  A  fully-
charged  battery  has  a  specific  gravity  of  1.270  to
1.290.  A  discharged  battery  has  a  specific  gravity  of
approximately 1.165.

Electrical System Checks

2200 SRM 1640

4

Содержание B262

Страница 1: ...Hyster B262 B60ZHD B80ZHD Forklift...

Страница 2: ...ELECTRICAL SYSTEM B60ZAC C230 B60ZHD B262 B80ZHD B257 PART NO 4096092 2200 SRM 1640...

Страница 3: ...iodic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use HYSTER APPROVED parts when...

Страница 4: ...ht Limit 12 Control Handle Standard 12 Disassemble 12 Assemble 13 Control Handle HD Option 15 Disassemble 15 Remove Top Cover 15 Remove Function Switches 15 Remove Throttle Sensor Assembly 15 Remove H...

Страница 5: ...ore information Please click here Then get the complete manual NOTE If there is no response to click on the link above please download the PDF document first and then click on it Have any questions pl...

Страница 6: ...TABLE OF CONTENTS Continued Troubleshooting 24 This section is for the following models B60ZAC C230 B60ZHD B262 B80ZHD B257 Table of Contents Electrical System ii...

Страница 7: ...the control handle and disconnect the battery This section describes the electrical systems used on the motorized hand lift trucks Procedures are outlined for the maintenance adjustment and repair th...

Страница 8: ...around the edge of the cover until it is freed from the truck 1 FLOOR MAT 2 DRIVE UNIT COMPARTMENT COVER 3 FRAME 4 CASTER ADJUSTMENT ACCESS Figure 2 Floor Mat 1 DRIVE UNIT COMPARTMENT COVER 2 RETAININ...

Страница 9: ...rom the truck connector 3 Remove the operator compartment cover 4 Discharge the internal capacitor in the controllers by connecting a 200 ohm 2 watt resistor across the con troller B and B terminals o...

Страница 10: ...olid one piece units Put a block in front and back of the tire or wheels touching the ground to prevent unexpected movement of the lift truck WARNING DO NOT raise the lift truck by attaching an over h...

Страница 11: ...between each terminal of the con nector that fastens to the battery and a clean connection on the frame Normally there is small voltage less than 30 percent of the battery voltage between the bat ter...

Страница 12: ...ttery voltage at control fuse Connect bat tery or check wiring between battery and fuse 1 1 Check for battery voltage at control fuse terminal of key switch 1 1 1 Battery voltage at key switch Check f...

Страница 13: ...jumper wire is re moved and cycle the key switch to the OFF position and then back to the ON position 8 Check the lift truck for proper operation Reinstall the drive unit compartment cover Repairs WAR...

Страница 14: ...itors in this section 4 Tag and disconnect wires from the controller See Fig ure 6 5 Remove nuts securing shield box to controller if equip ped 6 Remove mounting screws and remove controller Install 1...

Страница 15: ...battery is disconnec ted To prevent electrical shock and personal in jury discharge the capacitor before inspecting or repairing any component in the drive unit com partment Wear safety glasses Make c...

Страница 16: ...n and disconnect the battery again to finish repairs 8 Install the drive unit compartment covers as removed See GeneralGeneral in this section Return the lift truck to service Brake Switch Operation T...

Страница 17: ...ng on model To replace the brake switch es WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnec ted To prevent electrical shock and personal...

Страница 18: ...the controller When the controller senses a high current draw from the hydraulic pump it will shut down the pump There are two separate incidents that will cause this current draw The first is when t...

Страница 19: ...to the handle 8 8 Using the remaining butterfly knob slide the shaft out of the handle Be careful not to rotate the shaft within the control handle card 9 Refer to the wiring diagram or draw a sketch...

Страница 20: ...BUTTERFLY KNOB 7 WASHER 8 SCREW 9 SPRING 10 RH BUTTERFLY KNOB 11 SWITCH COVER 12 SPRING 13 SWITCH 14 HORN SWITCH COVER 15 SWITCH ASSEMBLY 16 LABEL 17 LABEL 18 LABEL 19 ACTUATOR 20 ACTUATOR 21 SPRING 2...

Страница 21: ...applying pressure to the tabs on one side of the switch mount and slightly lifting the switch mount away from the retainer Once clear remove the switch mount from the top cover 4 Remove the pin retain...

Страница 22: ...rom the handle casting and maneuver the link to disconnect it from the throttle sleeve 5 Slide the grips from the shaft Recover the locking rods from inside the grips if equipped 6 Move the butterfly...

Страница 23: ...ly 2 Connect the wiring removed during disassembly 3 Install the actuator and two springs into the cover 4 Place the switch base on the cover and install the as sembly to the handle with the two screw...

Страница 24: ...throttle sensor to the base using the cap screws washers and nuts removed during disassem bly Ensure the tang on the sensor aligns correctly with the shaft on the bottom assembly 7 Torque the capscre...

Страница 25: ...s analog signals from the con trol handle to digital signals for the controller to read If the controller is reporting an input error fault code then the control module may be malfunctioning Check the...

Страница 26: ...ents See the section Periodic Maintenance 8000SRM1644 3 Discharge the capacitors See Discharging the Internal Capacitors in this section 4 Disconnect all connectors from the control module 5 Remove ca...

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