Hyster B234 Service & Repair Manual
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Hyster B234 Service & Repair Manual

Hyster B234 Service & Repair Manual

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Hyster B234 (W60Z, W65Z, W80Z) Forklift

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Summary of Contents for Hyster B234

  • Page 1 Hyster B234 (W60Z, W65Z, W80Z) Forklift...
  • Page 2 ELECTRICAL SYSTEM B60Z [A230]; W60Z [A231, B231]; W65Z [A229, B229]; W80Z [A234, B234]; B80Z [A233] PART NO. 1492462 2200 SRM 0929...
  • Page 3 • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex- ceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

  • Page 4: Table Of Contents

    Short Circuit in an Armature Winding ......................33 Short Circuit in the Armature ..........................34 Open Circuit in a Field Coil ..........................34 Short Circuit in a Field Coil ..........................34 Short Circuit Between Field and Motor Case ....................35 Brush Holder ..............................35 ©2016 HYSTER COMPANY...
  • Page 5 Thanks very much for your reading, Want to get more 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 please write to me: admin@servicemanualperfect.com...
  • Page 6 Table of Contents TABLE OF CONTENTS (Continued) Troubleshooting ..............................35 This section is for the following models: (B60Z) [A230]; (W60Z) [A231, B231]; (W65Z) [A229, B229]; (W80Z) [A234, B234]; (B80Z) [A233]...

  • Page 7: General

    2200 SRM 0929 General General This manual describes the electrical systems used WARNING on the motorized hand lift trucks. Procedures are outlined for the maintenance, adjustment, and DO NOT make repairs or adjustments unless you repair that may be required when servicing these have both authorization and training.
  • Page 8 General 2200 SRM 0929 1. TRACTION MOTOR 10. PUMP CABLE (NEG.) 2. ELECTRIC BRAKE 11. WIRE HARNESS-MAIN 3. DRIVE UNIT 12. CABLE (POS.) 4. HYDRAULIC UNIT 13. CABLE (A1) 5. HORN 14. CABLE (A2) 6. IGNITION SWITCH 15. CABLE (F1) 7.
  • Page 9 2200 SRM 0929 General 1. TRACTION MOTOR 12. GRAB RAIL 2. ELECTRIC BRAKE 13. CONTROL BOX 3. DRIVE UNIT 14. WIRE HARNESS-HANDRAIL 4. HYDRAULIC UNIT 15. WIRE HARNESS-MAIN 5. HORN 16. CABLE (POS) 6. IGNITION SWITCH 17. CABLE (A1) 7. BATTERY GAGE/SPYGLASS 18.
  • Page 10 General 2200 SRM 0929 1. WASHER 19. LOCKWASHER 2. LOCKWASHER 20. NUT 3. CAPSCREW 21. NUT 4. CAPSCREW 22. LOCKWASHER 5. WASHER 23. NUT 6. LOCKWASHER 24. SCREW 7. WASHER 25. CONVERTER - 12 V ONLY 8. SCREW 26. WASHER 9.

  • Page 11: Electrical System Checks

    2200 SRM 0929 Electrical System Checks Electrical System Checks 3. Discharge capacitors in controllers by connect- WARNING ing a 200-ohm, 2-watt resistor across the con- troller's B+ and B- terminals. See Figure 4. DO Disconnect the battery and separate the connec- NOT short across the motor controller termi- tor before opening the compartment cover or in- nals with a screwdriver or jumper wire.
  • Page 12 Electrical System Checks 2200 SRM 0929 4. Using a hydrometer, check the specific gravity 6. Check for voltage between each terminal of the of the battery. If the specific gravity is less than connector that fastens to the battery and a 1.260, the battery is not fully charged or is clean connection on the frame.

  • Page 13: Repairs

    2200 SRM 0929 Repairs Repairs WARNING DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so. Improper repairs and adjustments can create dangerous operating conditions. DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately.

  • Page 14: Controller, Replace

    Repairs 2200 SRM 0929 2. Connect wires and cables to the proper termi- CONTROLLER, REPLACE nals as identified during the removal proce- dure. WARNING 3. Connect battery, turn the key switch to the ON Some checks require the battery to be connected. position, and turn parking brake to the OFF DO NOT connect the battery until the procedure position.
  • Page 15 2200 SRM 0929 Repairs 1. WASHER 14. BUSS BAR 2. LOCKWASHER 15. FUSE HOLDER 3. CAPSCREW 16. STAND-OFF 4. CAPSCREW 17. CONTROLLER 5. WASHER 18. CONTACTOR 6. LOCKWASHER 19. LOCKWASHER 7. WASHER 20. NUT 8. SCREW 21. NUT 9. SCREW 22.

  • Page 16: Contactor Tips, Replace

    Repairs 2200 SRM 0929 3. Remove cover, moving contact (2), and return CONTACTOR TIPS, REPLACE spring. 4. Remove capscrews, washers, and nuts that CAUTION make up the fixed contactor tips (1) from the All contactor tips must be replaced at the same top cover.
  • Page 17 2200 SRM 0929 Repairs Legend for Figure 7 1. FIXED CONTACTS 2. MOVING CONTACTS 3. TOP COVER 4. SCREW 5. RETURN SPRING 6. COIL AND FRAME 7. END CAP Figure 7. Contactor...

  • Page 18: Fuses

    Fuses 2200 SRM 0929 Fuses WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnec- ted. To prevent electrical shock and personal in- jury, discharge the capacitor before inspecting or repairing any component in the drive unit com- partment.

  • Page 19: Brake Switch - W60Z, W65Z, W80Z, B60Z (→Aug. 2003) And B80Z (→Aug. 2003)

    2200 SRM 0929 Brake Switch - W60Z, W65Z, W80Z, B60Z (→Aug. 2003) and B80Z (→Aug. 2003) Brake Switch - W60Z, W65Z, W80Z, B60Z (→Aug. 2003) and B80Z (→Aug. 2003) The brake switch is normally open until the control REMOVE AND INSTALL handle is moved to the operating position.

  • Page 20: Brake And Interlock Switches - B60Z (Aug. 2003→) And B80Z (Aug. 2003→)

    Brake and Interlock Switches - B60Z (Aug. 2003→) and B80Z (Aug. 2003→) 2200 SRM 0929 Brake and Interlock Switches - B60Z (Aug. 2003→) and B80Z (Aug. 2003→) DISASSEMBLE 1. Position the lift truck on a level surface. Turn the key switch to the OFF position and discon- nect the battery.

  • Page 21: Control Handle

    2200 SRM 0929 Control Handle Control Handle 9. Refer to the wiring diagram, or draw a sketch DISASSEMBLE of where each of the push button switches are plugged into the control handle card. Unplug WARNING switches from the control handle card and re- move the card.

  • Page 22: Control Handle Card (New Style)

    Control Handle 2200 SRM 0929 17. Move the jumper on the J1 terminal to the RUN mode. See Figure 13, 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.
  • Page 23 2200 SRM 0929 Control Handle 1. JUMPER TERMINALS (SV2) 4. LED DISPLAY SCREEN 2. HORN SWITCH (S1) 5. BELLY SWITCH (S) 3. THUMBWHEEL SWITCH (MAGNETIC HOLDER) 6. TURTLE SWITCH (S2) Figure 14. Control Handle Card (New Style) Legend for Figure 15 1.

  • Page 24: Calibrate

    Control Handle 2200 SRM 0929 7. The LED screen will change to show this seg- Calibrate ment complete. See Figure 16, view D. Release the thumbwheel so it returns to the neutral po- Refer to Figure 14 for the following instructions. sition.

  • Page 25: Assemble

    2200 SRM 0929 Control Handle ASSEMBLE CAUTION 1. Install control handle card in the upper half of DO NOT force the upper half onto the lower half control handle. See Figure 17. as this will cause damage to the retaining hooks of the upper half.
  • Page 26 Remote Control Box Switches (B60Z and B80Z) 2200 SRM 0929 1. LOWER HALF 12. SPRING 2. UPPER HALF 13. SWITCH 3. CONTROL HANDLE CARD ASSEMBLY 14. HORN SWITCH COVER 4. SHAFT 15. SWITCH ASSEMBLY 5. BUSHING 16. LABEL 6. LH BUTTERFLY KNOB 17.

  • Page 27: Motor Maintenance - General

    2200 SRM 0929 Motor Maintenance - General Motor Maintenance - General This portion of the electrical section describes dis- to the commutator and the armature. The mainte- assembly and assembly, brush replacement, inspec- nance of the commutator and the brushes is impor- tion, and checks for malfunction of DC motors.
  • Page 28 Brush and Commutator Inspection 2200 SRM 0929 Table 2. Normal Commutator Surfaces A light brown surface of the commutator, where it ro- tates on the brushes, is a normal condition. The sur- face of the commutator must be smooth. Variations between light brown and dark brown col- ors are normal.

This manual is also suitable for:

W60zW65zW80zA230A231A229 ... Show all

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