Hyster B230 (B60ZAC) Pallet Truck Service Manual
565 pages · Publication 1640810-B230
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- Models
- B230 (B60ZAC)
- Manual type
- Service Manual
- Pages
- 565
- Publication
- 1640810-B230
- Condition
- Brand new
What's inside
From the manual's own table of contents: 109 sections, 360 entries. See sample pages (PDF, 226 KB)
Frame
Safety Precautions Maintenance and Repair
General
Frame Separation and Assembly2 topics
- Frame Separation
- Frame Assembly
Painting Instructions
Label Replacement
Walkie Hydraulic Systems
Description of Operation6 topics
- Lifting a Load
- Lowering a Load
- Hydraulic Lines
- Hydraulic Oil
- Clean
- Sound Level
Special Precautions
Hydraulic Reservoir1 topic
- Description
Drive Unit Compartment Covers4 topics
- Remove
- Install
- Remove
- Install
Lift Pump and Motor13 topics
- General
- Remove
- Lift Pump and Motor Assembly
- Disassemble
- Remove Reservoir
- Remove Pump Motor
- Disassemble Pump
- Assemble
- Assemble Pump
- Install Pump Motor
- Install Reservoir to Pump
- Install
- Lift Pump and Motor Assembly
Valve Repair5 topics
- Lowering Valve
- Remove
- Install
- Relief Valve
- Check Valve
Lift Cylinder
Relief Valve Adjustment2 topics
- Relief Valve Pressure Check
- Adjust Relief Valve Pressure
Troubleshooting3 topics
- Lift Assemblies
- Lift Cylinders
- Lift Pump and Motor Assembly
Table 1. Hydraulic Reservoir
Table 2. Relief Valve Settings
Lifting Mechanism
Load Wheel
Caster Wheels3 topics
- Caster Shim Adjustment
- Caster Replacement
- Caster Lubrication
Rear Link and Load Wheel Assembly
Pull Rod3 topics
- End Replacement
- Adjust
- Rear Fork Adjustment
Rocker Arm
Show all 109 sections
Upper Link
Troubleshooting and Adjustments Using the AC Controls Program (E6 topics
- Computer Requirements
- Software, Install
- Language Selection
- Demo Mode
- Connect PC to Lift Truck
- Starting AC Controls Program
Lift Truck Control Setup6 topics
- Change Lift Truck Serial Number or Hourmeter
- Setting Factory Default Values or Changing Lift Truck Parameters
- Create New Custom Lift Truck Configuration
- Lift Truck Configuration Properties
- Import New Lift Truck Configuration From Disk
- Delete Custom Lift Truck Configuration or Password File
Dash Display3 topics
- Custom Display Languages
- Download Display Language
- Clear Operator Log
Password Functions7 topics
- Enable/Disable Password and Lift Truck Inspection Functions
- Truck Inspection Checklist
- Password
- Password Properties
- Create New Password File
- Download Passwords
- Upload Passwords
Reports Menu8 topics
- Devices Report
- Custom Report
- Password Report
- Operator Report
- Current Settings Report
- Status Code Report
- Status Codes Log
- Diagnostics
Help Menu2 topics
- Technical Support
- About Electric Truck AC Controls Program
Steering Mechanism2 topics
- Accessing the Drive Unit Compartment
- Electromagnetic Shield (Power Assist 6/2009⇒)
Calibration1 topic
- Power Assist Steering
Control Handle5 topics
- Control Handle Head
- Control Handle
- Standard Steering
- Power Assist Steering (⇒ 5/2009)
- Power Assist Steering (6/2009 ⇒)
Gas Spring1 topic
- Discharging the Gas Spring
Articulating Shaft and Pinions (Power Assist Models)3 topics
- Pinion Repair
- Upper Pinion
- Lower Pinion
Steer Motor Assembly4 topics
- Repair
- Steer Motor, Replace
- Steer Motor Gear, Replace
- Gearbox/Complete Assembly, Replace
Steer Support Assembly10 topics
- Standard Steering
- Remove (Complete Unit)
- Disassemble
- Assemble
- Install (Complete Unit)
- Power Assist Steering (Option)
- Remove (Complete Unit)
- Disassemble
- Assemble
- Install (Complete Unit)
Electronic Coast Control (Option)1 topic
- Checks
Brakes
Description
Brake Check4 topics
- Brake Release
- Brake Apply
- Air Gap
- Hold On Grade Test
Brake Assembly Repair6 topics
- Remove
- Repair
- Install
- Remove
- Repair
- Install
Table 1. Stator Resistance
Table 2. Adjustment Specifications
AC Motor Controller5 topics
- Discharging the Capacitors
- Electrical System
- AC Traction Motor
- Controller
- Service PC Connection
Parameters
Parameter Description18 topics
- Parameters
- Extended Shift
- Walk Speed (Both Directions)
- Hi Speed (FWD)
- Hi Speed (REV)
- Minimum Acceleration
- Maximum Acceleration
- Plugging
- ADS-Neutral
- ADS-Throttle
- Pick Acceleration
- Pick Deceleration
- Battery Full Voltage
- Lift Interrupt
- Non-Status Code Errors
- Powered Black Screen
- Tiller Oscillation and Bias (EPAS Option)
- Status Codes
Electrical Checks4 topics
- General Electrical System Checks
- Static Checks on Power and Ground Connections
- Static Checks on CAN Connections
- Tiller Harness Shorts and Continuity Checks
Control Card Functional Test6 topics
- Startup
- Status LED
- Performance Mode Indicator
- Hourmeter
- Battery Charge Indicator
- Fault Log
Connector Pin-Outs
System Logic Diagram
Table 1. Parameter Default Values
Table 2. Fault Codes
Electrical System1 topic
- Electromagnetic Shield (Power Assist Steering 6/2009⇒)
Electrical System Checks3 topics
- Safety Precautions
- Calibration Mode
- Power Assist Steering Sensor
Repairs5 topics
- Controller, Replace
- Remove
- Install
- Contactor Coil, Check
- Contactor, Replace
Fuses
Horn1 topic
- Replace
Brake Switch Operation
Brake and Interlock Switches - (Manual Steering)
Brake Switch and Handle Position Sensor - (Power Assist Steering4 topics
- Brake Switch(es)
- Handle Potentiometer Sensor (Power Assist Steering ⇒5/2009)
- Disassemble
- Assemble
Height Limit
Control Handle (Standard)
Proximity Switch (Power Assist Steering 6/2009⇒)
Remote Control Box Switches
Motor Tests3 topics
- Excessive Current Draw
- Measuring Current Draw
- Excessive Resistance
Table 1. Voltage Checks
Diagrams
Periodic Maintenance5 topics
- 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
Maintenance Schedule
Maintenance Procedures Every 8 Hours or Daily6 topics
- Checks With Key Switch Turned OFF
- Battery
- Hydraulic Leaks
- Drive Tire, Load Wheels, Casters, and Frame
- Checks With Key Switch Turned ON
- Operation
Maintenance Procedures Every 250 Hours or Every 6 Weeks
Maintenance Procedures Every 500 Hours or Every 3 Months13 topics
- Hydraulic System
- Hydraulic Oil
- Hydraulic Reservoir Breather
- Steering System
- Power Assist Steering
- Lift Linkage and Load Wheels
- Casters
- Caster Shim Check
- Caster Shim Adjust
- Master Drive Unit
- Change Gear Oil
- Check Oil Level
- Drive Tire Check
Maintenance Procedures Every 2000 Hours or Yearly7 topics
- Lubrication
- Repack Load Wheel Bearings
- Repack Steer Bearings (Manual Steer Only)
- Oil Change
- Brake
- Electrical
- Oil Change
Battery Maintenance4 topics
- How to Charge the Battery
- Equalizing Charge
- Normal Charge
- How to Change the Battery
Transporting2 topics
- Loading
- Unloading
Preparation for Storage2 topics
- Short-Term Storage (1 to 6 months)
- Long-Term Storage (6 months or longer)
Preparation for Use2 topics
- Preparation After Shipment
- Preparation After Storage
Table 1. Maintenance Schedule
Table 2. Specific Gravity Corrections
Capacities and Specifications
Hydraulic System
Hydraulic Oils
Gear Oils
Grease
Truck Weight
Tire Sizes
Torque Specifications4 topics
- Caster Assembly
- Drive Wheel Assembly
- Lift Mechanism
- Hydraulics
Battery Specifications
Table 1. B60Z AC
Table 2. B80Z AC
User Interface2 topics
- Dash Display Menu Access (Standard Handle)
- Dash Display Menu Access (Metal Handle Option)
Menu Navigation2 topics
- Standard Handle
- Metal Handle Option
Dash Display Versions
Supervisor Menu10 topics
- View Versions
- Hourmeters
- Fault Log
- Controller Inputs
- Control Handle Inputs
- Run Diagnostics
- Service Reminder
- Change Supervisor Password
- Operator Modes
- Exit to Run Mode
Table 1. Corresponding Buttons
Table 2. Supervisor Menu
Table 3. Diagnostics Menu
Table 4. Controller Inputs
Table 5. Control Handle Inputs
Table 6. Run Diagnostics Menu
Technician Menu31 topics
- Fault Log
- Controller Inputs
- Control Handle Inputs
- Run Diagnostics
- Set Performance
- Extended Shift
- Walk Speed
- High Speed (FWD)
- High Speed (REV)
- Minimum Acceleration
- Maximum Acceleration
- Plugging
- ADS-Neutral
- ADS-Throttle
- Pick Acceleration
- Pick Deceleration
- Battery Full
- Lift Interrupt
- Min Steer Assist FWD (Power Steering Assist Only)
- Min Steer Assist REV (Power Steering Assist Only)
- Max Steer Assist (Power Steering Assist Only)
- Defaults
- Save and Exit
- Exit Without Saving
- Set General Items
- A/V Alarm (Audible/Visual)
- Clear Fault Log
- Calibrations
- Throttle
- Steer Handle (Power Steering Assist Only)
- Change Service Technician Password
Table 2. Technician Menu
Table 7. Performance Parameters
Table 8. Set Performance Menu
Table 9. Set General Items Menu
Table 10. Calibrations Menu
Inside this manual
Real pages from this service manual (565 pages). Open the sample pages (PDF, 226 KB)
- Troubleshooting, page 385: Troubleshooting
- Diagram, page 457: Diagrams, Schematics, or Arrangements
- Specifications, page 505: Battery Specifications
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 565 pages
Quantity one is the manual described above.
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Other editions and similar models
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