FRAME

B60Z [A230]; W60Z [A231]; W65Z [A229];

B80Z [A233]; W80Z [A234]; B60Z AC [B230];
B80Z AC [B233]

PART NO. 1500193 100 SRM 960

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Frame Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Frame Separation and Assembly ...................................................................................................................... 1
Frame Separation .......................................................................................................................................... 1
Frame Assembly ............................................................................................................................................ 1
Painting Instructions......................................................................................................................................... 3
Label Replacement............................................................................................................................................. 3

This section is for the following models:

B60Z [A230];
W60Z [A231];
W65Z [A229];
B80Z [A233];
W80Z [A234];
B60Z AC [B230];
B80Z AC [B233]

©2006 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
100 SRM 960
General
This section contains the description and repair
procedures for the frame weldments of the lift truck.
These models have integral mounting brackets and
holes factory drilled for the mounting of covers, the
lift pump and motor, electrical components, lifting
mechanisms, and the master drive unit (MDU). See
Figure 1. The fork frame weldment is linked to the
main frame weldment by the lift links of the lifting
Frame Separation and Assembly
FRAME 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. Move the key to the OFF position. Dis-
connect 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 919 or Pe-
riodic Maintenance 8000 SRM 1298.
4. Remove the battery.
5. Remove the top clevis pin retaining the hydraulic
cylinder to the frame. See Hydraulic Cylinder in
Walkie Hydraulic Systems 1900 SRM 964.
6. Remove both pivot pins retaining the upper link
to the drive unit frame. See Upper Link, Remove
in Lifting Mechanism 4000 SRM 965.
7. Remove both drive unit frame pivot pins retain-
ing the rocker arm to the drive unit frame. See
Rocker Arm, Remove in Lifting Mechanism
4000 SRM 965.
Frame Separation and Assembly
mechanism system. The lift cylinder actuates to
evenly lift the fork frame and raise the load. The
battery end of the fork frame weldment is lifted
directly by the cylinder and pivots on the lift links
to the main frame weldment. The fork tips are lifted
simultaneously by push rods connecting the lift links
to the load wheel linkages near the end of the forks.
8. Carefully move one of the frames away from the
other.
FRAME 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 at-
tach the rocker arms to the drive unit frame.
See Rocker Arm, Install in Lifting Mechanism
4000 SRM 965.
3. Install both pivot pins to attach the upper link to
the drive unit frame. See Upper Link, Install in
Lifting Mechanism 4000 SRM 965.
4. Install the pivot pin to attach the hydraulic cylin-
der to the fork frame. See Hydraulic Cylinder, In-
stall in Walkie Hydraulic Systems 1900 SRM
964.
5. Install the battery.
6. Install the drive unit compartment covers.
7. Remove the blocks and lower the motorized
lift truck to the floor. Check the pull rod ad-
justment. See Pull Rod Adjustment in Lifting
Mechanism 4000 SRM 965.
8. Test the operation of the truck before returning
the truck to service.
1
Frame Separation and Assembly 100 SRM 960

Figure 1. Typical Frame Weldments

2
100 SRM 960
Legend for Figure 1
1. FRAME
2. MACHINED H CASTING
3. COVER
Painting Instructions
WARNING
Always use solvents and paints in an area with
ventilation. Do not use solvents or paints near
heat or fire.
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Wear protection
for eyes and skin. When using cleaning sol-
vents, always follow the recommendations of
the manufacturer.
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.
Label Replacement
WARNING
Replace damaged Warning or Caution labels
immediately.
If labels or information plates are missing or dam-
aged, they must be replaced. See Figure 2, Figure 3,
and Figure 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 com-
plete before installing a new nameplate cover. Fas-
ten the nameplate cover with the rivet heads outside.
Label Replacement
4. FRAME
5. MACHINED H CASTING
6. COVER
2. Remove the top surface of paint and all rust from
the metal using sandpaper. Paint all metal sur-
faces where the paint is completely removed us-
ing 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. 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.
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 re-
moved from under the label and the corners and
edges are tight.
3
Label Replacement 100 SRM 960

1. NAMEPLATE 9. LIFT TRUCK SERIAL NUMBER

2. U.L. LABEL 10. 9.65 mm (0.38 in.)
3. NO RIDERS WARNING LABEL 11. 47.75 mm (1.88 in.)
4. WARNING LABEL 12. 16.00 mm (0.63 in.)
5. BLACK HYSTER LABEL 13. 190.5 mm (7.50 in.)
6. MODEL LABEL 14. 38.1 mm (1.50 in.)
7. INFORMATION CASE - FASTEN SO RIVETS DO 15. DO NOT PAINT
NOT SHOW 16. ANTISLIP PAD
8. YELLOW HYSTER LABEL (BOTH SIDES)

Figure 2. Color Arrangement and Label Installation (B60Z and B80Z)

4
100 SRM 960 Label Replacement

1. GENERAL OPERATION WARNING 7. EE LABEL (UL TYPE ES)

2. CORROSIVE CONDITIONS 8. HYSTER DECAL
3. PATENTS AND TRADEMARKS LABEL 9. BATTERY DISCHARGE NOTICE LABEL
4. OPERATING MANUAL 10. UL BATTERY SPACING
5. SHIM STORAGE 11. NAMEPLATE
6. PINCH POINT WARNING

Figure 3. Color Arrangement and Label Installation (B60Z AC and B80Z AC)

5
Label Replacement 100 SRM 960

1. NAMEPLATE 6. MODEL LABEL

2. NO RIDING LABEL 7. 26 mm (1.02 in.)
3. WARNING LABEL 8. LIFT TRUCK SERIAL NUMBER
4. INFORMATION CASE - FASTEN SO THAT 9. PAINT HYSTER BLACK
RIVETS DO NOT SHOW 10. DO NOT PAINT
5. HYSTER LABEL

Figure 4. Color Arrangement and Label Installation (W60Z, W65Z, and W80Z)

6
 TECHNICAL PUBLICATIONS

100 SRM 960 11/06 (5/01) Printed in U.S.A.