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• 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 Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• 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.
• 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 hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Brakes Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Accessing the Drive Unit Compartment ...................................................................................................... 1
B60-80Z AC and B60-80Z HD........................................................................................................................ 1
C60-80Z AC and T5-7Z AC ............................................................................................................................ 2
Description ......................................................................................................................................................... 3
Special Precautions............................................................................................................................................ 5
Brake Check ....................................................................................................................................................... 6
Brake Release ................................................................................................................................................ 6
Brake Apply ................................................................................................................................................... 6
Air Gap ........................................................................................................................................................... 6
Hold On Grade Test ....................................................................................................................................... 8
Brake Assembly Repair ..................................................................................................................................... 8
B60Z AC, C60Z AC, T5Z AC, and B60Z HD .......................................................................................................... 8
Remove....................................................................................................................................................... 8
Repair......................................................................................................................................................... 9
Install ......................................................................................................................................................... 9
B80Z AC, C80Z AC, T7Z AC, B80Z HD ................................................................................................................. 10
Remove....................................................................................................................................................... 10
Repair......................................................................................................................................................... 10
Install ......................................................................................................................................................... 11
Troubleshooting ................................................................................................................................................. 12
B80Z HD [A257];
B60Z HD [A262];
B60Z AC [B230];
B80Z AC [B233];
T5Z AC [B476];
T7Z AC [B477];
C60Z AC [B478];
C80Z AC [B479]
HYSTER
APPROVED
PARTS
1800 SRM 1285 General
General
ACCESSING THE DRIVE UNIT
WARNING
COMPARTMENT
DO NOT operate a lift truck that needs repairs.
If a repair is necessary, attach a DO NOT OPER- B60-80Z AC and B60-80Z HD
ATE tag to the control handle and disconnect
the battery. The drive unit compartment is concealed behind a
molded cover which fits securely around the drive
WARNING unit and steer support to the frame. The floor mat
fits snugly in the operator platform after the drive
Before performing repairs or adjustments on
unit cover is installed.
the brake system, blocks must be placed under
each side of the frame to raise the drive tire off To remove the drive unit cover, first lift the corners
the ground. The blocks must prevent the lift of the floor mat and pull it out away from the drive
truck from falling and causing personal injury unit. See Figure 1. Next, reach under the side of
or property damage. See the section for your the drive unit cover, near the bottom, and find the
truck; Periodic Maintenance - How To Put A grip slot. With both hands, pull up and away from
Lift Truck On Blocks. the truck until the bottom of the cover kicks out from
the retaining clips. See Figure 2. Repeat this for the
This section describes the electric brake and outlines
other side of the cover. Work around the edge of the
the procedures for the maintenance, adjustment, and
cover until free from the truck.
repair that may be required for servicing these lift
trucks.
1
General 1800 SRM 1285
2
1800 SRM 1285 Description
Description
Motorized hand trucks have three methods of brak- a stop. Release the speed/direction control to remain
ing: stopped. If the speed/direction control is not released
1. Regenerative (Neutral) braking after the truck is stopped, the lift truck will acceler-
2. Controlled plugging ate in the direction the control is being turned. Con-
3. Application of the spring-applied, electrically-re- trolled plugging should stop the truck within one to
leased friction brake one and a half truck lengths, depending on speed and
load.
NOTE: The preferred method of stopping the truck is:
Regenerative (Neutral) braking A spring-applied, electrically-released friction brake
or is mounted to the drive motor. When the brake is ap-
Controlled plugging plied, springs inside the brake assembly compress a
rotating friction disk against two stationary plates.
Regenerative (Neutral) braking applies a retarding When the brake is released, the brake coil energizes
force to the drive wheel through the traction motor, and pulls the armature plate away from the friction
allowing the unit to slow to a gradual stop. It is ap- disk, releasing the brake as the drive motor is ac-
plied by returning the speed/direction control to the tivated. This brake functions primarily as a park-
NEUTRAL position. ing brake and is applied when the control handle
arm is in the BRAKE ON position (B60-80Z AC and
NOTE: The directional controls are spring loaded and
B60-80Z HD), when the parking brake switch is ON
will automatically return to the NEUTRAL position
or the brake lever is in position 3, (C60-80Z AC and
when released.
T5-7Z AC), when the key switch is in the OFF position
Controlled plugging is reversing the speed/direction or there is insufficient power to release the brake, or
control while traveling, causing the unit to slow to if a traction fault occurs. See Figure 4 or Figure 5.
3
Description 1800 SRM 1285
A. BRAKE ON
B. REGEN BRAKING
C. BRAKE OFF
4
1800 SRM 1285 Special Precautions
Special Precautions
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. Wear
safety glasses. Make certain the battery has
been disconnected. DO NOT use a screwdriver
to discharge the traction motor controller.
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 procedures when servicing
the controller.
5
Brake Check 1800 SRM 1285
Brake Check
BRAKE RELEASE BRAKE APPLY
To release the brake, the lift truck control arm must 1. To apply the brake, first release the brake (refer
be in the BRAKE OFF position with the key switch to Brake Release) then move the lift truck control
in the ON position and a properly charged battery arm to the BRAKE ON position. Listen for a
connected. If the brake does not release under these solid, single "click."
conditions, make the following checks to identify the
problem. 2. If the brake appears not to apply:
1. Move the truck to a safe, level area and turn the a. Turn the key switch to the OFF position. Lis-
key switch to the OFF position. Raise the drive ten for a solid, single "click."
tire and position on blocks to allow for testing
b. If "click" is present, check the brake switches
without danger of unexpected movement of the
for proper adjustment.
truck. See Periodic Maintenance 8000 SRM
1453, Periodic Maintenance 8000 SRM 1298, c. If brake appears to not have applied, attempt
or Periodic Maintenance 8000 SRM 1368 for to roll the lift truck slightly to determine if
more information on putting the lift truck on brake is holding the traction motor.
blocks.
d. If the truck can be rolled by hand with the
2. Remove the drive unit compartment cover. See key switch in the OFF position, repair or re-
Accessing the Drive Unit Compartment in this place the brake. See Brake Assembly Repair.
section.
3. If unsure whether brake is applying, test the
3. Check that the brake switch(es) and potentiome- brake using the "Hold On Grade" procedure. See
ter (power assist only) are adjusted properly Hold On Grade Test in this section. The brake is
and functioning correctly. Check their wiring for designed to hold the truck loaded to capacity on
damage, loose connections, and corrosion. a 10% grade.
4. Disconnect the brake wiring connector from the
AIR GAP
main wiring harness connector. Turn the key
switch to the ON position and move the control
handle to the BRAKE ON position. Touch volt- CAUTION
meter leads across the main wiring harness con- The brake is not adjustable. Check the air gap
nector pins. Voltage should read 24 ±5 VDC. to determine if repair or replacement is neces-
If voltage is not within specification, check the sary.
connector and wiring for damage. If problem
persists, troubleshoot the electrical system. If 1. Check the three outer socket head screws for ap-
supply voltage is within specification, proceed to propriate torque to secure the brake to the motor.
Step 5.
NOTE: The air gap is very thin and cannot be checked
5. Check the stator resistance using an ohmmeter. visually. Illustrations are not to scale and are for
If resistance is not within specification, check the location references only.
connector and wiring for damage. See Table 1. If
2. Check for correct air gap by measuring the dis-
problem persists, remove and replace the brake.
tance between the bottom of the stator and the
See Brake Assembly Repair.
top of the pressure plate with the brake applied
Table 1. Stator Resistance (disconnected) using feeler gauges. See Figure 7.
Specifications vary, depending on truck model.
B60Z AC, C60Z AC, T5Z AC, 13.3 to 15.3 Ohms See Table 2.
and B60Z HD
B80Z AC, C80Z AC, T7Z AC, 9.9 to 11.6 Ohms
and B80Z HD
6
1800 SRM 1285 Brake Check
1. LOCATION 1
2. LOCATION 2
3. LOCATION 3
4. LOCATION 4
5. LOCATION 5
6. LOCATION 6
7
Brake Assembly Repair 1800 SRM 1285
NOTE: During brake operation, brake should engage 2. Position the lift truck at the base of a 10% grade
and release with a solid, single-click noise. A double- with the forks facing uphill. Standing to the side
clicking noise indicates that one side of the brake is of the lift truck, slowly drive the lift truck up the
releasing before the other. grade and bring the lift truck to a stop using the
directional controls (plugging). See Figure 9.
6. Listen to verify brake releases and applies in one
smooth operation. A double-clicking noise indi- 3. Stand clear of the lift truck and move the control
cates that one side of the brake is releasing before handle to the BRAKE OFF position. If the brake
the other due to internal damage or tampering. fails to hold the lift truck on the grade, the brake
Replace the brake assembly. assembly must be repaired or replaced. For infor-
mation on repairing or replacing the brake, refer
HOLD ON GRADE TEST to Brake Assembly Repair in this section.
WARNING
DO NOT stand below or ride on the lift truck
when performing the hold on grade test.
8
1800 SRM 1285 Brake Assembly Repair
Repair
CAUTION
The brake is not adjustable. Be careful not to
alter the position of the standoff bolts during
repairs.
CAUTION
DO NOT disassemble beyond this point. The
brake is not adjustable. Be careful not to al-
ter the position of the standoff bolts during re-
pairs.
9
Brake Assembly Repair 1800 SRM 1285
3. Align the Woodruff key with the groove inside the 2. Remove the drive unit compartment cover. See
brake hub. Slide the brake hub down onto the Accessing the Drive Unit Compartment in this
traction motor shaft and Woodruff key. section.
4. Secure in place with upper snap ring as removed. 3. Discharge the capacitor. See Special Precautions
in this section.
NOTE: Hold the brake assembly components to-
gether while installing. Mounting capscrews will 4. Disconnect the brake wiring connector from the
hold the assembly together when installed. main wiring harness connector.
5. Position the brake assembly to align holes in 5. On the B80Z AC, the steering and dash assembly
brake with holes in traction motor head. Lower must be partially removed to access the brake
the brake assembly onto the brake hub. Slightly mounting screws. For additional information
turn the brake assembly to align splines and about removal and installation of the steer sup-
lower until the brake assembly touches the top port and dash, see Steering Mechanism 1600
of the traction motor. SRM 1449, Steering Mechanism 1600 SRM
1284, or Steering Mechanism 1600 SRM 1031.
6. Make sure the brake assembly holes align with
the holes in the traction motor head. Install 6. Remove the three capscrews securing the mount-
three mounting screws. Tighten to touch, then ing plate of the brake assembly to the motor end
torque to 8 N•m (71 lbf in). head.
7. Connect the brake wiring connector to the main 7. Slide the brake assembly up off the hub splines
wiring harness. and remove from the lift truck. See Figure 11.
10
1800 SRM 1285 Brake Assembly Repair
CAUTION
DO NOT disassemble beyond this point. The
brake is not adjustable. Be careful not to al-
ter the position of the standoff bolts during re-
pairs.
Install
WARNING
Use caution when removing or installing snap
rings. Snap rings can eject during removal or
installation with enough force to cause per-
sonal injury. Always use the proper snap ring
pliers and wear eye and face protection during
removal and installation.
5. Inspect mounting plate and pressure plate for 7. Connect the brake wiring connector to the main
damage. Replace the brake assembly if damaged. wiring harness.
11
Troubleshooting 1800 SRM 1285
8. On the B80Z AC, the steering and dash assembly 9. Reinstall the drive unit compartment cover. See
must be partially removed to access the brake Accessing the Drive Unit Compartment in this
mounting screws. Replace the steer support and section.
dash after the brake has been installed. See
Steering Mechanism 1600 SRM 1449, Steer- 10. Reconnect the battery and turn the key switch to
ing Mechanism 1600 SRM 1284, or Steering the ON position. Remove blocks from the wheels
Mechanism 1600 SRM 1031. and test for proper operation.
Troubleshooting
Brake does not release. Key switch is in the OFF position. Turn key switch to the ON position.
Handle is not in the BRAKE OFF Move the handle to the BRAKE OFF
position. position.
Brake coil has shorted to frame or be- Measure coil resistance. Refer to
tween the windings. Brake Check in this section. If resis-
tance is below specification, replace
the brake assembly.
Check coil for short to frame using
an ohmmeter. If shorted to frame,
replace the brake assembly.
12
1800 SRM 1285 Troubleshooting
Brake does not hold truck Air gap is too large. Repair or replace the brake assembly.
loaded to capacity on 10%
grade.
Brake will not apply. Mechanical failure within the brake Replace the brake assembly.
assembly.
Brake linings worn beyond specifica- Repair or replace the brake assembly.
tion. See Brake Check in this sec-
tion.
13
NOTES
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