Hyster Battery Indicators Maintenance And Repair

Description

• Model List:
  • Battery Indicators

• 1. RM0138-(08-2016)-US-EN
• 1.1. General
• 1.1.1. Indicators With Meter Movements
• 1.1.2. Battery Indicators With LCD or LED Displays
• 1.2. Battery Indicators Without Lift Interrupt Adjustment (Early Models)
• 1.3. Battery Indicators With Lift Interrupt Adjustment (Early Models)
• 1.3.1. Reset Potentiometer
• 1.3.2. Specific Gravity Alarm
• 1.4. Battery Indicators Without Lift Interrupt Check (Later Models)
• 1.5. Battery Indicators With Lift Interrupt Adjustment (Later Models)
• 1.5.1. Reset Potentiometer
• 1.5.2. Discharge Potentiometer
• 1.6. LED Display With Lift Interrupt
• 1.7. Curtis 933-1 Meter Check and Adjustment
• 1.7.1. Reset Check
• 1.7.2. Discharge Check
• 1.7.3. Lockout Check
• 1.7.4. LEDs Do Not Illuminate
• 1.7.5. Hourmeter Check
• 1.7.6. Hourglass Icon
• 1.8. SEVCON POWERGAUGE Adjustment
• 1.9. Curtis Dash Display Assembly
• 1.9.1. Description/Features
• 1.9.2. Operation
• 1.9.3. Testing
• 1.9.4. Install
• 1.9.5. Adjust (Setup, Early Models)
• 1.9.6. Adjust (Setup, Later Model)
• 1.10. Battery Indicators Replacement
• 1.11. Battery Indicator Controller Replacement
• 1.12. Display Panel Components Replacement
• 1.13. SEM Display Panel Replacement
• 1.13.1. Remove and Replace
• 2. RM0231-(08-2016)-US-EN
• 2.1. General
• 2.1.1. Threaded Fasteners
• 2.1.2. Nomenclature, Threads
• 2.1.3. Strength Identification
• 2.1.4. Cotter (Split) Pins
• 2.1.5. Fastener Torque Tables
• 2.1.6. Conversion Table
• 3. RM0919-(09-2016)-US-EN
• 3.1. General
• 3.1.1. How to Move a Disabled Truck
• 3.1.2. How to Raise the Lift Truck
• 3.1.3. How to Put a Lift Truck on Blocks
• 3.1.4. Welding Repairs
• 3.2. Maintenance Schedule
• 3.2.1. Checks and Inspection Procedures
• 3.2.2. Casters
• 3.3. Lubrication Instructions
• 3.3.1. Every 8 Hours or Daily
• 3.3.2. Every 50 Hours or 1 Month
• 3.3.3. Every 350 Hours or 2 Months
• 3.3.4. Every 2000 Hours or 1 Year
• 3.4. Recommended Schedule of Maintenance
• 3.5. Battery Maintenance
• 3.5.1. How to Charge the Battery
• 3.5.2. How to Change the Battery
• 4. RM0920-(08-2016)-US-EN
• 4.1. General Notes
• 5. RM0929-(08-2016)-US-EN
• 5.1. General
• 5.2. Electrical System Checks
• 5.2.1. Safety Precautions
• 5.3. Repairs
• 5.3.1. Controller, Replace
• 5.3.2. Contactor Coil, Check
• 5.3.3. Contactor, Replace
• 5.3.4. Contactor Tips, Replace
• 5.4. Brake Switch – W60Z, W65Z, W80Z, B60Z (Aug. 2003) and B80Z (Aug. 2003)
• 5.4.1. Remove and Install
• 5.5. Brake and Interlock Switches – B60Z (Aug. 2003) and B80Z (Aug. 2003)
• 5.5.1. Disassemble
• 5.5.2. Assemble
• 5.6. Height Limit
• 5.7. Control Handle
• 5.7.1. Disassemble
• 5.7.2. Control Handle Card (Old Style)
• 5.7.3. Control Handle Card (New Style)
• 5.7.4. Assemble
• 5.8. Remote Control Box Switches (B60Z and B80Z)
• 5.8.1. Install
• 5.9. Motor Maintenance – General
• 5.10. Brush and Commutator Inspection
• 5.10.1. Commutator Problems
• 5.11. Brush Replacement
• 5.12. Drive Motor
• 5.12.1. Disassemble
• 5.12.2. Assemble
• 5.12.3. Install
• 5.13. Lift Pump Motor
• 5.13.1. Install
• 5.14. Commutator Repairs
• 5.15. Testing the Drive Motor
• 5.15.1. Damaged Field and Armature
• 5.15.2. Short Circuit in an Armature Winding
• 5.15.3. Short Circuit in the Armature
• 5.15.4. Open Circuit in a Field Coil
• 5.15.5. Short Circuit in a Field Coil
• 5.15.6. Short Circuit Between Field and Motor Case
• 5.15.7. Brush Holder
• 5.16. Troubleshooting
• 6. RM0918-(08-2016)-US-EN
• 6.1. Hydraulic System
• 6.2. Hydraulic Oils
• 6.3. Gear Oils
• 6.4. Truck Weights
• 6.4.1. Weight (Basic Truck Without Battery)
• 6.4.2. Drive Tire
• 6.5. Torque Specifications
• 6.5.1. Caster Assembly
• 6.5.2. Master Drive Unit
• 6.5.3. Steering
• 6.5.4. Electrical
• 6.5.5. Lift Mechanism
• 6.6. Battery Specifications and Adjustments
• 6.6.1. B60Z and W60Z 24 Volt
• 6.6.2. W65Z 12 Volt
• 6.6.3. B80Z 24 Volt
• 6.6.4. W80Z 24 Volt
• 7. RM0928-(08-2016)-US-EN
• 7.1. General
• 7.1.1. Safety Precautions
• 7.2. Description
• 7.2.1. Curtis PMC 1297 Transistor Motor Controller
• 7.2.2. Principles of Operation
• 7.2.3. Install
• 7.2.4. Programming Controller
• 7.3. Programmer Handset
• 7.3.1. Description/Features
• 7.3.2. Scroll Display Keys
• 7.3.3. Change Value Keys
• 7.3.4. More Info Key
• 7.4. Operation
• 7.4.1. Connecting Handset to Traction Motor Controller
• 7.4.2. Disconnecting Handset From Traction Motor Controller
• 7.4.3. Programmer Self-Test
• 7.4.4. Menu Selections
• 7.5. Programming Traction Motor Controller – 1307 Handset
• 7.6. Programmer Handset
• 7.6.1. Description/Features
• 7.6.2. Operation
• 7.6.3. Main Menu Selections
• 7.7. Programming the Traction Motor Controller – 1311 Handset
• 7.8. Parameters
• 7.8.1. Adjusting Parameters
• 7.9. Battery Discharge Indicator (BDI)/Hourmeter
• 7.10. LED Fault Codes
• 7.11. Control Card Functional Test
• 8. RM0960-(08-2016)-US-EN
• 8.1. General
• 8.2. Frame Separation and Assembly
• 8.2.1. Frame Separation
• 8.2.2. Frame Assembly
• 8.3. Painting Instructions
• 8.4. Label Replacement
• 9. RM0962-(08-2016)-US-EN
• 9.1. General
• 9.2. Special Precautions
• 9.3. Control Handle Head
• 9.4. Control Handle (W60/65/80Z, W30/40ZA, W20/30ZR, and W25/30/40ZC)
• 9.4.1. Install
• 9.5. Control Handle (B60/80Z)
• 9.5.1. Remove (Handle)
• 9.5.2. Steer Bearings and Support
• 9.5.3. Install (Handle)
• 9.6. Gas Spring
• 9.6.1. Discharging the Gas Spring
• 9.6.2. Remove (W60/65/80Z, W30/40ZA, W20/30ZR, and W25/30/40ZC)
• 9.6.3. Remove (B60/80Z)
• 9.6.4. Install (W60/65/80Z, W30/40ZA, W20/30ZR, and W25/30/40ZC)
• 9.6.5. Install (B60/80Z)
• 9.7. Steering and Dash Assembly (Complete)
• 9.7.1. Install
• 9.8. Troubleshooting
• 10. RM0963-(08-2016)-US-EN
• 10.1. General
• 10.2. Description
• 10.3. Special Precautions
• 10.4. Brake Check
• 10.4.1. Hold On Grade Test
• 10.5. Brake Coil Check
• 10.6. Brake Assembly Repair
• 10.6.1. B60Z and W60Z (Up to10/2001)
• 10.6.2. B60Z and W60Z (10/2001 and Up), B80Z, T5Z, T7Z, C60Z, C80Z, W65Z, W80Z, W30/40ZA, W20/30ZR, and W25/30/40ZC
• 10.7. Brake Assembly Adjustment
• 10.7.1. Air Gap, Adjust
• 10.7.2. Torque Nut, Adjust
• 10.8. Troubleshooting
• 11. RM0964-(08-2016)-US-EN
• 11.1. General
• 11.2. Description of Operation
• 11.2.1. Lifting a Load
• 11.2.2. Lowering a Load
• 11.2.3. Hydraulic Lines
• 11.2.4. Hydraulic Oil
• 11.2.5. Sound Level
• 11.3. Special Precautions
• 11.4. Hydraulic Reservoir
• 11.4.1. Description
• 11.5. Drive Unit Compartment Covers
• 11.5.1. C60Z, C80Z, C60ZAC, and C80ZAC
• 11.5.2. B60Z, B80Z, B60ZAC, B80ZAC, W60Z, W65Z, and W80Z
• 11.6. Lift Pump and Motor
• 11.6.1. General
• 11.6.2. Disassemble
• 11.6.3. Assemble
• 11.6.4. Install
• 11.7. Valve Repair
• 11.7.1. Lowering Valve
• 11.7.2. Relief Valve
• 11.7.3. Check Valve
• 11.8. Lift Cylinder
• 11.8.1. Disassemble
• 11.8.2. Assemble
• 11.8.3. Install
• 11.9. Relief Valve Adjustment
• 11.9.1. Relief Valve Pressure Check
• 11.9.2. Adjust Relief Valve Pressure
• 11.10. Troubleshooting
• 11.10.1. Lift Assemblies
• 11.10.2. Lift Cylinders
• 11.10.3. Lift Pump and Motor Assembly
• 12. RM0965-(08-2016)-US-EN
• 12.1. General
• 12.2. Description of Operation
• 12.3. Load Wheel
• 12.3.1. Install
• 12.4. Caster Wheels
• 12.4.1. Caster Shim Adjustment
• 12.4.2. Caster Replacement
• 12.4.3. Disassemble
• 12.4.4. Assemble
• 12.4.5. Caster Lubrication
• 12.5. Rear Link and Load Wheel Assembly
• 12.5.1. Install
• 12.6. Pull Rod
• 12.6.1. End Replacement
• 12.6.2. Install
• 12.6.3. Rear Fork Adjustment
• 12.7. Rocker Arm
• 12.7.1. Install
• 12.8. Upper Link
• 12.8.1. Install
• 12.9. Troubleshooting
• 13. RM2005-(08-2016)-US-EN
• 13.1. General
• 13.1.1. Accessing the Drive Unit Compartment
• 13.2. Special Precautions
• 13.2.1. Discharging the Capacitors
• 13.3. Description
• 13.4. AC Motor Repair
• 13.4.1. Install
• 13.5. Troubleshooting
• 14. RM2006-(08-2016)-US-EN
• 14.1. Safety Precautions
• 14.2. General
• 14.2.1. Check Oil Level
• 14.3. Drive Tire
• 14.3.1. Install
• 14.4. Master Drive Unit
• 14.4.1. Disassemble
• 14.5. Troubleshooting