Hyster publication number 1500193 identifies this 352-page Hyster B60Z service manual PDF, the factory book for 22 motorized hand truck variants including the W60Z, T5Z, C80Z and the AC and HD versions. Wiring diagrams lay out the 24 volt and 12 volt electrical schematics, and hydraulic schematics show the walkie lift system with its reservoir, lift pump, lowering valve, relief valve and lift cylinder. Repair chapters also cover Curtis 1297 controller programming with the 1307 and 1311 handsets, LED fault codes, brake air gap adjustment and master drive unit disassembly. Check brake coil resistance against 14.0 ohms on the B60Z or 10.7 ohms on the B80Z, and torque drive tire lug nuts to 195 N•m (144 lbf ft). If you are chasing an electrical fault on a 24 volt truck, the schematic diagram shows how its circuits connect. Bookmarks and search lead you to the air gap figures.
What's Inside This Hyster B60Z, B80Z, W60Z–W80Z Series Manual
| System | Pages | Key Topics |
|---|---|---|
| Frame | 1-14 | Frame Separation, Frame Assembly, Painting Instructions, Label Replacement |
| Master Drive Unit | 15-40 | Drive Unit Specifications, Check Oil Level, Change Gear Oil, Drive Tire Removal, Master Drive Unit Disassembly |
| Steering Mechanism | 41-62 | Control Handle Head, Control Handle Removal, Steer Bearings and Support, Gas Spring, Steering and Dash Assembly |
| Brakes | 63-84 | Brake Check, Brake Coil Check, Brake Assembly Repair, Brake Assembly Adjustment, Air Gap Adjustment |
| Walkie Hydraulic Systems | 85-122 | Hydraulic Reservoir, Lift Pump and Motor, Lowering Valve, Relief Valve, Lift Cylinder |
| Curtis 1297 Transistor Motor Controller | 123-172 | Programming Controller, 1307 Programmer Handset, 1311 Programmer Handset, LED Fault Codes, Control Card Functional Test |
| Electrical System | 173-214 | Electrical System Checks, Controller Replacement, Contactor Replacement, Fuses, Brake Switch |
| Industrial Battery | 215-242 | Lead-Acid Batteries, Battery Maintenance, Charging Battery, Battery Connectors, Troubleshooting |
| Lifting Mechanism | 243-270 | Load Wheel, Caster Wheels, Rear Link and Load Wheel Assembly, Pull Rod, Rocker Arm |
| Metric and Inch (SAE) Fasteners | 271-290 | Threaded Fasteners, Strength Identification, Cotter Pins, Fastener Torque Tables, Conversion Table |
| Capacities and Specifications | 291-304 | Hydraulic System, Truck Weights, Torque Specifications, Battery Specifications |
| Periodic Maintenance | 305-332 | Maintenance Schedule, Lubrication Instructions, Battery Maintenance, Road and Load Test |
| Diagrams | 333-352 | General Notes, Schematic Diagram 24 Volt, Schematic Diagram 12 Volt |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| B80Z, B80ZAC, B80ZHD, B80ZHD2, C80Z, C80ZAC, T7Z, T7ZAC, B60Z, B60ZAC, B60ZHD, B60HD2, C60Z, C60ZAC, T5Z, T5ZAC, W60/65/80Z | ||
| Wheel bolts or lug nuts torque | 200 ±9 N•m (148 ±7 lbf ft) | p. 25 |
| All Models | ||
| Brake capscrews torque | 12 to 14 N·m (8.8 to 10.3 lbf ft) | p. 27 |
| Drive Tire Wheel Capscrew Torque | 200 N•m (148 lbf ft) | p. 297 |
| Drive Tire Wheel Lug Nut Torque | 195 N•m (144 lbf ft) | p. 297 |
| Brake coil resistance (B80Z, T7Z, C80Z) | 10.7 ohms | p. 72 |
| Fully charged specific gravity | 1.265 to 1.310 at 25°C (77°F) | p. 328 |
| B80Z, T7Z, C80Z | ||
| Brake Coil Resistance (B80Z, T7Z, C80Z) | 10.7 ohms | p. 72 |
| W65Z | ||
| Brake Coil Resistance (W65Z) | 4.0 ohms | p. 72 |
| B60Z, B60ZAC, C60Z, C60ZAC, W60Z | ||
| Relief valve setting | 18.96 MPa (2750 psi) | p. 113 |
| Relief Valve Setting (B60Z, B60ZAC, C60Z, C60ZAC, W60Z) | 18.96 MPa (2750 psi) | p. 113 |
| B80Z, B80ZAC, C80Z, C80ZAC, W65Z, W80Z | ||
| Relief Valve Setting (B80Z, B80ZAC, C80Z, C80ZAC, W65Z, W80Z) | 24.2 MPa (3500 psi) | p. 113 |
| W60-65-80Z, T5Z, T7ZAC, W30-40ZA, W25-40ZC, W20-30ZR, B60Z, C60Z, B60ZAC, C60ZAC, B60ZHD, B60HD2 | ||
| M14 Bolt Torque (Drive Unit to Frame) | 145 N•m (107 lbf ft) | p. 35 |
Hyster B60Z, B80Z, W60Z–W80Z Series Common Problems This Manual Covers
Hyster B60Z brake will not release with key switch on and handle in brake release position
Test the Brake/Run Switch, clean the battery connectors, and trace the wiring diagrams following the chart on page 81. Before working on the brake, turn the key OFF, disconnect the battery connector so it is completely free, tag it DO NOT CONNECT, and discharge the capacitors (page 26). Adjust excessive air gap to 0.3 mm (0.012 +0.002 in.) on B60Z per page 78. Replace the brake assembly or coil if the coil is defective.
Manual Section: Brake Troubleshooting p. 81Master drive unit oil seeping out around the fill plug or drain plug
Clean dirt from between the sealing ring and housing, and replace the sealing ring if an old one was reused. Tighten loose plugs following page 37: torque the drain plug to 60 N•m (44 lbf ft) and the fill plug to 45 N•m (33 lbf ft). Wipe the housing dry and recheck it for fresh seepage.
Manual Section: Master Drive Unit Troubleshooting p. 37Control handle arm does not spring back to the vertical position when released
Inspect the gas spring ball stud first and retighten or replace it if it is broken or loose, following page 59. If the gas spring is weak or broken, replace it. The spring is under tension and can release with enough force to injure you (page 55). Discharging it is destructive, so wear goggles and a face shield when drilling, and install a new gas spring.
Manual Section: Steering Mechanism Troubleshooting p. 59Lift pump and motor run but the forks will not lower with lower button pressed
Check the lower valve cartridge for contamination and damage, and replace the cartridge if defective, following page 118. Verify the lowering solenoid and the LOWER switch are connected; replace either one if damaged. If the controller flashes code 1,4 (Lower Valve Fault), test the lowering valve and its connection for an open circuit per page 149. Repair or replace a damaged lift cylinder.
Manual Section: Hydraulic System Troubleshooting p. 118Walkie hydraulic system lift pump making abnormal noise when the raise button is pressed
Check reservoir oil level and fill to the correct level, then look for leaks. Inspect the inlet hose for restrictions and clean the screen; tighten a loose inlet fitting or hose clamp and remove air from the system, following page 117. Tighten loose pump housing and mounting capscrews, and clean, adjust, or replace a stuck-open relief valve.
Manual Section: Hydraulic System Troubleshooting p. 117Curtis 1297 controller intermittently flashing fault codes 11, 13, 23, 32, 34, or 42 during use
Test by cycling the key switch OFF then ON; if the code remains, the truck must be serviced. For repeat faults, disconnect the battery, discharge the controller capacitor, and wear safety glasses before inspecting (page 55). Never set tools on top of the battery. Check battery cable connectors, battery terminals, and controller wiring for loose connections per page 148, and check battery cells for proper voltage and state of charge.
Manual Section: Curtis 1297 Controller Troubleshooting p. 148Frequently Asked Questions
How do I reset the fault codes on a Hyster B60Z or B80Z?
Fault codes 11, 13, 23, 32, 34, or 42 may appear intermittently. Turning the key switch to the OFF position and then back to the ON position will usually clear these fault codes. If the codes remain after cycling the key switch, the lift truck must be serviced. p. 148
Why does a Hyster B60Z/B80Z have no travel or lift function?
If the truck is inoperative with the key switch in the ON position, check for missing B+ or B- voltage at the controller. Ensure the battery is connected, check the condition of fuse FU 1, and verify battery voltage at pin #J1-1. If these checks are normal, the motor controller may be defective and require replacement. p. 151
How do I clear the diagnostic history on a Hyster pallet truck using the 1307 programmer?
To clear the diagnostic history, press the program key while holding the more info key. Press the scroll down key until 'CLEAR DIAG HISTORY' appears in the top line of the display. Press the more info key again, and then press the value up key to clear the history. p. 137
What is the correct torque for the drive tire wheel bolts on a Hyster lift truck?
The drive tire wheel bolts must be tightened to 200 ±9 N•m (148 ±7 lbf ft). p. 25
What is the recommended gear oil capacity for the Carraro MDU on a B80Z or W80Z?
The drive unit capacity for the B80Z and W80Z is 2.0 liters (2.1 qt). Do not overfill. p. 321
How quickly can I access this Hyster B60Z manual after buying?
All 352 pages arrive as one searchable PDF at checkout. Read it at the desk, then take the phone out to the machine.
Am I free to print this Hyster B60Z Service Manual?
Yes. Print a chapter or just the pages for the job at hand, for use in your own shop. Any home or office printer works.
Reviews
There are no reviews yet.