Hyster C230 (B60ZAC) Forklift Parts Manual

B60ZAC (C230)

4096116 01/2016

©2015 HYSTER COMPANY

UNIT CODE C230 NORTH AMERICA

01/2016

SECTIONS 1

FRAME/DRIVE UNIT

2

ELECTRICAL SYSTEM

3

STEER HANDLE/BRAKE SYSTEM

4

LIFT LINKAGE, LOAD WHEELS, AND FORKS

5

HYDRAULIC SYSTEM

6

OPTIONS

7

FIELD CONVERSION KITS

8

NUMERICAL INDEX

This Parts Manual is divided into 8 major sections which are listed above. Quick reference to these sections can be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages to the corresponding tab.

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01/2016

UNIT CODE C230 NORTH AMERICA

TABLE OF CONTENTS DESCRIPTION

PAGE

A AUDIBLE ALARM ............................................................................................................................................

AUXILIARY CONTROL BOX AND GRAB RAIL ASSEMBLY .........................................................................

6-5 2-5

B BATTERY DISCONNECT ...............................................................................................................................

2-8 BATTERY RETENTION .................................................................................................................................. 1-26 BATTERY ROLLER ASSEMBLY ....................................................................................................................

6-8 BATTERY SPACER ........................................................................................................................................ 1-28 BRAKE ASSEMBLY WITH CARRARO MDU ...............................................................................................................................

3-2 WITH KORDEL MDU ..................................................................................................................................

1-3 C CASTER ASSEMBLY SPRING LOADED - STANDARD ................................................................................................................

SPRING LOADED - HEAVY DUTY .............................................................................................................

SPRING LOADED - HEAVY DUTY, SEALED BEARINGS .........................................................................

COAST CONTROL MANUAL STEERING ..................................................................................................................................

POWER STEERING ...................................................................................................................................

CONTROL MODULE .......................................................................................................................................

CONVENIENCE TRAY ....................................................................................................................................

COVERS AND FLOORMAT ............................................................................................................................

4-14 4-16 4-18 3-3 3-4 2-6 6-2 1-24

D DASH DISPLAY ..............................................................................................................................................

2-7 DECALS .......................................................................................................................................................... 1-32 DRIVE UNIT INSTALLATION, WITH WHEEL AND TIRE AND STATIC STRAP MANUAL STEERING - WITH CARRARO MDU .........................................................................................

1-6 POWER STEERING ...................................................................................................................................

1-8 DRIVE WHEEL AND TIRE AND STATIC STRAP - WITH KORDEL MDU .............................................................................................

1-4 E ELECTRICAL SYSTEM ...................................................................................................................................

2-2

H HEATER INSTALLATION ............................................................................................................................... 2-10 ALTERNATE CONFIGURATION ................................................................................................................ 2-12 HYDRAULIC ASSEMBLY ...............................................................................................................................

5-2 HYDRAULIC POWER UNIT ............................................................................................................................

5-4 L LIFT CYLINDER ASSEMBLY ..........................................................................................................................

5-6 LIFT LINKAGE .................................................................................................................................................

4-2 LOAD BACKREST BOLT-ON .................................................................................................................................................... 1-31 PIVOTED ..................................................................................................................................................... 1-30

©2015 HYSTER COMPANY

See Service Manual for service procedures.

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

LOAD WHEELS DUAL WHEEL ............................................................................................................................................. 4-10 DUAL WHEEL - SEALED ............................................................................................................................ 4-11 DUAL WHEEL, SEALED - ALTERNATE CONFIGURATION ..................................................................... 4-12 SINGLE WHEEL, FOUR BEARINGS ..........................................................................................................

4-7 SINGLE WHEEL, FOUR BEARINGS - SEALED ........................................................................................

4-8 SINGLE WHEEL, FOUR BEARINGS - SEALED - ALTERNATE CONFIGURATION .................................

4-9 SINGLE WHEEL, TWO BEARINGS ...........................................................................................................

4-4 SINGLE WHEEL, TWO BEARINGS - SEALED ..........................................................................................

4-5 SINGLE WHEEL, TWO BEARINGS - SEALED - ALTERNATE CONFIGURATION ..................................

4-6 M MASTER DRIVE UNIT KORDEL ......................................................................................................................................................

1-2 MANUAL STEERING - CARRARO ............................................................................................................. 1-12 POWER STEERING ................................................................................................................................... 1-16 R RF TERMINAL .................................................................................................................................................

6-4

S STEER STOP ADVANCED COAST CONTROL ................................................................................................................ 6-10 T TELEMETRY KITS ..........................................................................................................................................

TILLER ARM ASSEMBLY COMPOSITE HANDLE - MANUAL STEERING ..........................................................................................

METAL HANDLE - POWER STEERING .....................................................................................................

TILLER HEAD ASSEMBLY COMPOSITE - MANUAL STEERING .........................................................................................................

METAL HANDLE - POWER STEERING .....................................................................................................

TILLER SWIVEL ASSEMBLY WITH COAST CONTROL - POWER STEERING .......................................................................................

WITH COAST CONTROL - MANUAL STEERING, WITH CARRARO MDU ..............................................

WITH COAST CONTROL - MANUAL STEERING, WITH KORDEL MDU .................................................

WITHOUT COAST CONTROL OR WITH MANUAL COAST CONTROL - POWER STEERING ...............

WITHOUT COAST CONTROL OR WITH MANUAL COAST CONTROL - MANUAL STEERING, WITH CARRARO MDU .........................................................................................................................................

WITHOUT COAST CONTROL OR WITH MANUAL COAST CONTROL - MANUAL STEERING, WITH KORDEL MDU ............................................................................................................................................

TRACTION MOTOR WITH KORDEL MDU ..................................................................................................................................

TRACTION MOTOR ASSEMBLY WITH CARRARO MDU ...............................................................................................................................

V VISIBLE ALARM ..............................................................................................................................................

ii

See Service Manual for service procedures.

7-2 3-6 3-8 3-10 3-14 3-22 3-30 3-38 3-18 3-26 3-34 1-22 1-20 6-6

©2015 HYSTER COMPANY

01/2016

UNIT CODE C230 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

W WIRE HARNESS ADVANCED COAST CONTROL - MANUAL STEERING ...........................................................................

ADVANCED COAST CONTROL - POWER STEERING ............................................................................

AUDIBLE ALARM ........................................................................................................................................

COAST CONTROL - MANUAL STEERING ................................................................................................

HANDRAIL ..................................................................................................................................................

HEATER APPLICATION .............................................................................................................................

HEATER ASSEMBLY .................................................................................................................................

MANUAL STEERING ..................................................................................................................................

MANUAL STEERING - ALTERNATE PART, PAGE 1 OF 2 .......................................................................

MANUAL STEERING - ALTERNATE PART, PAGE 2 OF 2 .......................................................................

MICRO SWITCH - TILLER SWITCH INSTALLATION ................................................................................

MICRO SWITCH - HEATER INSTALLATION .............................................................................................

POWER STEERING ...................................................................................................................................

POWER STEERING - ALTERNATE PART, PAGE 1 OF 2 ........................................................................

POWER STEERING - ALTERNATE PART, PAGE 2 OF 2 ........................................................................

RF TERMINAL ............................................................................................................................................

SIDE GLIDE ................................................................................................................................................

STROBE LIGHT ..........................................................................................................................................

THERMOSTAT ............................................................................................................................................

TILLER HANDLE - COMPOSITE HANDLE, MANUAL STEERING ............................................................

TILLER HANDLE - METAL HANDLE, POWER STEERING .......................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

2-41 2-42 2-51 2-52 2-39 2-48 2-49 2-18 2-22 2-26 2-43 2-44 2-28 2-32 2-36 2-46 2-40 2-45 2-50 2-14 2-16

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ABBREVIATIONS QUICK REFERENCE SHEET Listed below are abbreviations used in parts manuals to denote the following expressions: spacer TERM

DEFINITION

TERM

DEFINITION

Amp

Amperes

FRE

Freezer Environment

AR

As Required

in.

inches

BDI

Battery Discharge Indicators

LPG

Liquefied Petroleum Gas

BWI

Brush Wear Indicator

MAP

Manifold Absolute Pressure

CE

Communicator End

mm

millimeters

CRE

Corrosive Environment

MSTS

Microprocessor Spark Timing System

D/B

Date Break

NPT

National Pipe Threads

dbA

Decibel "A" Scale

O/S

Oversize

DE

Drive End

PTO

Power Take Off

ECH

Empty Container Handler

RPM

Revolutions per Minute

ECH-3

Empty Container Handler - 3 High Stacking

S/N

Serial Number

TMM

Truck Management Module

ECH-4

Empty Container Handler - 4 High Stacking

UL Type D

Diesel-Powered Safety Rating

ECH-5

Empty Container Handler - 5 High Stacking

UL Type DS

Diesel-Powered Safety Rating

UL Type E

Battery-Powered Safety Rating

ECH-6

Empty Container Handler - 6 High Stacking

UL Type EE

Battery-Powered Safety Rating

UL Type ES

Battery-Powered Safety Rating

ECH-7

Empty Container Handler - 7 High Stacking

UL Type G

Gasoline-Powered Safety Rating

UL Type GS

Gasoline-Powered Safety Rating

ECM

Electronic Control Module

UL Type LP

Gas-Powered Safety Rating

ECN

Engineering Change Notice

UL Type LPS

LP Gas-Powered Safety Rating

EEPROM

Electrically Erasable Programmable Read Only Memory

U/S

Undersize

EPA

US Environmental Protection Agency

UL

Underwriters Laboratory

EPROM

Electrically Programmable Read Only Memory

V

Volts

iv

See Service Manual for service procedures.

©2015 HYSTER COMPANY

01/2016

UNIT CODE C230 NORTH AMERICA

HOW TO USE THE ILLUSTRATED PARTS MANUAL This parts manual describes and illustrates assemblies, subassemblies, and detail parts needed for service replacement.

©2015 HYSTER COMPANY

The different constructions are indicated by keys and footnotes. The callouts correspond to descriptions found on the next page.

See Service Manual for service procedures.

v

UNIT CODE C230 NORTH AMERICA

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HOW TO FIND THE DESIRED PART NUMBER

1.

2.

3.

4.

5.

WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN: Determine the function and application of the part required. Turn to the Sections Page. Choose the general area of reference most likely to include the part.

Turn to the section you chose. Use the Section Table of Contents to determine the assembly which would normally contain the part required.

Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN: Determine the assembly the required part is used on. Turn to the Table of Contents (Page i).

Locate the assembly the required part is used on and turn to the page indicated for that assembly.

Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS KNOWN: Use the Numerical Index (Page 8-1) to find the part number. Turn to the page listed and locate the part as indicated by the item number.

GENERAL:

6.

The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.

Parts Supersession Information. Part numbers that have this history will be displayed in the parts list in the order that they were superseded (from oldest to newest). The superseded part numbers will be shown with a line through them.

Five periods in the PART NO. column (. . . . .) indicate that the part is either Not Serviced Separately or there is a reference to another figure.

A figure reference is denoted by a pointing hand followed by a figure number in the DESCRIPTION column (FFigure 10)

7.

8.

vi

Keys are used to show two or more similar assemblies, RH and LH assembly parts, etc.

Select the appropriate key, "A", "B", "C", "D", or "E" and the corresponding quantity column to find the required parts. Two periods in the QTY column (..) indicate that the part is not used for that assembly.

Indented descriptions under the DESCRIPTION column are used to indicate assemblies and

subparts of assemblies. In the example on the previous page, BEARING CAP (Item 2) is a subpart of the major assembly CASE. 9. Quantities shown are for one assembly. The quantities of the subpart BEARING CAP are indicated as two and two. This means two per CASE assembly.

10. Serial number breaks identify the most current parts information and are shown as follows: → S/N D001H2628 Indicates last serial number affected.

S/N D001H2629 → Indicates the first serial number affected.

S/N D001H1553 ↔ S/N D001H3291 Indicates a range of serial numbers affected.

ECN numbers for pending serial numbers are shown to allow for the inclusion of the most current parts information and are identified as follows: → S/N Pending Per ECN 63243 Indicates a pending serial number for last unit affected.

S/N Pending Per ECN 63243 → Indicates a pending serial number for first unit affected.

Date breaks are used to indicate when a change occurred but a subsequent serial number break was not recorded. This is an arbitrary date usually based on the ECN release and are identified as follows: → D/B 3/00 Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 → Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 ↔ D/B 4/00 Indicates a range of production dates of the item affected.

Contact your local dealer for Hyster lift trucks for serial number information for items with a ECN or a date break.

ORDERING PARTS: When ordering replacement parts, give the unit serial number, part number, name of part and quantity required.

For any further information on parts, service, or ordering, consult your local dealer for Hyster lift trucks.

See Service Manual for service procedures.

©2015 HYSTER COMPANY

UNIT CODE C230 NORTH AMERICA

01/2016

IDENTIFICATION OF TRUCK SERIAL NUMBERS

(1) and (2)

The first letter and three numbers indicate the truck unit code.

(3)

The second letter indicates the plant of manufacture.

(4)

The four or five digit number indicates the production sequence number of the truck.

(5)

The final letter indicates the year of manufacture starting with "A" in 1957, 1980, and 2003.

The letters "I", "O", and "Q" will not be used.

For pending serial numbers contact your local dealer for Hyster lift trucks.

Parts referred to in this book as right or left hand parts are in accordance with the illustration above.

©2015 HYSTER COMPANY

See Service Manual for service procedures.

vii

UNIT CODE C230 NORTH AMERICA

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PUBLICATIONS Every new lift truck is provided with an OPERATING MANUAL. This manual has information that the operator must know for inspection and operation of the lift truck.

SERVICE MAINTENANCE MANUALS, which provide service and overhaul procedures, and PARTS

MANUALS with complete replacement part identification, are available at a nominal fee from your Hyster dealer to assist users in effectively maintaining Hyster lift trucks in a safe, useful condition. See the list below for information on ordering specific publications for this model lift truck.

PUBLICATION

HYSTER PART NUMBER

Operating Manual........................................................................................................................ 4092828 Service Manual (Complete)......................................................................................................... 4096086 Parts Manual............................................................................................................................... 4096116

viii

See Service Manual for service procedures.

©2015 HYSTER COMPANY

UNIT CODE C230 NORTH AMERICA

01/2016

1

FRAME/DRIVE UNIT

01/2016

UNIT CODE C230 NORTH AMERICA

SECTION 1 FRAME/DRIVE UNIT DESCRIPTION

PAGE

BATTERY RETENTION ..................................................................................................................................

BATTERY SPACER ........................................................................................................................................

BRAKE ASSEMBLY WITH KORDEL MDU ..................................................................................................................................

COVERS AND FLOORMAT ............................................................................................................................

DECALS ..........................................................................................................................................................

DRIVE UNIT INSTALLATION, WITH WHEEL AND TIRE AND STATIC STRAP MANUAL STEERING - WITH CARRARO MDU .........................................................................................

POWER STEERING ...................................................................................................................................

DRIVE WHEEL AND TIRE AND STATIC STRAP - WITH KORDEL MDU .............................................................................................

LOAD BACKREST BOLT-ON ....................................................................................................................................................

PIVOTED .....................................................................................................................................................

MASTER DRIVE UNIT KORDEL ......................................................................................................................................................

MANUAL STEERING - CARRARO .............................................................................................................

POWER STEERING ...................................................................................................................................

TRACTION MOTOR WITH KORDEL MDU ..................................................................................................................................

TRACTION MOTOR ASSEMBLY WITH CARRARO MDU ...............................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

1-26 1-28 1-3 1-24 1-32 1-6 1-8 1-4 1-31 1-30 1-2 1-12 1-16 1-22 1-20

1-1

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MASTER DRIVE UNIT (FIGURE 1-1) KORDEL

ITEM 1 1 1 1 1 2 3 4

1-2

PART NO.

DESCRIPTION

QTY

4639518 4129814 4129815 4129816 4129818 1475398 296424 2039316

Master Drive Unit Assembly ...............................................................................

Kit-Seal (Lower Radial Shaft) .........................................................................

Kit-Plug ...........................................................................................................

Kit-Bearing (Steering) .....................................................................................

Kit-Gear (Helical) ............................................................................................

Capscrew ............................................................................................................

Washer ...............................................................................................................

Nut ......................................................................................................................

See Service Manual for service procedures.

1 1 1 1 1 4 4 4

©2015 HYSTER COMPANY

UNIT CODE C230 NORTH AMERICA

01/2016

BRAKE ASSEMBLY (FIGURE 1-2) WITH KORDEL MDU

ITEM 1 2 3 4 5 6

PART NO. 2085166 a. . . . .

1641614 4038762 4028093 1641926 2094737

DESCRIPTION

QTY

Brake Assembly , Magnetic (With Diode) ...........................................................

Inductor Assembly ..........................................................................................

Rotor Assembly ..............................................................................................

Flange ............................................................................................................

Kit-Screw ........................................................................................................

Hub .................................................................................................................

Brake Enclosure Kit (Brake) ...............................................................................

1 1 1 1 1 1 1

FOOTNOTES: a

Supplied complete with items 2, 3, 4, and 5.

©2015 HYSTER COMPANY

See Service Manual for service procedures.

1-3

UNIT CODE C230 NORTH AMERICA

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DRIVE WHEEL AND TIRE (FIGURE 1-3) AND STATIC STRAP — WITH KORDEL MDU

ITEM 1 1 1 2 3 3 3 4 5 6 7 8 9 10

PART NO. 2040499 2040753 2059612 2038719 2037928 2306688 2059613 1343502 296424 a 15057 a 15129 a 15157 a 239906 a 18557

DESCRIPTION

QTY

Wheel and Tire (Rubber) ....................................................................................

Wheel and Tire (Poly) .........................................................................................

Wheel and Tire (Siped Poly) ...............................................................................

Drive Wheel ....................................................................................................

Tire (Polyurethane, 90 Durometer) .................................................................

Tire (Rubber) ..................................................................................................

Cushion Tire (Siped Poly) ..............................................................................

Capscrew ............................................................................................................

Washer ...............................................................................................................

Nut ......................................................................................................................

Lockwasher .........................................................................................................

Lockwasher .........................................................................................................

Static Strap (10 in.) .............................................................................................

Capscrew ............................................................................................................

1 1 1 1 1 1 1 5 9 1 2 1 1 1

FOOTNOTES: a

1-4

Used with Polyurethane Wheel and Tire Assembly

See Service Manual for service procedures.

©2015 HYSTER COMPANY

01/2016

UNIT CODE C230 NORTH AMERICA

NOTES

©2015 HYSTER COMPANY

See Service Manual for service procedures.

1-5