BRAKES

B60Z AC [B230];
B80Z AC [B233]; T5Z AC [B476];
T7Z AC [B477]; C60Z AC [B478]; C80Z AC [B479]

PART NO. 1640804 1800 SRM 1285

Brakes Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Accessing the Drive Unit Compartment ...................................................................................................... 1
B60-80Z AC .................................................................................................................................................. 1
C60-80Z AC and T5-7Z AC ............................................................................................................................ 2
Description ......................................................................................................................................................... 3
Special Precautions............................................................................................................................................ 4
Brake Check ....................................................................................................................................................... 5
Brake Release ................................................................................................................................................ 5
Brake Apply ................................................................................................................................................... 5
Air Gap ........................................................................................................................................................... 5
Hold On Grade Test ....................................................................................................................................... 7
Brake Assembly Repair ..................................................................................................................................... 7
B60Z AC, C60Z AC, and T5Z AC ........................................................................................................................ 7
Remove....................................................................................................................................................... 7
Repair......................................................................................................................................................... 8
Install ......................................................................................................................................................... 9
B80Z AC, C80Z AC, and T7Z AC ........................................................................................................................ 9
Remove....................................................................................................................................................... 9
Repair......................................................................................................................................................... 10
Install ......................................................................................................................................................... 11
Troubleshooting.................................................................................................................................................. 12

This section is for the following models:

B60Z AC [B230];
B80Z AC [B233];
T5Z AC [B476];
T7Z AC [B477];
C60Z AC [B478];
C80Z AC [B479]

2008 HYSTER COMPANY i

1800 SRM 1285 General

General
WARNING
DO NOT operate a lift truck that needs repairs.
If a repair is necessary, attach a DO NOT OPER-
ATE tag to the control handle and disconnect
the battery.

WARNING
Before performing repairs or adjustments on
the brake system, blocks must be placed under
each side of the frame to raise the drive tire
off the ground. The blocks must prevent the
lift truck from falling and causing personal in-
jury or property damage. See Periodic Mainte-
nance 8000 SRM 1368 or Periodic Maintenance
8000 SRM 1298 - How To Put A Lift Truck On 1. FLOORMAT
Blocks. 2. DRIVE UNIT COMPARTMENT COVER
3. FRAME
This section describes the electric brake and outlines 4. CASTER ADJUSTMENT ACCESS
the procedures for the maintenance, adjustment, and
repair that may be required for servicing these lift Figure 1. Floormat
trucks.

ACCESSING THE DRIVE UNIT

COMPARTMENT
B60-80Z AC
The drive unit compartment is concealed behind a
molded cover which fits securely around the drive
unit and steer support to the frame. The floormat
fits snugly in the operator platform after the drive
unit cover is installed.

To remove the drive unit cover, first lift the corners

of the floormat and pull it out away from the drive
unit. See Figure 1. Next, reach under the side of
the drive unit cover, near the bottom, and find the
grip slot. With both hands, pull up and away from
the truck until the bottom of the cover kicks out from
the retaining clips. See Figure 2. Repeat this for the
other side of the cover. Work around the edge of the
cover until free from the truck. 1. DRIVE UNIT COMPARTMENT COVER
2. RETAINING CLIPS
3. GRIP SLOT
4. FRAME

Figure 2. Drive Unit Compartment Cover

1
General
To install the drive unit cover, make sure the floor-
mat is pulled away from the drive unit and place the
bottom of the drive unit cover onto the operator plat-
form and position the lower edges partially into the
lower retaining clips. Push the top of the cover par-
tially into the upper retaining clips. Do not push ei-
ther edge of the cover in completely in before start-
ing all edges into the proper place. When the cover
is aligned and started properly, press the cover com-
pletely into the retaining clips and place the floormat
into the operator platform around the cover.
C60-80Z AC and T5-7Z AC
The drive unit compartment is concealed behind a
contoured, front cover which fits securely around the
drive unit and steer support to the frame. A lower
cover fits around the base of the drive unit platform
and is secured in place with three screws after the
front cover has been installed.
To remove the covers, first remove the three screws
securing the lower cover and remove the lower cover
1. FRONT COVER
2. LOWER COVER
Figure 3. Drive Unit Compartment Covers
2
1800 SRM 1285
from the lift truck. Next, reach under the side of
the front cover, near the bottom, and find the grip
slot. With both hands, pull up and away from the
truck until the bottom of the cover kicks out from the
retaining clips. Repeat this for the other side of the
cover. Work around the edge of the cover until free
from the truck. See Figure 3.
To install the covers, place the bottom of the front
cover onto the operator platform and position the
lower edges partially into the lower retaining clips.
Push the top of the cover partially into the upper
retaining clips. Do not push either edge of the
cover in completely before starting all edges into
the proper place. When the cover is aligned and
started properly, press the cover completely into the
retaining clips. Position the lower cover around the
base of the front cover as removed. Make sure the
spring nut clips and the lower cover mounting holes
are aligned. Install the three screws to secure the
lower cover in place.
3. SPRING NUT CLIPS
4. SCREWS
1800 SRM 1285 Description

Description
Motorized hand trucks have three methods of brak- If the battery state of charge is too low, or if there is
ing: damage to the brake, MDU, or electrical system, then
1. Regenerative (Neutral) braking it may be necessary to physically remove the brake
2. Controlled plugging or service the truck where it is located.
3. Application of the spring-applied, electrically-re-
leased friction brake

NOTE: The preferred method of stopping the truck is:

Regenerative (Neutral) braking
or
Controlled plugging

Regenerative (Neutral) braking applies a retarding

force to the drive wheel through the traction motor,
allowing the unit to slow to a gradual stop. It is ap-
plied by returning the speed/direction control to the
NEUTRAL position.

NOTE: The directional controls are spring loaded and

will automatically return to the NEUTRAL position
when released.

Controlled plugging is reversing the speed/direction

control while traveling, causing the unit to slow to
a stop. Release the speed/direction control to remain
stopped. If the speed/direction control is not released
after truck is stopped, the lift truck will accelerate in
the direction the control is being turned. Controlled
plugging should stop the truck within one to one and
a half truck lengths, depending on speed and load. A. BRAKE ON C. BRAKE OFF
B. REGEN BRAKING
A spring-applied, electrically-released friction brake
is mounted to the drive motor. When the brake is ap- Figure 4. Brake Operation (B60-80Z AC)
plied, springs inside the brake assembly compress a
rotating friction disk against two stationary plates.
When the brake is released, the brake coil energizes
and pulls the armature plate away from the friction
disk, releasing the brake as the drive motor is acti-
vated. This brake functions primarily as a parking
brake and is applied when the control handle arm is
in the BRAKE ON position (B60-80Z AC), when the
parking brake switch is ON or the brake lever is in
position 3, (C60-80Z AC and T5-7Z AC), when the key
switch is in the OFF position or there is insufficient
power to release the brake, or if a traction fault oc-
curs. See Figure 4 or Figure 5.

The parking brake must be released before the lift

truck can be towed. If there is not sufficient battery
power, placing the control handle in the operating po-
sition will not release the parking brake. Connect a
properly charged battery to the lift truck if necessary.
1. BRAKES DISENGAGED (POSITION ONE)
2. REGENERATIVE BRAKING (POSITION TWO)
3. MECHANICAL BRAKING (POSITION THREE)
Figure 5. Brake Operation (C60-80Z AC and
T5-7Z AC)

3
Special Precautions 1800 SRM 1285

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.

To avoid personal injury and prevent electrical

shock, perform the following steps before per-
forming any troubleshooting or adjustments,
and connecting or disconnecting a handset or
PC.

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.

1. Turn the key switch to the OFF position and dis-

connect the battery.

2. Remove the drive unit compartment cover to ac-

cess the controller.

3. Remove the four screws securing the cover of the

controller shield box (Arctic option only).

4. Discharge the capacitors in the controllers by

connecting a 200-ohm, 2-watt resistor across the
controllers B+ and B terminals. See Figure 6.
DO NOT short across the motor controller ter-
minals with a screwdriver or jumper wire. 1. CONTROLLER
2. POSITIVE CONNECTION
5. Remove the 200-ohm, 2-watt resistor and install 3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
the cover to the shield box before reconnecting 5. NEGATIVE CONNECTION
the battery. Install drive unit compartment cov-
ers as removed when repairs are complete. Figure 6. Discharging the Controller

4
1800 SRM 1285
Brake Check
BRAKE RELEASE
To release the brake, the lift truck control arm must
be in the BRAKE OFF position with the key switch
in the ON position and a properly charged battery
connected. If the brake does not release under these
conditions, make the following checks to identify the
problem.
1. Move the truck to a safe, level area and turn the
key switch to the OFF position. Raise the drive
tire and position on blocks to allow for testing
without danger of unexpected movement of the
truck. See Periodic Maintenance 8000 SRM
1298 or Periodic Maintenance 8000 SRM 1368
for more information on putting the lift truck on
blocks.
2. Remove the drive unit compartment cover. See
Accessing the Drive Unit Compartment in this
section.
3. Check that the brake switch(es) and potentiome-
ter (power assist only) are adjusted properly
and functioning correctly. Check their wiring for
damage, loose connections, and corrosion.
4. Disconnect the brake wiring connector from the
main wiring harness connector. Turn the key
switch to the ON position and move the control
handle to the BRAKE ON position. Touch volt-
meter leads across the main wiring harness con-
nector pins. Voltage should read 24 5 VDC.
If voltage is not within specification, check the
connector and wiring for damage. If problem
persists, troubleshoot the electrical system. If
supply voltage is within specification, proceed to
Step 5.
5. Check the stator resistance using an ohmmeter.
If resistance is not within specification, check the
connector and wiring for damage. See Table 1. If
problem persists, remove and replace the brake.
See Brake Assembly Repair.
Table 1. Stator Resistance
B60Z AC, C60Z AC, 13.3 to 15.3 Ohms
and T5Z AC
B80Z AC, C80Z AC, 9.9 to 11.6 Ohms
and T7Z AC
Brake Check
BRAKE APPLY
1. To apply the brake, first release the brake (refer
to Brake Release) then move the lift truck control
arm to the BRAKE ON position. Listen for a
solid, single "click."
2. If the brake appears not to apply:
a. Turn the key switch to the OFF position. Lis-
ten for a solid, single "click."
b. If "click" is present, check the brake switches
for proper adjustment.
c. If brake appears to not have applied, attempt
to roll the lift truck slightly to determine if
brake is holding the traction motor.
d. If the truck can be rolled by hand with the
key switch in the OFF position, repair or re-
place the brake. See Brake Assembly Repair.
3. If unsure whether brake is applying, test the
brake using the "Hold On Grade" procedure. See
Hold On Grade Test in this section. The brake is
designed to hold the truck loaded to capacity on
a 10% grade.
AIR GAP
CAUTION
The brake is not adjustable. Check the air gap
to determine if repair or replacement is neces-
sary.
1. Check the three outer socket head screws for ap-
propriate torque to secure the brake to the motor.
NOTE: The air gap is very thin and cannot be checked
visually. Illustrations are not to scale and are for
location references only.
2. Check for correct air gap by measuring the dis-
tance between the bottom of the stator and the
top of the pressure plate with the brake applied
(disconnected) using feeler gauges. See Figure 7.
specifications vary, depending on truck model.
See Table 2.
5
Brake Check 1800 SRM 1285

1. LOCATION 1
2. LOCATION 2
3. LOCATION 3
4. LOCATION 4
5. LOCATION 5
6. LOCATION 6

Figure 8. Check Locations (Typical Brake)

4. If the air gap allows the maximum feeler gage to

enter any of the six locations, replace the friction
disk or the entire brake assembly. See Brake As-
sembly Repair.
1. STATOR 5. If the air gap is too tight for a minimum feeler
2. AIR GAP
3. PRESSURE PLATE gage to enter any of the six locations, the air gap
4. FEELER GAUGE has been altered by internal damage or tamper-
ing. Replace the brake assembly.
Figure 7. Air Gap

3. The air gap should be checked for maximum and

minimum clearance at the six locations shown in
Figure 8.

Table 2. Adjustment Specifications

Air Gap Mounting Capscrews Minimum Friction

Truck Model
Min Max Torque Disk Thickness
AC AC
B60Z , C60Z , 0.25 mm 0.40 mm
8 Nm (71 lbf in) 8.50 mm (0.33 in.)
and T5Z AC (0.010 in.) (0.016 in.)
B80Z AC, C80Z AC, 0.20 mm 0.35 mm
22 Nm (16 lbf ft) 11.75 mm (0.46 in.)
and T7Z AC (0.008 in.) (0.014 in.)

6
1800 SRM 1285
NOTE: During brake operation, brake should engage
and release with a solid, single-click noise. A double-
clicking noise indicates that one side of the brake is
releasing before the other.
6. Listen to verify brake releases and applies in one
smooth operation. A double-clicking noise indi-
cates that one side of the brake is releasing before
the other due to internal damage or tampering.
Replace the brake assembly.
HOLD ON GRADE TEST
The brake should be checked for hold capacity every
2000 hours or yearly or any time substandard brake
performance is suspected.
WARNING
DO NOT stand below or ride on the lift truck
when performing the hold on grade test.
1. Load the truck to capacity with a stable load cen-
tered on the forks. See Periodic Maintenance
8000 SRM 1298 or Periodic Maintenance 8000
SRM 1368.
NOTE: The 10% grade refers to a slope with a 1.0 m
rise in 10.0 m (3 ft rise in 30 ft).
Brake Assembly Repair
B60Z AC, C60Z AC, AND T5Z AC
CAUTION
The brake is not adjustable. Be careful not to
alter the position of the standoff bolts during
repairs.
Three hollow stand-off bolts are installed up through
holes in the pressure plate and thread into the bot-
tom of the stator. Three mounting screws are in-
stalled into the top of the stator and down through
the stand-off bolts to secure the brake assembly to
the motor end head.
Remove
1. Move the truck to a safe, level area. Turn the key
switch to the OFF position and disconnect the
battery. Block the wheels to prevent unexpected
Brake Assembly Repair
2. Position the lift truck at the base of a 10% grade
with the forks facing uphill. Standing to the side
of the lift truck, slowly drive the lift truck up the
grade and bring the lift truck to a stop using the
directional controls (plugging). See Figure 9.
3. Stand clear of the lift truck and move the control
handle to the BRAKE OFF position. If the brake
fails to hold the lift truck on the grade, the brake
assembly must be repaired or replaced. For infor-
mation on repairing or replacing the brake, refer
to Brake Assembly Repair in this section.
1. CAPACITY LOAD
2. 10-PERCENT GRADE
3. FORKS UPHILL
Figure 9. Hold On Grade Test
movement. See Periodic Maintenance 8000
SRM 1298 or Periodic Maintenance 8000 SRM
1368.
2. Remove the drive unit compartment cover. See
Accessing the Drive Unit Compartment in this
section.
3. Discharge the capacitor. See Special Precautions
in this section.
4. Disconnect the brake wiring connector from the
main wiring harness connector.
5. Remove the three socket head screws from the
top of the brake. See Figure 10.
6. Slide the brake assembly up off the hub splines
and remove from the lift truck.
7
Brake Assembly Repair 1800 SRM 1285

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.

7. Remove the snap ring from the top of the traction

motor shaft securing the brake hub in place.

8. Slide the brake hub up off the traction motor

shaft. Recover the Woodruff key. Remove the
lower snap ring if necessary.

Repair

CAUTION
The brake is not adjustable. Be careful not to
alter the position of the standoff bolts during
repairs.

1. Remove the parking brake from the drive motor.

Place on a clean workbench with the mounting
plate facing up.

2. Lift mounting plate from brake assembly.

3. Remove old friction disc.

4. Inspect mounting plate and pressure plate for

damage. Replace the brake assembly if damaged.

CAUTION
1. SOCKET HEAD SCREWS DO NOT disassemble beyond this point. The
2. BRAKE ASSEMBLY brake is not adjustable. Be careful not to al-
3. UPPER SNAP RING ter the position of the standoff bolts during re-
4. BRAKE HUB
5. LOWER SNAP RING pairs.
6. MOTOR SHAFT
7. WOODRUFF KEY 5. Install new friction disk onto pressure plate with
8. TRACTION MOTOR splined hub side down.

Figure 10. Brake Assembly (B60Z AC, C60Z AC, 6. Carefully position mounting plate on top of as-
and T5Z AC) sembly with mounting holes aligned with stand-
off bolts.

8
1800 SRM 1285
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.
1. Install lower snap ring as removed.
2. Position Woodruff key into the groove on the trac-
tion motor shaft as removed.
3. Align the Woodruff key with the groove inside the
brake hub. Slide the brake hub down onto the
traction motor shaft and Woodruff key.
4. Secure in place with upper snap ring as removed.
NOTE: Hold the brake assembly components to-
gether while installing. Mounting capscrews will
hold the assembly together when installed.
5. Position the brake assembly to align holes in
brake with holes in traction motor head. Lower
the brake assembly onto the brake hub. Slightly
turn the brake assembly to align splines and
lower until the brake assembly touches the top
of the traction motor.
6. Make sure the brake assembly holes align with
the holes in the traction motor head. Install
three mounting screws. Tighten to touch, then
torque to 8 Nm (71 lbf in).
7. Connect the brake wiring connector to the main
wiring harness.
8. Reinstall the drive unit compartment cover. See
Accessing the Drive Unit Compartment in this
section.
9. Reconnect the battery and turn the key switch to
the ON position. Remove blocks from the wheels
and test for proper operation.
Brake Assembly Repair
B80Z AC, C80Z AC, AND T7Z AC
CAUTION
The brake is not adjustable. Be careful not to
alter the position of the standoff bolts during
repairs.
Three hollow stand-off bolts are installed up through
holes in the pressure plate and thread into the bot-
tom of the stator. Three countersunk screws are in-
stalled into the bottom of the mounting plate and
up through the stand-off bolts into the stator to se-
cure the stand-off bolts in place between the mount-
ing plate and the stator.
Remove
1. Move the truck to a safe, level area. Turn the key
switch to the OFF position and disconnect the
battery. Block the wheels to prevent unexpected
movement.
2. Remove the drive unit compartment cover. See
Accessing the Drive Unit Compartment in this
section.
3. Discharge the capacitor. See Special Precautions
in this section.
4. Disconnect the brake wiring connector from the
main wiring harness connector.
5. On the B80Z AC, the steering and dash assembly
must be partially removed to access the brake
mounting screws. For additional information
about removal and installation of the steer sup-
port and dash, see Steering Mechanism 1600
SRM 1284 or Steering Mechanism 1600 SRM
1031.
6. Remove the three capscrews securing the mount-
ing plate of the brake assembly to the motor end
head.
7. Slide the brake assembly up off the hub splines
and remove from the lift truck. See Figure 11.
9
Brake Assembly Repair 1800 SRM 1285

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.

8. Remove the snap ring from the top of the traction

motor shaft securing the brake hub in place.

9. Slide the brake hub up off the traction motor

shaft. Recover the Woodruff key. Remove the
lower snap ring if necessary.

Repair

CAUTION
The brake is not adjustable. Be careful not to
alter the position of the standoff bolts during
repairs.

1. Remove the parking brake from the drive motor.

Place on a clean workbench with the mounting
plate facing up.

2. Remove three countersunk, socket-head screws

from the mounting plate of the brake assembly.

3. Lift mounting plate from brake assembly.

4. Remove old friction disc.

5. Inspect mounting plate and pressure plate for

damage. Replace the brake assembly if damaged.

CAUTION
DO NOT disassemble beyond this point. The
1. SOCKET HEAD SCREWS brake is not adjustable. Be careful not to al-
2. BRAKE ASSEMBLY ter the position of the standoff bolts during re-
3. UPPER SNAP RING pairs.
4. BRAKE HUB
5. LOWER SNAP RING 6. Install new friction disk onto pressure plate with
6. MOTOR SHAFT splined hub side down.
7. WOODRUFF KEY
8. TRACTION MOTOR 7. Carefully position mounting plate on top of as-
sembly with mounting holes aligned with stand-
Figure 11. Brake Assembly (B80Z AC, C80Z AC,
off bolts.
and T7Z AC)
8. Install three countersunk mounting screws
WARNING through mounting plate, standoff bolts, and
Use caution when removing or installing snap pressure plate into the stator as removed.
rings. Snap rings can eject during removal or

10
1800 SRM 1285
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.
1. Install lower snap ring as removed.
2. Position the Woodruff key into the groove on the
traction motor shaft as removed.
3. Align the Woodruff key with the groove inside the
brake hub. Slide the brake hub down onto the
traction motor shaft and Woodruff key.
4. Secure in place with upper snap ring as removed.
5. Position the brake assembly to align holes in
brake with holes in traction motor head. Lower
the brake assembly onto the brake hub. Slightly
turn the brake assembly to align splines and
Brake Assembly Repair
lower until the brake assembly touches the top
of the traction motor.
6. Make sure the brake assembly holes align with
the holes in the traction motor head. Install
three mounting screws. Tighten to touch, then
torque to 22 Nm (16 lbf ft).
7. Connect the brake wiring connector to the main
wiring harness.
8. On the B80Z AC, the steering and dash assembly
must be partially removed to access the brake
mounting screws. Replace the steer support and
dash after the brake has been installed. See
Steering Mechanism 1600 SRM 1284 or Steer-
ing Mechanism 1600 SRM 1031.
9. Reinstall the drive unit compartment cover. See
Accessing the Drive Unit Compartment in this
section.
10. Reconnect the battery and turn the key switch to
the ON position. Remove blocks from the wheels
and test for proper operation.
11
Troubleshooting
Troubleshooting
PROBLEM POSSIBLE CAUSE
Brake does not release. Key switch is in the OFF position.
Battery is not connected or properly
charged.
Handle is not in the BRAKE OFF
position.
Control handle arm prox switch is
out of adjustment/damaged.
Brake coil open circuit.
Brake coil has shorted to frame or be-
tween the windings.
Incorrect or no voltage supplied to
brake.
Brake does not hold truck Air gap is too large.
loaded to capacity on 10%
grade.
Friction disk is too worn.
Brake hub damaged.
Brake will not apply. Mechanical failure within the brake
assembly.
Brake linings worn beyond specifica-
tion. See Brake Check in this sec-
tion.
12
1800 SRM 1285
PROCEDURE OR ACTION
Turn key switch to the ON position.
Connect or clean battery connections.
Charge if necessary.
Move the handle to the BRAKE OFF
position.
Adjust/replace control handle arm
prox switch. See the section Elec-
trical System 2200 SRM 1287 or
Electrical System 2200 SRM 1357.
Measure coil resistance. Refer to
Brake Check in this section. If resis-
tance is above specification, replace
the brake assembly.
Measure coil resistance. Refer to
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.
Measure voltage to brake using a
voltmeter. If voltage is not 24 VDC
10%, troubleshoot brake wiring.
Troubleshoot electrical system and
controller.
Repair or replace the brake assembly.
Repair or replace the brake assembly.
Replace brake and hub assembly.
Replace the brake assembly.
Repair or replace the brake assembly.