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Brakes - PDF t5
Brakes - PDF t5
B60Z AC [B230];
B80Z AC [B233]; T5Z AC [B476];
T7Z AC [B477]; C60Z AC [B478]; C80Z AC [B479]
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
B60Z AC [B230];
B80Z AC [B233];
T5Z AC [B476];
T7Z AC [B477];
C60Z AC [B478];
C80Z AC [B479]
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.
1
General 1800 SRM 1285
To install the drive unit cover, make sure the floor- from the lift truck. Next, reach under the side of
mat is pulled away from the drive unit and place the the front cover, near the bottom, and find the grip
bottom of the drive unit cover onto the operator plat- slot. With both hands, pull up and away from the
form and position the lower edges partially into the truck until the bottom of the cover kicks out from the
lower retaining clips. Push the top of the cover par- retaining clips. Repeat this for the other side of the
tially into the upper retaining clips. Do not push ei- cover. Work around the edge of the cover until free
ther edge of the cover in completely in before start- from the truck. See Figure 3.
ing all edges into the proper place. When the cover
is aligned and started properly, press the cover com- To install the covers, place the bottom of the front
pletely into the retaining clips and place the floormat cover onto the operator platform and position the
into the operator platform around the cover. lower edges partially into the lower retaining clips.
Push the top of the cover partially into the upper
C60-80Z AC and T5-7Z AC retaining clips. Do not push either edge of the
cover in completely before starting all edges into
The drive unit compartment is concealed behind a the proper place. When the cover is aligned and
contoured, front cover which fits securely around the started properly, press the cover completely into the
drive unit and steer support to the frame. A lower retaining clips. Position the lower cover around the
cover fits around the base of the drive unit platform base of the front cover as removed. Make sure the
and is secured in place with three screws after the spring nut clips and the lower cover mounting holes
front cover has been installed. are aligned. Install the three screws to secure the
lower cover in place.
To remove the covers, first remove the three screws
securing the lower cover and remove the lower cover
2
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
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.
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.
4
1800 SRM 1285 Brake Check
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
1298 or Periodic Maintenance 8000 SRM 1368 c. If brake appears to not have applied, attempt
for more information on putting the lift truck on to roll the lift truck slightly to determine if
blocks. brake is holding the traction motor.
2. Remove the drive unit compartment cover. See d. If the truck can be rolled by hand with the
Accessing the Drive Unit Compartment in this key switch in the OFF position, repair or re-
section. place the brake. See Brake Assembly Repair.
3. Check that the brake switch(es) and potentiome- 3. If unsure whether brake is applying, test the
ter (power assist only) are adjusted properly brake using the "Hold On Grade" procedure. See
and functioning correctly. Check their wiring for Hold On Grade Test in this section. The brake is
damage, loose connections, and corrosion. designed to hold the truck loaded to capacity on
a 10% grade.
4. Disconnect the brake wiring connector from the
main wiring harness connector. Turn the key
AIR GAP
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- CAUTION
nector pins. Voltage should read 24 5 VDC. The brake is not adjustable. Check the air gap
If voltage is not within specification, check the to determine if repair or replacement is neces-
connector and wiring for damage. If problem sary.
persists, troubleshoot the electrical system. If
supply voltage is within specification, proceed to 1. Check the three outer socket head screws for ap-
Step 5. propriate torque to secure the brake to the motor.
5. Check the stator resistance using an ohmmeter. NOTE: The air gap is very thin and cannot be checked
If resistance is not within specification, check the visually. Illustrations are not to scale and are for
connector and wiring for damage. See Table 1. If location references only.
problem persists, remove and replace the brake.
2. Check for correct air gap by measuring the dis-
See Brake Assembly Repair.
tance between the bottom of the stator and the
Table 1. Stator Resistance top of the pressure plate with the brake applied
(disconnected) using feeler gauges. See Figure 7.
B60Z AC, C60Z AC, 13.3 to 15.3 Ohms specifications vary, depending on truck model.
and T5Z AC 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
6
1800 SRM 1285 Brake Assembly Repair
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.
Three hollow stand-off bolts are installed up through 3. Discharge the capacitor. See Special Precautions
holes in the pressure plate and thread into the bot- in this section.
tom of the stator. Three mounting screws are in-
stalled into the top of the stator and down through 4. Disconnect the brake wiring connector from the
the stand-off bolts to secure the brake assembly to main wiring harness connector.
the motor end head.
5. Remove the three socket head screws from the
Remove top of the brake. See Figure 10.
1. Move the truck to a safe, level area. Turn the key 6. Slide the brake assembly up off the hub splines
switch to the OFF position and disconnect the and remove from the lift truck.
battery. Block the wheels to prevent unexpected
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.
Repair
CAUTION
The brake is not adjustable. Be careful not to
alter the position of the standoff bolts during
repairs.
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 Brake Assembly Repair
WARNING CAUTION
Use caution when removing or installing snap The brake is not adjustable. Be careful not to
rings. Snap rings can eject during removal or alter the position of the standoff bolts during
installation with enough force to cause per- repairs.
sonal injury. Always use the proper snap ring
pliers and wear eye and face protection during Three hollow stand-off bolts are installed up through
removal and installation. holes in the pressure plate and thread into the bot-
tom of the stator. Three countersunk screws are in-
1. Install lower snap ring as removed. stalled into the bottom of the mounting plate and
up through the stand-off bolts into the stator to se-
2. Position Woodruff key into the groove on the trac-
cure the stand-off bolts in place between the mount-
tion motor shaft as removed.
ing plate and the stator.
3. Align the Woodruff key with the groove inside the
brake hub. Slide the brake hub down onto the Remove
traction motor shaft and Woodruff key.
1. Move the truck to a safe, level area. Turn the key
4. Secure in place with upper snap ring as removed. switch to the OFF position and disconnect the
battery. Block the wheels to prevent unexpected
NOTE: Hold the brake assembly components to- movement.
gether while installing. Mounting capscrews will
hold the assembly together when installed. 2. Remove the drive unit compartment cover. See
Accessing the Drive Unit Compartment in this
5. Position the brake assembly to align holes in section.
brake with holes in traction motor head. Lower
the brake assembly onto the brake hub. Slightly 3. Discharge the capacitor. See Special Precautions
turn the brake assembly to align splines and in this section.
lower until the brake assembly touches the top
4. Disconnect the brake wiring connector from the
of the traction motor.
main wiring harness connector.
6. Make sure the brake assembly holes align with
5. On the B80Z AC, the steering and dash assembly
the holes in the traction motor head. Install
must be partially removed to access the brake
three mounting screws. Tighten to touch, then
mounting screws. For additional information
torque to 8 Nm (71 lbf in).
about removal and installation of the steer sup-
7. Connect the brake wiring connector to the main port and dash, see Steering Mechanism 1600
wiring harness. SRM 1284 or Steering Mechanism 1600 SRM
1031.
8. Reinstall the drive unit compartment cover. See
Accessing the Drive Unit Compartment in this 6. Remove the three capscrews securing the mount-
section. ing plate of the brake assembly to the motor end
head.
9. Reconnect the battery and turn the key switch to
the ON position. Remove blocks from the wheels 7. Slide the brake assembly up off the hub splines
and test for proper operation. and remove from the lift truck. See Figure 11.
9
Brake Assembly Repair 1800 SRM 1285
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
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 Brake Assembly Repair
1. Install lower snap ring as removed. 8. On the B80Z AC, the steering and dash assembly
must be partially removed to access the brake
2. Position the Woodruff key into the groove on the mounting screws. Replace the steer support and
traction motor shaft as removed. dash after the brake has been installed. See
Steering Mechanism 1600 SRM 1284 or Steer-
3. Align the Woodruff key with the groove inside the
ing Mechanism 1600 SRM 1031.
brake hub. Slide the brake hub down onto the
traction motor shaft and Woodruff key. 9. Reinstall the drive unit compartment cover. See
Accessing the Drive Unit Compartment in this
4. Secure in place with upper snap ring as removed.
section.
5. Position the brake assembly to align holes in
10. Reconnect the battery and turn the key switch to
brake with holes in traction motor head. Lower
the ON position. Remove blocks from the wheels
the brake assembly onto the brake hub. Slightly
and test for proper operation.
turn the brake assembly to align splines and
11
Troubleshooting 1800 SRM 1285
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.
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.
12