Hyster T5Z Manual

PERIODIC
MAINTENANCE
T5Z [A476];
T7Z [A477];
C60Z [A478];
C80Z [A479]
PART NO. 1524180 8000 SRM 1032

Periodic Maintenance Table of Contents
TABLE OF CONTENTS
Introduction........................................................................................................................................................ 1
General........................................................................................................................................................... 1
Drive Unit Compartment Covers.................................................................................................................. 1
Remove....................................................................................................................................................... 1
Install......................................................................................................................................................... 1
How to Move a Disabled Truck ..................................................................................................................... 2
How to Tow the Truck ............................................................................................................................... 3
How to Put the Truck on Blocks ................................................................................................................... 4
How to Raise Drive/Steer Tire.................................................................................................................. 4
How to Raise the Load Wheels ................................................................................................................. 4
Special Precautions............................................................................................................................................ 5
Maintenance Schedule....................................................................................................................................... 6
Maintenance Procedures Every 8 Hours or Daily............................................................................................ 9
Checks With the Key Switch OFF ................................................................................................................ 9
Safety Labels ............................................................................................................................................. 9
Battery ....................................................................................................................................................... 10
Frame......................................................................................................................................................... 10
Load Wheels, Drive Tire, and Casters ..................................................................................................... 10
Lift Linkage (C60Z and C80Z).................................................................................................................. 11
Coupler (T5Z and T7Z).............................................................................................................................. 11
Steering Operation.................................................................................................................................... 11
Checks With the Key Switch ON .................................................................................................................. 11
Control Handle .......................................................................................................................................... 11
Gauges ....................................................................................................................................................... 11
Fuses .......................................................................................................................................................... 12
High Speed Switch .................................................................................................................................... 12
Hydraulic (C60Z and C80Z)...................................................................................................................... 12
Hand Brake ............................................................................................................................................... 12
Maintenance Procedures Every 350 Hours or Every 2 Months ...................................................................... 13
Battery Equalizing Charge ........................................................................................................................... 13
Coupler Lubrication (T5Z and T7Z).............................................................................................................. 13
Control Handle Pivot..................................................................................................................................... 14
Brakes ............................................................................................................................................................ 14
Drive Tire and Wheel .................................................................................................................................... 14
Drive Unit Assembly ..................................................................................................................................... 14
Check Oil Level ......................................................................................................................................... 14
Motor Brushes ............................................................................................................................................... 15
Maintenance Procedures Every 2000 Hours or Yearly .................................................................................... 16
Load Wheel Bearings (T5Z and T7Z)............................................................................................................ 16
Remove....................................................................................................................................................... 16
Inspect........................................................................................................................................................ 16
Install......................................................................................................................................................... 16
Contactor........................................................................................................................................................ 18
Inspecting the Contacts ............................................................................................................................ 18
Hydraulic System (C60Z and C80Z) ............................................................................................................. 18
Changing the Hydraulic Oil...................................................................................................................... 18
Master Drive Unit ......................................................................................................................................... 23
Drive Unit Gear Oil................................................................................................................................... 23
Welding Repairs ................................................................................................................................................. 24
Battery Maintenance ......................................................................................................................................... 24
How to Charge Battery.................................................................................................................................. 24
©2007 HYSTER COMPANY i

Table of Contents Periodic Maintenance
TABLE OF CONTENTS (Continued)
How to Change Battery................................................................................................................................. 25
Adjusting the Battery Spacers.................................................................................................................. 25
Changing Battery With Rollers ................................................................................................................ 26
Remove .................................................................................................................................................. 26
Install..................................................................................................................................................... 27
Remove Battery Using Overhead Crane.................................................................................................. 27
Install Battery Using Overhead Crane.................................................................................................... 27
Battery Specifications ................................................................................................................................... 28
This section is for the following models:
T5Z [A476];
T7Z [A477];
C60Z [A478];
C80Z [A479]
ii

8000 SRM 1032 Introduction
Introduction
GENERAL
This manual contains the instructions for periodic
maintenance and inspection and a Maintenance
Schedule.
The Maintenance Schedule has time intervals for in-
spection, lubrication, and periodic maintenance. The
time intervals are based on normal operation. Nor-
mal operation is considered to be one 8-hour shift
per day in a relatively clean environment on an im-
proved surface. Multiple shifts, dirty operating con-
ditions, etc., will require a reduction in the recom-
mended time periods in the Maintenance Schedule.
WARNING
DO NOT make repairs or adjustments unless
you have authorization and training. Repairs
and adjustments that are not correct can cre-
ate dangerous operating conditions.
DO NOT operate a truck that needs repairs. Re-
port the need for repairs to your supervisor im-
mediately. If repair is necessary, attach a DO
NOT OPERATE tag to the control handle.
Some users have service personnel and facilities to
perform the procedures listed in the Maintenance
Schedule. Service Manuals are available from your
Hyster®lift truck dealer to help users who do their
own repairs.
Your Hyster lift truck dealer has the trained person-
nel and equipment to conduct a complete program
of inspection, lubrication, and maintenance. This
complete program will help your truck operate bet-
ter over a longer period of time.
NOTE: The front end of the truck is the control han-
dle end. Forward travel is movement with the load
wheels trailing. Reverse is travel with the drive tire
trailing. Left and right refer to the operator’s left-
and right-hand sides when standing on the truck,
driving in the forward direction. See Figure 1.
DRIVE UNIT COMPARTMENT COVERS
Many procedures require access to the drive unit
compartment. The drive unit compartment is lo-
cated at the front of the truck in front of the battery
and below the control handle assembly. Two covers
must be removed to access the drive unit compart-
ment. The covers must be correctly reinstalled to
protect the electrical system and other components
housed in the drive unit compartment.
Remove
1. Remove the three screws retaining the lower
drive unit compartment cover.
2. Lift the lower cover from the drive unit compart-
ment.
3. Pull the bottom edge on one side of the upper
cover from the drive unit compartment. Con-
tinue pulling around the edge of the cover until
completely removed from the truck.
Install
1. Place the top corners of the upper cover into the
retaining clips in the drive unit compartment.
2. Working around each side, bump the cover into
place using the heel of the hand or a rubber ham-
mer.
3. Place the lower cover into the bottom of the drive
unit compartment.
4. Secure lower cover into place using three screws.
1

Introduction 8000 SRM 1032
A. RH SIDE
B. LH SIDE C. FORWARD D. REVERSE
Figure 1. Truck Orientation
HOW TO MOVE A DISABLED TRUCK
Trucks are not normally towed. If the traction sys-
tem will not operate, make repairs at the location, if
possible. If the truck must be towed, tow the truck
forward (in the direction of the control handle).
CAUTION
Never attempt to tow by fastening any towing
device to the control handle.
Carefully attach the tow chain completely around
the motor compartment and battery compartment.
Make sure the tow chain is installed on the truck
so the chain will not cause damage. Make sure the
parking brake is released on the truck. Steer the
truck with the control handle while it is being towed.
DO NOT get between the towing vehicle and the
disabled truck.
2

8000 SRM 1032 Introduction
How to Tow the Truck
WARNING
Use extra care when moving a truck during the
following conditions:
• Brake does not operate correctly
• Steering does not operate correctly
• Tire is damaged
• Traction conditions are bad
If there is no power, the drive wheel will not
turn freely. Poor traction can cause the dis-
abled truck or towing vehicle to slide. Grades
will require additional distance to stop.
Never carry a disabled truck unless it MUST
be moved and cannot be towed. The lift truck
used to lift the disabled truck MUST have a
rated capacity equal to or greater than the
weight of the truck. See the nameplate on the
truck for the approximate total weight. The
fork spread must be equal to half the width of
the disabled truck. The forks must extend the
full width of the disabled truck. Put the weight
of the disabled truck at the center of the forks
and be careful not to damage the underside of
it. Tilt the mast back and travel slowly.
Be sure to stay clear of the tow chain, towing
vehicle, and truck during the towing operation
to prevent injury.
CAUTION
Never tow the lift truck faster than the speed
of a person walking. Steering can be difficult
and motor damage can occur at higher speeds.
Always tow smoothly without sudden starts.
Never tow the lift truck using the control han-
dle. Make sure the brake has been released
during towing.
1. Remove the drive unit compartment covers. See
Drive Unit Compartment Covers. Fasten the tow
chain completely around the motor and battery
compartments. Make sure the tow chain has the
capacity to tow the weight. The chain must not
causedamagetoeithertruck.
2. Connect the battery. Turn the key switch to the
ON position and the parking brake switch to the
OFF position.
WARNING
Make sure no one except the driver is near the
truck during towing. Both the tow truck and
the disabled truck can cause an injury during
towing.
CAUTION
Travel slowly and DO NOT tow on grades.
NEVER tow the lift truck faster than a normal
walking speed. Always tow smoothly without
sudden starts or stops.
Until repairs are complete, keep a DO NOT OP-
ERATE tag on the control handle.
3. Tow the lift truck slowly while a driver steers the
truck while walking along side.
4. If towing with lift truck, add weight to the forks
of the lift truck if the drive wheels are near the
forks. The total weight of the lift truck and load
must be equal to or greater than the weight of the
disabled truck. Install a load of approximately
half the maximum capacity on the forks of the
towing lift truck. This load will increase the trac-
tion of the lift truck.
DO NOT add weight to the forks if the lift truck
used for towing has a master drive unit (MDU)
or drive unit on the opposite end as the forks.
Additional weight on the forks may DECREASE
thetractionofthedrivewheel. Makesurethat
the towing truck has a total weight equal to or
greater than the weight of the disabled truck.
Keep the load on the forks lowered as much as
possible.
3

Introduction 8000 SRM 1032
HOW TO PUT THE TRUCK ON BLOCKS
WARNING
DO NOT put the truck on blocks if the surface
is not solid, even, and level. Make sure that any
blocks used to support the truck are solid, one-
piece units. Put a block in front and back of
the tires touching the ground to prevent move-
ment of the lift truck.
DO NOT raise the truck by attaching an
overhead lifting device to areas that can be
damaged. Some points of the truck are not de-
signed to support the weight of the truck. The
truck can be damaged or it can fall, causing
serious injury. Attach the chain or sling to a
support structure of the lift truck frame.
DO NOT make repairs or adjustments unless specif-
ically authorized to do so. Repairs and adjustments
must be performed by trained service technicians.
How to Raise Drive/Steer Tire
1. Put blocks on both the front and back sides of the
load wheels to prevent movement of the truck.
Use a special low-clearance hydraulic jack,
crane, or a lift truck to raise the drive tire. Make
sure that the jack, crane, or lift truck has the
correct capacity rating. The capacity must equal
at least 2/3 the weight of the truck, including the
battery. See the nameplate for truck weight. On
the C60Z and C80Z, the lifting mechanism may
be used to lift the truck and lower it onto blocks.
2. Raise the lift truck enough to suspend the drive
tire. Install hardwood blocks under the frame on
both sides of the truck.
How to Raise the Load Wheels
WARNING
Never raise the truck any higher than neces-
sary to change the load wheels. Always raise
both sides at the same time. Raising either side
too high can cause the truck to tip over and
cause damage or serious injury.
1. Put blocks on both the front and back sides of the
drive tire to prevent movement of the truck.
2. Use an overhead lifting device and web sling un-
der the truck at the rear to raise the load wheels.
A lift truck can also be used to raise the rear of
thetruck.Makesuretheoverheadliftingdevice
and web sling or lift truck has a capacity of at
least 2/3 the total weight of the truck being lifted,
including the battery. See the nameplate for the
lift truck weight. On the C60Z and C80Z, the lift-
ing mechanism may be used to lift the truck and
lower onto blocks.
3. Raise the truck enough to suspend the load
wheels. Install blocks under the truck to the
front of the load wheels to support the truck.
4

8000 SRM 1032 Special Precautions
Special Precautions
WARNING
DO NOT make repairs or adjustments unless
you have both authorization and training. Re-
pairs and adjustments that are not correct can
create a dangerous operating condition. DO
NOT operate a lift truck that needs repairs. Re-
port the need for repairs to your supervisor im-
mediately. If repair is necessary, put a DO NOT
OPERATE tag on the control handle. Remove
thekeyfromthekeyswitch.
Disconnect the battery and separate the con-
nector before opening the drive unit com-
partment cover or inspecting or repairing the
electrical system. If a tool causes a short cir-
cuit, the high current flow from the battery
can cause personal injury or property damage.
Some checks and adjustments are done with
the battery connected. DO NOT connect the
battery until the procedure tells you to do so.
Never have any metal on your fingers, arms,
or neck. Metal items can accidentally make an
electrical connection and cause injury.
Before performing any tests or adjustments,
block the lift truck to prevent unexpected
movement.
The capacitor in the transistor controller can
hold an electrical charge after the battery is
disconnected. To prevent an electrical shock
and personal injury, discharge the capacitor
before inspecting or repairing any component
in the drive unit compartment. Wear safety
glasses. Make certain that the battery has
been disconnected.
CAUTION
To avoid controller damage, always disconnect
the battery, discharge the capacitor, and never
put power to the controller while any power
wires are disconnected. Never short any con-
troller terminal or motor terminal to the bat-
tery. Make sure to use proper procedure when
servicing the controller.
1. Block load wheels to prevent lift truck from mov-
ing.
2. Turn the key switch to the OFF position and dis-
connect the battery.
3. Discharge the capacitors in the controllers by
connecting a 200-ohm, 2-watt resistor across
the controller’s B+ and B terminals. DO NOT
short across the motor controller terminals with
a screwdriverorjumperwire.
4. Remove the 200-ohm, 2-watt resistor before re-
connecting the battery. See Figure 2.
1. POSITIVE CONNECTION
2. NEGATIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
Figure 2. Discharging the Capacitors
5

Maintenance Schedule 8000 SRM 1032
Maintenance Schedule
The maintenance schedule has time intervals for in-
spection, lubrication, and maintenance for your lift
truck. The service intervals are given both in oper-
ating hours recorded by the BDI/hourmeter and in
calendar time. The recommendation is to use the in-
terval that comes first.
CAUTION
Trucks operating in nonstandard or severe
conditions may require special optional envi-
ronmental packages, additional maintenance
procedures, more frequent service intervals,
and/or special lubricants.
The maintenance schedules are made according to
the maximum service intervals for average condi-
tions. Inspect and lubricate more frequently when
operating in dirty or difficult conditions.
Theapproximatelocationsoftheitemsindicatedin
Table 1 are shown in Figure 3.
Figure 3. Maintenance Points
Table 1. Maintenance Schedule
Item
No. Item 8hr
or 1 day3
350 hr
or 2
month3
2000 hr
or 1
year3
Procedure or
Quantity Specification
1Safety Labels and
Operating Manual XReplace if Necessary See Parts Manual
XCheck Water Level
2
Battery XEqualization
Charge1
3Frame XCheck Condition
X=Check C=Change L=Lubricate
NOTE: Never use steam to clean electrical parts.
6

8000 SRM 1032 Maintenance Schedule
Table 1. Maintenance Schedule (Continued)
Item
No. Item 8hr
or 1 day3
350 hr
or 2
month3
2000 hr
or 1
year3
Procedure or
Quantity Specification
XCheck Condition
Load Wheels
(T5Z and T7Z) LRepack Bearings
Replace if Necessary Multipurpose Grease2
XCheck Condition
4
Load Wheels and
Casters
(C60 and 80Z) LLubricate Fittings Multipurpose
Grease2
XCheck Operation
5Lift Linkage
(C60Z and C80Z) LLubricate Multipurpose
Grease2
XCheck Operation
6Coupler
(T5Z and
T7Z) LLubricate SAE 20W or 30W
Engine Oil
XCheck Operation
7Steering Bearing LLubricate Synthetic Grease6
Control Handle
Directional/Speed
Control XCheck Operation
Lift Lower Con-
trols (C60Z and
C80Z) X
Horn X
8
Pivot Pin and
Spring-Loaded
Adjustment Pin X L Lubricate SAE 20W or 30W
Engine Oil
Electrical
Gauges XCheck Operation
Fuses XCheck Condition
9
Contactor XCheck Condition
10 High Speed Switch XCheck Operation
X=Check C=Change L=Lubricate
NOTE: Never use steam to clean electrical parts.
7

Maintenance Schedule 8000 SRM 1032
Table 1. Maintenance Schedule (Continued)
Item
No. Item 8hr
or 1 day3
350 hr
or 2
month3
2000 hr
or 1
year3
Procedure or
Quantity Specification
XCheck Level
Hydraulic System C1.1 liter (1.2 qt) Hydraulic Oil6
XInspect for Leaks,
Visible Damage,
and Defects
Repair or Replace
as Necessary
11
Hydraulic Hoses
and Fittings
XInspect for Kinked,
Flattened, Stiff, or
Charred Hoses
Replace as
Necessary
Brakes XCheck Operation Releases and
Applies Smoothly
C60Z and
C80Z XCheck Operation Hold On 10% Grade4
12
T5Z and
T7Z XCheck Operation Hold On 5% Grade5
Drive Tire and
Wheel XCheck Condition
Lug Bolt Torque
(T5Z and C60Z) XTighten if Required 195 N•m (144 lbf ft)
13
Lug Nut Torque
(T7Z and C80Z) XTighten if Required 201 N•m (148 lbf ft)
Drive Unit Gear Oil
(C60Z and T5Z) X C 1.7 liter (1.8 qt) SAE 80W-90 Gear
Oil
14
(C80Z and T7Z) X C 2.0 liter (2.1 qt) SAE 80W-90 Gear
Oil
X=Check C=Change L=Lubricate
NOTE: Never use steam to clean electrical parts.
8

8000 SRM 1032 Maintenance Procedures Every 8 Hours or Daily
Table 1. Maintenance Schedule (Continued)
Item
No. Item 8hr
or 1 day3
350 hr
or 2
month3
2000 hr
or 1
year3
Procedure or
Quantity Specification
Motor-Traction
Brushes
C60Z and T5Z) XMeasure 15.00 mm (.59 in.) Min. Brush Length
Brushes
(C80Z and T7Z) XMeasure 15.00 mm (.59 in.) Min. Brush Length
Springs XCheck Condition
15
Contactor Tips XDisassemble Check Condition
1Equalization charge approximately each month but not more than each week.
2Use Amsoil®GHD multipurpose grease (lithium complex) with 2 to 4% molybdenum disulfide.
3Whichever comes first.
4With capacity load.
5With 2268 kg (5000 lb) load (trailer plus load weight).
6Use ISO VG 46 antiwear (HCE-140) for standard configurations. Use Exxon Univis®HVI 26 (synthetic)
for freezer, cold storage, arctic, and food processing configurations.
X=Check C=Change L=Lubricate
NOTE: Never use steam to clean electrical parts.
Maintenance Procedures Every 8 Hours or Daily
CHECKS WITH THE KEY SWITCH OFF
NOTE: Be certain to read and understand the in-
formation covered in the Introduction section before
performing any of the Maintenance Procedures
that follow.
WARNING
The capacitor in the transistor controller can
hold an electrical charge after the battery is
disconnected. To prevent electrical shock and
injury, discharge the capacitor before inspect-
ing or repairing any component in the drive
unit compartment. Wear safety glasses. Make
certain the battery has been disconnected.
Put the lift truck on a level surface. Lower the forks
and turn the key switch to the OFF position. Discon-
nect the battery. Open the MDU compartment cover.
Discharge the capacitor. Check for leaks and con-
ditions that are not normal. Clean any oil or other
spills. Make sure that lint, dust, paper, and other
materials are removed from the compartments.
Safety Labels
WARNING
If labels that have warnings or instructions are
damaged, they must be replaced immediately.
Check that all safety labels are installed in the
correct locations on the lift truck. Make sure
that all labels are not damaged and that they
can be read. If necessary, see the Parts Manual
for your lift truck for the correct location of the
labels.
Safety labels are installed on the lift truck to give
information about possible hazards. It is important
that all safety labels are installed on the lift truck
and can be read. See the Parts Manual for label
placement for your lift truck.
9

Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1032
Battery
WARNING
DO NOT lay tools on top of the battery.
The acid in the electrolyte can cause injury. If
the electrolyte is spilled, use water to flush the
area. Make the acid neutral with a solution of
sodium bicarbonate (soda) and water. Acid in
the eyes must be immediately flushed with wa-
ter continuously for 15 minutes, then seek med-
ical attention.
Batteries generate explosive fumes. Keep the
vents in the caps clean. Keep sparks or open
flames away from the battery area. DO NOT
make a spark from the battery connections.
Disconnect the battery when performing main-
tenance.
The battery must fit the battery compartment
so the battery restraint panels will operate cor-
rectly. Use spacers to prevent the battery from
moving more than 13.0 mm (0.5 in.) in any di-
rection.
NOTE: Battery water levels can be maintained with-
out removing the battery from the truck.
Check for loose or broken electrical connections and
damaged wires or cables. Examine the battery case
for damage and leakage. See the battery dealer in the
area to repair any damage to the battery or cables.
Check that the vent caps are clear. Check the level of
the electrolyte daily on a minimum of one cell. Add
only distilled water, as necessary, if the cell is low. If
one cell is low, check the rest of the cells. The correct
level is halfway between the top of the plates and the
bottom of the fill hole. Use a hydrometer to check
that the battery is not discharged below the mini-
mum specific gravity given by the manufacturer and
has enough charge to complete a work period. See
How to Charge Battery in this section.
Remove the battery as described in the section In-
dustrial Battery 2240 SRM 1. Check the battery
case, connector, and cables for damage, cracks, or
breaks. See the battery dealer in your area to re-
pair any damage. Keep the battery case and the bat-
tery compartment clean and painted. Leaks and cor-
rosion from the battery can cause a malfunction in
the electric controls of the lift truck. Use a water
and soda solution to clean the battery and the bat-
tery compartment. Keep the top of the battery clean,
dry, and free of corrosion.
Make sure the battery is the correct weight and size.
Prevent side-to-side movement of the battery by ad-
justing the brackets on either side of the battery. The
correct battery is specified in How to Change Bat-
tery and in the Operating Manual.TheOperat-
ing Manual is located in the container on the Drive
Unit cover. This is a permanent reference and must
be available for use at all times.
Frame
WARNING
Forklift truck frames and components may
have polyurethane paint. Welding, burning, or
other heat sufficient to cause thermal decom-
position of the paint may release isocyanates.
These chemicals are allergic sensitizers to
the skin and respiratory tract and overex-
posure may occur without odor warning.
Always utilize good industrial hygiene prac-
tices, including removal of all paint (prime
and finish coats) to the metal around the area
to be welded. Use local ventilation and/or
supplied-air respiratory protection when re-
pairing the frame.
Check the frame for damage. Inspect for rust and
cracks especially near welds. All surfaces of the
frame should be covered with paint to prevent rust
and corrosion. Heat can weaken metal, preventing
some areas of the frame from being repaired. See
Welding Repairs.
Load Wheels, Drive Tire, and Casters
CAUTION
If the drive tire has been removed and in-
stalled, check all wheel bolts after 2 to 5 hours
of operation. Tighten the bolts in a cross
pattern (see Drive Tire and Wheel) to the cor-
rect torque value shown in the Maintenance
Schedule. When the bolts stay tight after eight
hours, the interval for checking the torque can
be extended to 350 hours.
Inspect the standard or optional casters, drive tire,
andloadwheelsfordamage. Inspectthetreadand
remove any objects that will cause damage. See Fig-
ure 4. Inspect the wheels and casters for loose or
10

8000 SRM 1032 Maintenance Procedures Every 8 Hours or Daily
missing parts. Remove any wire, strapping, or other
material wound around the axles or casters.
1. OBJECTS EMBEDDED IN TIRE.
2. GROOVES, CUTS, OR OTHER DAMAGE TO
TIRE.
Figure 4. Tire and Wheel Inspection
Lift Linkage (C60Z and C80Z)
A series of levers and rods compose the lift linkage.
These devices are connected together and to the
frame and lift cylinder in series. The lift cylinder
applies force in only one direction. The lift linkage
transfers that force to the load wheel linkage and
the drive end frame linkage, lifting the truck and
load evenly and smoothly. Many pivot points indi-
rectly shoulder the weight of the truck and load.
These points must be lubricated every 350 hours/2
months to ensure minimal resistance from friction
and damage from heat.
Coupler (T5Z and T7Z)
The coupler is mounted to the rear of the truck and
can be released from the truck using a hand lever.
The design of the coupler allows hand-free connec-
tions by backing the truck up to the connecting load
until the coupler latches. Check that the hand lever
moves easily with little resistance and returns to the
latched position when released. A simple drop pin-
type connector option is also available.
Steering Operation
Check that the steering operates smoothly and gives
good steering control. Move the handle to the left or
right to steer the lift truck in the desired direction of
travel. Reposition the steering control handle up and
down to ensure easy adjustment during use.
CHECKS WITH THE KEY SWITCH ON
Control Handle
WARNING
Make sure the area around the lift truck is
clear before moving the lift truck or checking
for correct operation. Be careful when making
the checks.
Check that the speed/direction control and the foot
switch for high speed operates as described in the
Operating Manual.Alsocheckthatthehorn
switch is operational.
The speed/direction control is for selecting forward
or reverse movement and the travel speed of the lift
truck. The control is spring loaded and should return
to the neutral position when the control is released.
Thecontrolcanbeoperatedbyeitherhand.Theop-
erator controls the speed and direction of travel by ro-
tating the control in the desired direction. Maximum
rotation of the control causes maximum travel speed.
To stop or change direction, the operator rotates the
control in the opposite direction. The lift truck will
come to a stop. If the speed/direction control is not re-
leased when the lift truck stops, it will accelerate in
the opposite direction. Changing the direction with
the speed/direction control is called plugging. Arrows
on the control indicate the direction of travel.
Check the operation of the horn. The key switch
must be in the ON position for the horn to operate.
Gauges
NOTE: The electrical controls will not operate until
the key switch is turned to the ON position.
Check that all the instruments and controls operate
as described in the Operating Manual.TheOp-
erating Manual is located in the container on the
MDU cover. This is a permanent reference and must
be available for use at all times.
Check the operation of the gauges. The key switch
must be in the ON position for the gauges to operate.
The battery discharge indicator/hourmeter displays
the total operation hours. Periodic maintenance rec-
ommendations are based on these operating hours.
11

Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1032
Fuses
WARNING
The capacitor in the transistor controller can
hold an electrical charge after the battery is
disconnected. To prevent electrical shock and
injury, discharge the capacitor before inspect-
ing or repairing any component in the drive
unit compartment. Refer to Special Precau-
tions. Wear the proper protective eyewear.
Make certain the battery has been discon-
nected.
There is a control fuse located in a spring clip and
a power fuse located on standoffs on the contactor
panel. The contactor panel is located in the MDU
compartment. Remove the MDU compartment cover
to check the fuses. Check that the fuses are the cor-
rect ampere size and are not burned. Some types of
fuses must be checked with an ohmmeter. Replace a
bad fuse with a fuse with the correct rating. NEVER
use a fuse with a higher rating. The power and the
control fuses have the following ratings:
Control Fuse Traction Power Fuse
5Amps 400 Amps
High Speed Switch
The high speed switch is a foot switch located in the
floor of the driver’s compartment. The high speed
function activates when:
a. The key switch is in the ON position.
b. The parking brake switch is in the OFF position.
c. The directional controls of the control handle are
rotated.
d. The battery discharge indicator/hourmeter (BDI)
reads 20% or greater.
e. The high speed switch is depressed.
Test for proper operation of the high speed switch
daily to ensure the truck is performing at optimal
efficiency.
Hydraulic (C60Z and C80Z)
WARNING
Always wear the proper protective equipment
including eye protection and petroleum-resis-
tant gloves when handling hydraulic oil. Thor-
oughly wash oil from exposed areas of skin as
soon as possible.
Completely lower forks to relieve hydraulic
pressure before disassembling any part of
the lift pump or disconnecting any hydraulic
hoses.
The hydraulic oil is hot at normal operating
temperatures. Be careful when draining the
oil.
Never check for leaks by putting hands on
hydraulic lines or components under pressure.
Hydraulic oil under pressure can be injected
into the skin.
CAUTION
Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
system.
Never operate the pump without the proper
amount of oil in the hydraulic system. The
operation of the hydraulic pump with low oil
levels will damage the pump.
Inspect the hydraulic system for leaks and damaged
or loose components.
Inspect all hydraulic hoses and fittings for leaks.
Check for broken or defective clamping devices.
Repair or replace any damaged components as nec-
essary.
The hydraulic oil level must be checked daily. Oper-
ating a truck without enough hydraulic oil can cause
substandard performance and can damage the hy-
draulic system. Fill the reservoir to the MIN mark
with hydraulic oil.
Hand Brake
WARNING
DO NOT operate a truck with an improperly
functioning brake.
Atwo-st
age hand brake is mounted just below the
control handle and connects to the control handle
wiring harness. The hand brake assembly consists
of two independent handles, various linkages, and
three switches to perform two different braking func-
tions. Check for proper operation of the brake. When
either hand brake handle is placed in the first po-
sition, the controller places the traction motor into
re-gen mode. This slows the truck by using opposing
magnetic fields inside the traction motor. A spring-
applied/electrically released brake is mounted to the
12

8000 SRM 1032 Maintenance Procedures Every 350 Hours or Every 2 Months
top of the traction motor. When the key switch is in
the ON position and the parking brake is in the OFF
position, the coil pulls the pressure plate away from
the friction disc disengaging the brake. The brake is
applied when the brake handle is placed in the sec-
ond position, the parking brake switch is in the ON
position,orwhenthekeyswitchisintheOFF posi-
tion.
Maintenance Procedures Every 350 Hours or Every 2 Months
BATTERY EQUALIZING CHARGE
WARNING
DO NOT lay tools on the top of the battery.
The acid in the electrolyte can cause injury. If
the electrolyte is spilled, use water to flush the
area. Make the acid neutral with a solution of
sodium bicarbonate (soda) and water. Acid in
the eyes must be immediately flushed with wa-
ter continuously for 15 minutes, then seek med-
ical attention.
Batteries generate explosive fumes. Keep the
vents in the caps clean. Keep sparks or open
flames away from the battery area. DO NOT
make a spark from the battery connections.
Disconnect the battery when performing main-
tenance.
The battery must fit the battery compartment
so the battery restraint panels will operate cor-
rectly. Use spacers to prevent the battery from
moving more than 13.0 mm (0.5 in.) in any di-
rection.
If the lift truck has been operated using a low
battery, check the contactors for welded con-
tacts BEFORE connecting a charged battery.
The lift truck cannot be controlled if the con-
tacts are welded.
CAUTION
Never connect the battery charger plug to the
plug of the lift truck. You can damage the
traction control circuit. Always make sure the
charger voltage is the correct voltage for the
battery.
An equalizing charge is an additional charge at a
slow rate to balance the charge of the batteries. This
is normally recommended once a month and no more
than once a week.
COUPLER LUBRICATION (T5Z AND T7Z)
The coupler linkage requires lubrication regularly.
Lubricatethepivotpointwhereallthepartsinter-
sect using an oil can and SAE 20W or 30W engine oil.
Work the release handle back and forth to ensure to-
tal coverage and smooth operation. See Figure 5.
NOTE: Clean up any oil that drips onto the floor im-
mediately.
Lubrication may be necessary at more frequent in-
tervals, depending on operating conditions.
Figure 5. Coupler Linkage Lubrication
13

Maintenance Procedures Every 350 Hours or Every 2 Months 8000 SRM 1032
CONTROL HANDLE PIVOT
The control handle is connected to the hub by a pivot
pin. Bushings in the hub cushion the pin and help re-
duce wear. The handle only moves on the pivot when
adjusting the control handle height. An adjusting pin
locks the handle in place. Lubricate the pivot pin and
the adjusting pin using motor oil.
BRAKES
In addition to the 8-hour check for operation, test the
brakes to ensure it will hold on grade to specification.
1. Load the truck to specification.
2268 kg (5000 lb) (trailer plus load weight) -
T5Z and T7Z
Capacity Load - C60Z and C80Z
2. Slowly drive the truck up grade.
5% Grade - T5Z and T7Z
10% Grade - C60Z and C80Z
3. Hold the hand brake in the second position to
stop the truck.
If the brake cannot hold the loaded truck on the spec-
ified grade, the brake must be repaired or replaced.
Refer to the section Brakes 1800 SRM 963.
DRIVE TIRE AND WHEEL
Inspect the wheel rim for rust and cracks. DO NOT
weld a cracked wheel rim or straighten a bent rim.
Welding, heating, or bending a wheel rim can weaken
it’s capacity. Always replace damaged tires or wheel
rims immediately. DO NOT operate a truck with a
broken stud (or missing lug nuts or bolts). Make sure
the drive wheel fasteners are tightened to the correct
torque value. Tighten the fasteners in a criss-cross
pattern. See Figure 6. Tighten to the correct torque
value shown in Maintenance Schedule.
DRIVE UNIT ASSEMBLY
Check Oil Level
NOTE: The fill plug may be obstructed by the MDU.
Push the control handle completely to the left or right
to access the fill plug.
Check the level of lubricant by removing the fill plug
and roll the truck slowly until the hole in the gear
lines up with the fill hole. There is enough lubricant
when the lubricant is up to the bottom of the gear or
halfway to the top of the gear. See Figure 7.
Figure 6. Torquing Drive Wheel
1. DRIVE UNIT HOUSING
2. OILFILLHOLE
3. OIL LEVEL
4. FILL PLUG
5. WASHER
6. DRAIN PLUG
Figure 7. Check Oil Level
14

8000 SRM 1032 Maintenance Procedures Every 350 Hours or Every 2 Months
MOTOR BRUSHES
WARNING
Turn the key switch to the OFF position and
disconnect the battery before making any
checks on the motors. Personal injury or
equipment and tool damage can occur if the
battery is not disconnected.
CAUTION
Low battery voltage causes the motor current
to increase to do the same work. This higher
current can damage the motor and the contac-
tor contacts. DO NOT operate the lift truck if
the battery has a specific gravity of 1.130 or
less.
Inspect the brushes, brush springs, brush holders,
and commutator every 350 hours on all electric mo-
tors. Use a vacuum cleaner or dry, low pressure com-
pressed air under low pressure to remove any brush
dust.
1. Move the truck to a safe location, turn the key
switch to the OFF position, and disconnect the
battery.
2. Remove the MDU compartment cover. See In-
troduction - Drive Unit Compartment Covers.
3. Tag and identify the electrical wires for proper
reassembly. Disconnect the wires from the ter-
minals.
4. Remove the brush band.
5. Move the brush spring and remove the brush
from the holder. Inspect the commutator, see
the section DC Motor Maintenance Brush and
Commutator Inspection. All motor brushes must
be replaced before they damage the surface of the
commutator.
WARNING
If the lift truck has been operated using a
battery that is almost discharged, inspect
for welded contacts BEFORE connecting a
charged battery. A contactor with welded
contacts can cause operations that are not
expected and possible injury when a charged
battery is connected. Check the battery con-
nector for damage.
6. Inspect the brushes. Replace brushes before they
are worn to the values shown in Figure 8. Inspect
the brush holders for burns or damage. Make
sure the brush holder is fastened tightly to the
mounts. Make sure the brushes will move freely
and smoothly in the brush holders and do not
have wire breaks. Inspect the brush springs for
damage from heat (color changes) and corrosion.
Replace a damaged brush spring.
A. MINIMUM DIMENSION
1. TAPERED END
(SPRING) 2. WEAR END 3. BRUSH SPRING
Figure 8. Traction Motor Brushes Inspection
15

Maintenance Procedures Every 2000 Hours or Yearly 8000 SRM 1032
Maintenance Procedures Every 2000 Hours or Yearly
NOTE: Perform these procedures in addition to the
8-hour and the 350-hour checks.
LOAD WHEEL BEARINGS (T5Z AND T7Z)
WARNING
Move the lift truck to a level location where it
can be serviced. Disconnect the battery and re-
move the key.
The lift truck must be put on blocks to perform main-
tenance on the load wheel bearings.
Remove
Follow the steps below to remove the load wheel bear-
ings. See Figure 9.
1. Put the lift truck on blocks and disconnect the
battery.
2. Remove hub cap (6) and attaching screws (7).
3. Remove cotterpin(10)fromendoftheaxleshaft
(14).
4. Remove nut (9) and washer (5).
5. Remove load wheel (15) and bearing assemblies
by pulling the load wheel off the axle shaft.
6. Remove bearing cones (1, 4), and remaining
washers (11, 12, 13, 8) from the axle shaft.
7. Remove the bearing cups (3, 2) ONLY if they are
damaged andmustbereplaced.
Inspect
The bearing cups, cones, washers, and load wheels
should be cleaned and inspected when removed. Any
damaged parts should be replaced. To inspect the
load wheel and bearings:
1. Wipe grease and dirt from bearing cups and
cones, load wheel, washers, and axle shaft.
2. Wash the bearing cones in solvent to remove all
dirt and grease.
3. Inspect the cups and washers for pits and grooves
or other damage.
4. Inspect the cones for looseness, wear, and other
damage.
5. Place bearing cone inside cup and slowly turn the
cone while pressing down with the palm of the
hand. The bearings should roll smoothly without
interruption.
NOTE: If any damage is found on a bearing cup or
cone, then BOTH the matching bearing cup and cone
must be replaced.
Install
Install the load wheel assembly by reversing the or-
der of removal until installing the nut (9) and then
by following these instructions:
1. Install bearing cups to load wheel if removed.
2. Pack the wheel bearing cones with Amsoil®GHD
synthetic multipurpose (lithium complex) with 2
to 4% molybdenum disulfide. The wheel hub cav-
ity between the bearing cups should be packed
with the same lubricant to a level even with the
center of the bearing cups. Apply a light coat of
grease to the spindle and the finished surface on
whichtheoilsealrides.
3. Install washers (8, 13, 12, and 11) to axle shaft.
4. Install bearing cones to load wheel and install
load wheel and bearing assemblies on to axle
shaft.
5. Install washer (5) and nut (9) to axle shaft.
6. Tighten the wheel adjusting nut (9) while slowly
rotating the wheel until wheel will not rotate.
SeeFigure9.
7. Back off adjusting nut (turn counterclockwise)
1/16 to 1/4 turn until slot in lock nut lines up with
hole in axle shaft.
NOTE: Hub should turn freely with 0.0254 to
0.254 mm (0.0010 to 0.010 in.) end play.
8. Install cotter pin (10).
9. Place hub cap (6) over hub and align screw holes.
Attach the hub cap with screws (7).
16

8000 SRM 1032 Maintenance Procedures Every 2000 Hours or Yearly
1. OUTER BEARING CONE
2. OUTER BEARING CUP
3. INNER BEARING CUP
4. INNER BEARING CONE
5. WASHER
6. HUB CAP
7. SCREW
8. WASHER
9. NUT
10. COTTER PIN
11. WASHER
12. FELT WASHER
13. WASHER
14. AXLE SHAFT
15. LOAD WHEEL
Figure 9. Load Wheel Assembly (T5Z and T7Z)
17