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