Hyster T5ZAC Instructions for use

PERIODIC
MAINTENANCE
T5ZAC [B476]; T7ZAC [B477];
C60ZAC [B478]; C80ZAC [B479]
PART NO. 1684026 8000 SRM 1368

Periodic Maintenance Table of Contents
TABLE OF CONTENTS
Introduction........................................................................................................................................................ 1
General........................................................................................................................................................... 1
Drive Unit Compartment Covers.................................................................................................................. 3
Remove....................................................................................................................................................... 3
Install......................................................................................................................................................... 3
How to Move a Disabled Truck ..................................................................................................................... 4
How to Tow the Truck ............................................................................................................................... 4
How to Put the Truck on Blocks ................................................................................................................... 5
How to Raise Drive/Steer Tire.................................................................................................................. 5
How to Raise the Load Wheels ................................................................................................................. 5
Special Precautions............................................................................................................................................ 6
Maintenance Schedule....................................................................................................................................... 7
Maintenance Procedures Every 8 Hours or Daily............................................................................................ 11
Checks With the Key Switch OFF ................................................................................................................ 11
Safety Labels ............................................................................................................................................. 11
Battery ....................................................................................................................................................... 12
Frame......................................................................................................................................................... 12
Drive Tire, Casters (Optional), and Trail Wheels or Load Wheels......................................................... 13
Lift Linkage (C60-80ZAC).......................................................................................................................... 13
Coupler (T5-7ZAC)...................................................................................................................................... 13
Steering Operation.................................................................................................................................... 13
Checks With the Key Switch ON .................................................................................................................. 13
Control Handle .......................................................................................................................................... 13
Gauges ....................................................................................................................................................... 14
Fuses .......................................................................................................................................................... 14
High Speed Switch .................................................................................................................................... 14
Hydraulic (C60-80ZAC).............................................................................................................................. 14
Hand Brake ............................................................................................................................................... 15
Maintenance Procedures Every 250 Hours or Every 6 Weeks ........................................................................ 15
Caster Lubrication......................................................................................................................................... 15
Maintenance Procedures Every 500 Hours or Every 3 Months ..................................................................... 16
Hydraulic System .......................................................................................................................................... 16
Hydraulic Oil ............................................................................................................................................. 17
Hydraulic Reservoir Breather .................................................................................................................. 17
Steering System............................................................................................................................................. 17
Steer Column and Tilt Mechanism .......................................................................................................... 17
Lift Linkage and Load Wheels (C60-80ZAC) ................................................................................................ 17
Casters ........................................................................................................................................................... 17
Caster Shim Check.................................................................................................................................... 17
Caster Shim Adjust ................................................................................................................................... 18
Master Drive Unit ......................................................................................................................................... 19
Change Gear Oil........................................................................................................................................ 19
Check Oil Level ......................................................................................................................................... 19
Drive Tire Check............................................................................................................................................ 20
Maintenance Procedures Every 2000 Hours or Yearly .................................................................................... 20
Trail Wheel Bearings (T5-7ZAC).................................................................................................................... 20
Remove....................................................................................................................................................... 20
Inspect........................................................................................................................................................ 20
Install......................................................................................................................................................... 21
Hydraulic System (C60-80ZAC)..................................................................................................................... 22
Changing the Hydraulic Oil...................................................................................................................... 22
©2008 HYSTER COMPANY i

Table of Contents Periodic Maintenance
TABLE OF CONTENTS (Continued)
Master Drive Unit ......................................................................................................................................... 26
Drive Unit Gear Oil................................................................................................................................... 26
Brakes ........................................................................................................................................................ 26
Welding Repairs ................................................................................................................................................. 27
Battery Maintenance ......................................................................................................................................... 27
How to Charge Battery.................................................................................................................................. 27
How to Change Battery................................................................................................................................. 28
Adjusting the Battery Spacers.................................................................................................................. 28
Changing Battery With Rollers ................................................................................................................ 28
Remove .................................................................................................................................................. 29
Install..................................................................................................................................................... 29
Remove Battery Using Overhead Crane.................................................................................................. 29
Install Battery Using Overhead Crane.................................................................................................... 30
Battery Specifications ................................................................................................................................... 30
This section is for the following models:
T5ZAC [B476];
T7ZAC [B477];
C60ZAC [B478];
C80ZAC [B479]
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8000 SRM 1368 Introduction
Introduction
GENERAL
This section 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 been properly trained and authorized
to do so. Improper repairs and adjustments
can create dangerous operating conditions.
DO NOT operate a truck that needs repairs. If
repair is necessary, attach a DO NOT OPER-
ATE tag to the control handle. Report the need
for repairs to your supervisor immediately.
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
personnel and equipment to conduct a complete pro-
gram of inspection, lubrication, and maintenance.
This program will help maximize your truck’s per-
formance and reliability.
NOTE: The front end of the truck is the control han-
dle end. Forward travel refers to movement in the
direction of the control handle with the load wheels
trailing. Reverse is travel in the direction of the forks
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.
1

Introduction 8000 SRM 1368
A. RH SIDE
B. LH SIDE C. FORWARD D. REVERSE
Figure 1. Truck Orientation
2