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]
ii

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

8000 SRM 1368 Introduction
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. See Figure 2.
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 in place using three screws.
1. FRONT COVER
2. LOWER COVER 3. SPRING NUT CLIPS 4. SCREWS
Figure 2. Drive Unit Compartment Covers
3

Introduction 8000 SRM 1368
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.
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
before towing. Refer to the section Brakes
1800 SRM 1285.
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.
The control handle should be marked with a
DO NOT OPERATE tag until the repairs have
been completed.
3. Tow the lift truck slowly while a driver steers the
truck while walking along side.
4

8000 SRM 1368 Introduction
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.
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 C60-80ZAC, 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.
HowtoRaisetheLoadWheels
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. Putblocksonboththefrontandbacksidesofthe
drivetiretopreventmovementofthetruck.
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. Makesuretheoverheadliftingde-
vice 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 C60-80ZAC,the
lifting 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.
5

Special Precautions 8000 SRM 1368
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 dangerous operating conditions. DO
NOT operate a lift truck that needs repairs.
Report the need for repairs to your supervisor
immediately. If repair is necessary, turn the
key switch to the OFF position, disconnect the
battery, and attach a DO NOT OPERATE tag to
the control handle.
Verify that the battery had been disconnected
before opening the drive unit compartment
cover or inspecting or repairing the electrical
system. If a tool causes a short circuit, 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 wear jewelry or other metallic objects on
your fingers, arms, or neck when servicing the
lift truck. Metal items can accidentally make
an electrical connection and cause injury.
Before performing any tests or adjustments,
block the lift truck wheels to prevent unex-
pected movement.
The capacitor in the transistor controller can
hold an electrical charge after the battery
has been disconnected. To prevent an electri-
cal 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. 1. CONTROLLER
2. POSITIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
5. NEGATIVE CONNECTION
Figure 3. Discharging the Capacitors
(C60-80ZAC and T5-7ZAC)
6

8000 SRM 1368 Maintenance Schedule
CAUTION
To avoid controller damage, always disconnect
the battery and discharge the capacitor. 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 screwdriver or jumper wire.
4. Remove the 200-ohm, 2-watt resistor before re-
connecting the battery. See Figure 3.
Maintenance Schedule
The Maintenance Schedule is divided into four time
intervals which call for particular maintenance pro-
cedures to be performed. The intervals are 1 Day
or 8 Hours, 6 Weeks or 250 Hours, 3 Months or 500
Hours, and 1 Year or 2000 Hours for normal opera-
tion (whichever comes first). Normal operation is
considered one 8-hour shift per day, in a relatively
clean environment, on an improved surface. Op-
erating a lift truck for more than eight hours per
day is considered Heavy operation and requires
the3-month/500-hourcheckstobeperformedat2
months/350 hours. Lift trucks operating in freezer
environments or dirty conditions are considered
Severe operation and require the 3-month/500-hour
checks to be performed at 1 month/200 hours. The
approximate locations of the items listed in the
Maintenance Schedule are shown in Figure 4.
Figure 4. Maintenance Points
7

Maintenance Schedule 8000 SRM 1368
Table 1. Maintenance Schedule
Item
No. Item 1 day/
8hr
6
wk/
250
hr
3
mo/
500
hr
1yr/
2000
hr
Procedure or
Quantity Specification
1Safety Labels and Operating
Manual XReplace if
Missing or
Damaged See Parts Manual
Battery XCheck Charge
Status
(See NOTE 1)
Charge or Change
Out
Electrolyte XCheck Level Distilled Water
Restraint Panels XCheck Condition Repair as Necessary
2
Power Disconnect XCheck
Operation Repair as Necessary
3Frame XVisually Inspect Repair as Necessary
Trail Wheels
(T5-7ZAC)XCheck Condition Repair or Replace as Necessary
Bearings C
Repack
Bearings/
Replace As
Necessary
Multipurpose
Grease
(See NOTE 2)
Wheels XInspect for
Damage
Smooth Edges/
Remove Embedded
Objects
4
Axles LLube Antiseize Lubricant
Load Wheels
(C60-80ZAC)XCheck Condition Replace as Necessary
Wheels and Bearings LLube Fitting Multipurpose
Grease
(See NOTE 2)
4
Axle Bolts (Food Process-
ing) LLube Antiseize Lubricant
Casters and Load Wheels
(C60-80ZAC)XCheck Condition Repair as Necessary
Caster Adjustment XCheck
Adjustment Gap Adjust With Shims as Necessary
Caster Swivel – STD L L Lube Fitting
(See NOTE 7)
Multipurpose
Grease
(See NOTE 2)
4
Caster Wheel – HD L L Lube Fitting
(See NOTE 7)
Multipurpose
Grease
(See NOTE 2)
X=Check C=Change L=Lubricate
8

8000 SRM 1368 Maintenance Schedule
Table 1. Maintenance Schedule (Continued)
Item
No. Item 1 day/
8hr
6
wk/
250
hr
3
mo/
500
hr
1yr/
2000
hr
Procedure or
Quantity Specification
Lift and Lower Linkage
(C60-80ZAC)XCheck Operation Repair as Necessary
Load Roller Linkage LLube Fittings Multipurpose
Grease
(See NOTE 2)
5
Forks to Drive End Frame
Linkage LLube Fittings Multipurpose
Grease
(See NOTE 2)
XCheck
Operation
6
Coupler
(T5-7ZAC)LLubricate SAE 20 or 30
Engine Oil
Steering XCheck
Operation Repair as Necessary
Tilt Pivot and Pin LLubricate SAE 20 or 30
Engine Oil
7
Steer Bearings XCheck
Operation Repair as Necessary
8Control Handle and Horn XCheck
Operation Repair as Necessary
9BDI, Horn, Key Switch, and
Electrical Circuits XCheck Operation Repair as Necessary
10 High Speed Switch XCheck
Operation Repair as Necessary
X=Check C=Change L=Lubricate
9

Maintenance Schedule 8000 SRM 1368
Table 1. Maintenance Schedule (Continued)
Item
No. Item 1 day/
8hr
6
wk/
250
hr
3
mo/
500
hr
1yr/
2000
hr
Procedure or
Quantity Specification
Hydraulic System
(C60-80ZAC)XCheck for Leaks Repair as Necessary
XVisually Inspect
for Leaks Repair as Necessary
Hydraulic Hoses and
Fittings XCheck for Hose
Damage and
Loose Fittings
Repair or Replace
as Necessary
XCheck Level
(Full Mark on
Tank)
Hydraulic Oil
CChange
(See NOTE 5)
Hydraulic Oil
(See NOTE 3)
11
Hydraulic Oil Strainer X/C Inspect / Replace
as Necessary See Parts Manual
XCheck
Operation Repair as Necessary
12
Parking Brake
X
Hold on Grade
Test
(With Capacity
Load)
5% Grade
(T5-7ZAC)
10% Grade
(C60-80ZAC)
Drive Wheel and Tire XCheck Condition Repair as Necessary
Tire XInspect for
Damage
Smooth Edges/
Remove Embedded
Objects
Axle Seal XInspect for Oil
Leaks Remove Wrapped Debris
13
Wheel Bolts
Lug Nuts XTighten as
Required
(See NOTE 4)
200 ±9 N•m (148
±7 lbf ft)
Master Drive Unit XCheck
Operation Repair as Necessary
MDU Gearcase XCheck
Operation Repair as Necessary
Oil XCheck Level
(T5ZAC and C60ZAC)1.7 liter (1.8 qt)
14
(T7ZAC and C80ZAC)C2.0 liter (2.1 qt)
Gear Oil
(See NOTE 5 and
NOTE 6)
X=Check C=Change L=Lubricate
10

8000 SRM 1368 Maintenance Procedures Every 8 Hours or Daily
Table 1. Maintenance Schedule (Continued)
Item
No. Item 1 day/
8hr
6
wk/
250
hr
3
mo/
500
hr
1yr/
2000
hr
Procedure or
Quantity Specification
NOTE 1: Equalization charge approximately each month, but not more than each week.
NOTE 2: Use Mobilgrease®28 synthetic extra-protection grease (clay) for standard, freezer, and cold storage
configurations.
Use Amsoil®GHD synthetic multipurpose grease (lithium complex) with 2 to 4% molybdenum disulfide for
arctic and food processing configurations and for standard steer bearings on all configurations.
NOTE 3: Use ISO VG 46 (conventional) antiwear (HCE-140) for standard, freezer, and cold storage configu-
rations.
Use Exxon Univis®HVI 26 (synthetic) for arctic and food processing configurations.
NOTE 4: Apply antiseize at installation and check every 2 to 5 hours until nuts/bolts stay tight for an entire
8-hour shift. Check tightness every 3 months or 500 hours thereafter.
NOTE 5: Replace after the first 500 hours of service and every 2000 hours or yearly thereafter.
NOTE 6: Use conventional 80W-90 (GL-5) for standard, freezer, and cold storage configurations. Use syn-
thetic 75W-90 (GL-5) for arctic and food processing configurations.
NOTE 7: Lubricate every 8 hours if using in a food processing or corrosive environment.
X=Check C=Change L=Lubricate
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.
11

Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1368
Battery
WARNING
DO NOT lay tools on top of the battery.
The acid in the electrolyte can cause injury. If
the electrolyte is spilled, make the acid neutral
with a solution of sodium bicarbonate (soda)
and water, then flush the area with water. Acid
in the eyes must be immediately flushed with
water continuously for 15 minutes, then seek
medical 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 volt-
age size. Prevent side-to-side movement of the bat-
tery by adjusting the brackets on either side of the
battery. The correct battery is specified in How to
Change Battery and in the Operating Manual.The
Operating Manual is located in the container on
the Drive Unit cover. This is a permanent reference
andmustbeavailableforuseatalltimes.
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.
CAUTION
All welding repairs must be pre-approved by
Hyster™ company Contact Management.
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.
12

8000 SRM 1368 Maintenance Procedures Every 8 Hours or Daily
Drive Tire, Casters (Optional), and Trail
Wheels or Load Wheels
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 500 hours.
Inspect the drive tire, casters (optional), and trail
wheels or load wheels for damage. Inspect the tread
and remove any objects that will cause damage. See
Figure 5. Inspect the wheels and casters for loose or
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 5. Tire and Wheel Inspection
Lift Linkage (C60-80ZAC)
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 500 hours/3
months to ensure minimal resistance from friction
and damage from heat.
Coupler (T5-7ZAC)
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.
13

Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1368
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.
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.
A control fuse is located in-line on the harness and a
power fuse is located on the controller. Remove the
MDU compartment cover to check the fuses. Check
that the fuses are the correct 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 (C60-80ZAC)
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.
14

8000 SRM 1368 Maintenance Procedures Every 250 Hours or Every 6 Weeks
Hand Brake
WARNING
DO NOT operate a truck with an improperly
functioning brake.
A two-stage 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
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 250 Hours or Every 6 Weeks
CASTER LUBRICATION
CAUTION
Use only the recommended lubricants for your
application. Refer to Capacities and Specifica-
tions 8000 SRM 1033 for lubrication specifica-
tions for your lift truck.
Wipe grease fittings clean before greasing.
NOTE: Some optional packages may utilize sealed
bearings or different grease fitting configurations.
Contact your Hyster™ dealer for information on
optional packages.
The casters should be lubricated every 250 hours or 6
weeks during normal operation. The standard caster
has one grease fitting above the springs which pro-
vides lubrication to the swivel bearing. See Figure 6.
1. SWIVEL MOUNT
2. GREASE FITTING
3. SPRINGS
4. CASTER WHEEL
Figure 6. Standard Caster
15

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Maintenance Procedures Every 500 Hours or Every 3 Months 8000 SRM 1368
The heavy-duty caster has one grease fitting in the
end of the caster wheel axle which lubricates the
caster wheel bearings. See Figure 7.
1. SWIVEL MOUNT
2. SPRINGS
3. CASTER WHEEL
4. GREASE FITTING
Figure 7. Heavy-Duty Caster
Maintenance Procedures Every 500 Hours or Every 3 Months
HYDRAULIC SYSTEM
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
Perform the following checks.
16