Hyster T5ZAC Periodic Maintenance
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Hyster T5ZAC Periodic Maintenance

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PERIODIC
MAINTENANCE
AC
AC
T5Z
[B476]; T7Z
[B477];
AC
AC
C60Z
[B478]; C80Z
[B479]
PART NO. 1684026
8000 SRM 1368

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Summary of Contents for Hyster T5ZAC

  • Page 1 PERIODIC MAINTENANCE [B476]; T7Z [B477]; C60Z [B478]; C80Z [B479] PART NO. 1684026 8000 SRM 1368...

  • Page 2: Table Of Contents

    Change Gear Oil ............................Check Oil Level ............................Drive Tire Check............................Maintenance Procedures Every 2000 Hours or Yearly ..................Trail Wheel Bearings (T5-7Z )........................Remove............................... Inspect................................ Install ................................. Hydraulic System (C60-80Z ) ........................Changing the Hydraulic Oil........................©2008 HYSTER COMPANY...
  • Page 3 Table of Contents Periodic Maintenance TABLE OF CONTENTS (Continued) Master Drive Unit ............................Drive Unit Gear Oil........................... Brakes ................................ Welding Repairs ..............................Battery Maintenance ............................How to Charge Battery..........................How to Change Battery ..........................Adjusting the Battery Spacers........................Changing Battery With Rollers ........................ Remove ..............................

  • Page 4: Introduction

    This section contains the instructions for periodic Schedule. Service Manuals are available from your maintenance and inspection and a Maintenance Hyster™ lift truck dealer to help users who do their Schedule. own repairs. The Maintenance Schedule has time intervals for in- Your Hyster™...
  • Page 5 Introduction 8000 SRM 1368 A. RH SIDE C. FORWARD B. LH SIDE D. REVERSE Figure 1. Truck Orientation...

  • Page 6: Drive Unit Compartment Covers

    8000 SRM 1368 Introduction DRIVE UNIT COMPARTMENT COVERS 3. Pull the bottom edge on one side of the upper cover from the drive unit compartment. Con- Many procedures require access to the drive unit tinue pulling around the edge of the cover until compartment.

  • Page 7: How To Move A Disabled Truck

    Introduction 8000 SRM 1368 HOW TO MOVE A DISABLED TRUCK Be sure to stay clear of the tow chain, towing vehicle, and truck during the towing operation Trucks are not normally towed. If the traction sys- to prevent injury. tem will not operate, make repairs at the location, if possible.

  • Page 8: How To Put The Truck On Blocks

    8000 SRM 1368 Introduction 4. If towing with lift truck, add weight to the forks Use a special low-clearance hydraulic jack, of the lift truck if the drive wheels are near the crane, or a lift truck to raise the drive tire. Make forks.

  • Page 9: Special Precautions

    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. NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately.

  • Page 10: Maintenance Schedule

    8000 SRM 1368 Maintenance Schedule 2. Turn the key switch to the OFF position and dis- CAUTION connect the battery. To avoid controller damage, always disconnect 3. Discharge the capacitors in the controllers by the battery and discharge the capacitor. Never connecting a 200-ohm, 2-watt resistor across put power to the controller while any power the controller’s B+ and B...
  • Page 11 Maintenance Schedule 8000 SRM 1368 Table 1. Maintenance Schedule Item Item 1 yr/ Procedure or Specification day/ 2000 Quantity 8 hr Replace if Safety Labels and Operating Missing or See Parts Manual Manual Damaged Check Charge Charge or Change Battery Status (See NOTE 1) Electrolyte...
  • Page 12 8000 SRM 1368 Maintenance Schedule Table 1. Maintenance Schedule (Continued) Item Item 1 yr/ Procedure or Specification day/ 2000 Quantity 8 hr Lift and Lower Linkage Check Repair as Necessary (C60-80Z Operation Multipurpose Load Roller Linkage Lube Fittings Grease (See NOTE 2) Multipurpose Forks to Drive End Frame Lube Fittings...
  • Page 13 Maintenance Schedule 8000 SRM 1368 Table 1. Maintenance Schedule (Continued) Item Item 1 yr/ Procedure or Specification day/ 2000 Quantity 8 hr Hydraulic System Check for Leaks Repair as Necessary (C60-80Z Visually Inspect Repair as Necessary for Leaks Hydraulic Hoses and Check for Hose Fittings Repair or Replace...

  • Page 14: Maintenance Procedures Every 8 Hours Or Daily

    8000 SRM 1368 Maintenance Procedures Every 8 Hours or Daily Table 1. Maintenance Schedule (Continued) Item Item 1 yr/ Procedure or Specification day/ 2000 Quantity 8 hr NOTE 1: Equalization charge approximately each month, but not more than each week. ®...

  • Page 15: Battery

    All welding repairs must be pre-approved by level is halfway between the top of the plates and the Hyster™ company Contact Management. bottom of the fill hole. Use a hydrometer to check that the battery is not discharged below the mini- Check the frame for damage.

  • Page 16: Drive Tire, Casters (Optional), And Trail Wheels Or Load Wheels

    8000 SRM 1368 Maintenance Procedures Every 8 Hours or Daily Drive Tire, Casters (Optional), and Trail months to ensure minimal resistance from friction and damage from heat. Wheels or Load Wheels Coupler (T5-7Z CAUTION If the drive tire has been removed and in- The coupler is mounted to the rear of the truck and stalled, check all wheel bolts after 2 to 5 hours can be released from the truck using a hand lever.

  • Page 17: Gauges

    Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1368 Gauges e. The high speed switch is depressed. NOTE: The electrical controls will not operate until Test for proper operation of the high speed switch the key switch is turned to the ON position. daily to ensure the truck is performing at optimal efficiency.

  • Page 18: Hand Brake

    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.
  • Page 19 More Content includes Brake system, Capacities, and specifications, Frame, Hydraulic, System, Industrial battery, Main control, Valve, Mast repair, Fasteners, Schematics diagrams, Steering axle, Steering system, Wire harness repair And more) Click Here Get all the content after purchase Thank very much.

  • Page 20: Maintenance Procedures Every 500 Hours Or Every 3 Months

    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.

  • Page 21: Hydraulic Oil

    8000 SRM 1368 Maintenance Procedures Every 500 Hours or Every 3 Months Hydraulic Oil and check for damage to lift linkage components before greasing. NOTE: The hydraulic oil should be changed after the initial 500 hour break-in period and then every 2000 Some load wheel axles are also fitted with a grease hours thereafter.

  • Page 22: Caster Shim Adjust

    Maintenance Procedures Every 500 Hours or Every 3 Months 8000 SRM 1368 5. If the caster wheel is not touching the floor, check wheel, the caster is properly adjusted. Re- the caster for under shimming: peat checks for other caster. a.

  • Page 23: Master Drive Unit

    8000 SRM 1368 Maintenance Procedures Every 500 Hours or Every 3 Months 4. Position a floor jack centered under the drive end 11. Lower the lift truck and check for proper adjust- of the lift truck. Raise the casters off the floor. ment.

  • Page 24: Drive Tire Check

    Maintenance Procedures Every 2000 Hours or Yearly 8000 SRM 1368 DRIVE TIRE CHECK WARNING When the drive tire has been installed, check all wheel bolts after 2 to 5 hours of operation. When the wheel bolts stay tight after an 8-hour check, the interval for checking the torque can be extended to 500 hours.

  • Page 25: Install

    8000 SRM 1368 Maintenance Procedures Every 2000 Hours or Yearly 1. OUTER BEARING CONE 6. HUB CAP 11. WASHER 2. OUTER BEARING CUP 7. SCREW 12. FELT WASHER 3. INNER BEARING CUP 8. WASHER 13. WASHER 4. INNER BEARING CONE 9.

  • Page 26: Hydraulic System (C60-80Z Ac )

    Maintenance Procedures Every 2000 Hours or Yearly 8000 SRM 1368 6. Tighten the wheel adjusting nut (9) while slowly 4. Discharge the capacitor. rotating the wheel until wheel will not rotate. 5. Tag and disconnect all power wires, control See Figure 11. wires, and hoses to the lift pump and motor 7.
  • Page 27 8000 SRM 1368 Maintenance Procedures Every 2000 Hours or Yearly Figure 12. Lift Pump and Motor Assembly (C60Z...
  • Page 28 Maintenance Procedures Every 2000 Hours or Yearly 8000 SRM 1368 Legend for Figure 12 1. LIFT PUMP MOTOR 14. RESERVOIR 2. COUPLING 15. TORX-HEAD SCREW 3. LIFT PUMP 16. WASHER 4. CLAMP 17. TWO-PIECE CLAMP 5. TUBE 18. RELIEF VALVE 6.
  • Page 29 8000 SRM 1368 Maintenance Procedures Every 2000 Hours or Yearly Figure 13. Lift Pump and Motor Assembly (C80Z...

  • Page 30: Master Drive Unit

    Maintenance Procedures Every 2000 Hours or Yearly 8000 SRM 1368 Legend for Figure 13 1. CAPSCREW 17. FILLER ELBOW 2. LIFT PUMP MOTOR 18. FLAT SEAL 3. ADAPTER PLATE 19. BREATHER/FILLER CAP 4. COUPLING 20. O-RING 5. TUBE 21. O-RING 6.

  • Page 31: Welding Repairs

    8000 SRM 1368 Battery Maintenance Welding Repairs and finish coats) to the metal around the area WARNING to be welded. Use local ventilation, and/or Disconnect the battery connector and remove supplied-air respiratory protection. the battery before welding. Welding can cause a fire and/or an explosion.

  • Page 32: How To Change Battery

    Battery Maintenance 8000 SRM 1368 after an equalizing charge. If the difference in spe- cific gravity is more than 0.020 between cells of a bat- tery after an equalizing charge, there may be a cell that has a malfunction. Consult your battery dealer. NOTE: Many customers have battery chargers that can follow a program to automatically charge a battery according to recommendations of the bat-...

  • Page 33: Remove

    8000 SRM 1368 Battery Maintenance WARNING To prevent personal injury and equipment damage, DO NOT permit hook to touch battery cell terminals. 5. Attach the hook of the battery puller to the lifting hole of the battery. DO NOT touch battery cell terminals with the hook.

  • Page 34: Install Battery Using Overhead Crane

    Have autho- CAUTION rized personnel replace or adjust the battery spacers for that battery. See your Hyster. lift truck dealer for Disposal of batteries must meet local environ- the correct spacers. DO NOT damage the battery ca- mental regulations.
  • Page 35 8000 SRM 1368 Battery Maintenance Table 4. Battery Specifications (C80Z Truck Specifications Battery Specifications Battery Ampere Kilo- Length Width Height Weight Compartment Hours watt (Max) (Max) Volts (Max) (Max) (Max) Hours mm (in.) mm (in.) Width Length mm (in.) kg (lbs) (Max) "X"...
  • Page 36 Battery Maintenance 8000 SRM 1368 Table 6. Battery Specifications (T7Z Truck Specifications Battery Specifications Battery Kilo- Length Width Height Weight Compartment pere watt (Max) (Max) Volts (Max) (Max) Hours Hours mm (in.) mm (in.) Width Length mm (in.) kg (lbs) (Max) (Max) "X"...

This manual is also suitable for:

T7zacC60zacC80zacB476B477B478 ... Show all

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