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SERVICE REPAIR
C80Z [A479]
8000 SRM 1033 Hydraulic Oils
Hydraulic System (C60-80Z and C60-80ZAC
)
Specification C60Z and C60ZAC
C80Z and C80ZAC
Motor Power1
1.2 kW (1.6 hp) 1.5 kW (2.0 hp)
Hydraulic Relief Pressure 2700 psi 3500 psi
Lifting Speed
With Load2
4.7 seconds 5.7 seconds
Without Load 3.5 seconds 3.9 seconds
Lowering Speed
With Load2
1.2 seconds 2.4 seconds
Without Load 1.8 seconds 6.5 seconds
Pump Displacement 1.50 cm3
(0.092 in.3
)/rev 2.00 cm3
(0.122 in.3
)/rev
Allowable Drift With Load 6.4 mm (0.25 in.) Maximum in 10 minutes @ 21 C
(70 F) Oil Temperature
Hydraulic Reservoir Capacity 0.71 liter (0.75 qt) 0.85 liter (0.90 qt)
1
24 Volts DC
2
Capacity Load
Hydraulic Oils
Operating Condition Standard CS/Freezer/Food
Processing
Arctic
Truck Temperature
Range
0 to 84 C
(32 to 120 F)
18 to 84 C
(0 to 120 F)
40 to 84 C
( 40 to 120 F)
For All Hydraulically Actuated Equipment
Specification ISO VG 46 Antiwear
(HCE-140)
Exxon Univis® HVI 26 Exxon Univis® HVI 26
Pour Point Maximum 15 C (5.0 F) 60 C ( 76.0 F) 60 C ( 76.0 F)
Field Personnel Note: The product listed above is the approved source that meets or exceeds HYSTER
specifications. The use of products other than that listed above is unauthorized.
1
Gear Oils 8000 SRM 1033
Master Drive Unit Specifications
Model Motor Power Gear Ratio Capacity Oil Specification
T5Z and C60Z 2.0 kW (2.7 hp) 16:1 1.7 liter (1.8 qt) Gear Oil
T7Z and C80Z 2.8 kW (3.8 hp) 17.8:1 2.0 liter (2.1 qt) Gear Oil
T5ZAC
and
C60ZAC 4.0 kW (5.36 hp) 16:1 1.7 liter (1.8 qt) Gear Oil
T7ZAC
and
C80ZAC 4.0 kW (5.36 hp) 17.8:1 2.0 liter (2.1 qt) Gear Oil
Gear Oils
Operating Condition Standard/CS/Freezer/Food
Processing
Arctic
SAE Grade 80W-90 75W-90
Type Multipurpose EP Multipurpose EP
Base Oil Conventional Petroleum Synthetic
MIL-Specification No. MIL-L-2105C MIL-L-2105C
API Service Classification GL-5 GL-5
Anticipated Ambient
Temperature
18 to 49 C ( 15 to 100 F)
Most HYSTER lift truck
operations will fall within this
temperature range.
As low as 60 C ( 51 F)
Primarily intended for cold
storage and/or Arctic conditions;
can be used as high as 90 C (32 F).
Approved Sources
Chevron Chevron Universal Gear
Lube 80W/90
No Product
Exxon Exxon Gear Oil GX 80W/90 No Product
Mobil Mobilube HD 80W/90 Mobilube SHC 75W/90
Pennzoil Pennzoil MP 4092 No Product
Phillips 66 Philube SMP Gear Oil 80W/90 No Product
Solene Lub. Inc. Solene Gear Oil #905 No Product
Sun Sunfleet GL-5 Gear Lube 80W/90 No Product
Union 76 Unocal MP Gear Lube LS 80W/90 No Product
Field Personnel Note: The products listed above are the approved sources that meet or exceed HYSTER
specifications. The use of products other than that listed above is unauthorized.
2
8000 SRM 1033 Tire Specifications
Grease
Fittings and Bearings
Application Standard/CS/Freezer Arctic/Food
Processing
Steer Bearings
Approved Vendor Mobilgrease® 28 Amsoil GHD® Amsoil GHD®
Oil Synthetic Synthetic Synthetic
Thickener Clay Lithium Complex Lithium Complex
Grade NGLI 1.5 2.0 2.0
Moly-Fortified No Yes Yes
Dropping Pt. 310 C (590 F) 288 C (550 F) 288 C (550 F)
Field Personnel Note: The product listed above is the approved source that meets or exceeds HYSTER
specifications. The use of products other than that listed above is unauthorized.
Tire Specifications
Drive Tire Load Wheel Casters
Lift Truck
Model Size Composition Size Composition Size Composition
T5Z and
T5ZAC 10.0 × 5.0 in.
Poly1
(Standard)
Rubber2
(Optional)
Siped-Poly1
(Optional)
8.0 × 5.0 in.
Rubber2
(Standard)
Poly3
(Optional)
Not Available
T7Z and
T7ZAC 12.0 × 4.5 in. Poly1
8.0 × 5.0 in.
Rubber2
(Standard)
Poly3
(Optional)
Not Available
3.25 × 6.50 in.
Single/Poly4
(Standard)
C60Z and
C60ZAC 10.0 × 5.0 in.
Rubber2
(Standard)
Poly1
(Optional)
Siped-Poly1
(Optional)
3.250 × 3.125 in.
Dual/Poly4
(Optional)
4.0 × 2.5 in. Poly4
3.25 × 6.50 in.
Single/Poly4
(Standard
C80Z and
C80ZAC 12.0 × 4.5 in. Poly1
3.250 × 3.125 in.
Dual/Poly4
(Optional)
4.0 × 2.5 in. Poly5
1
Durometer 90
2
Durometer 65
3
Durometer 93
4
Durometer 95
5
Durometer 92
3
Torque Specifications 8000 SRM 1033
Torque Specifications
MASTER DRIVE UNIT
Lower Nut on Motor Mounting Stud (4 Places)
26 N•m (19 lbf ft)
Upper Nut on Motor Mounting Stud (4 Places)
20 N•m (15 lbf ft)
Transmission to Frame Mounting Bolts
(4 Each)(C60Z, C60ZAC
, T5Z, and T5ZAC
)
201 N•m (148 lbf ft)
Transmission to Frame Mounting Bolts
(4 Each)(C80Z, C80ZAC
, T7Z, and T7ZAC
)
300 N•m (221 lbf ft)
Top Cover to Support Bracket
32 N•m (24 lbf ft)
Pinion Gear to Shaft
180 N•m (133 lbf ft)
Drive Shaft Gear Retaining Nut
300 N•m (221 lbf ft)
Drain Plug
60 N•m (44 lbf ft)
Fill Plug
45 N•m (33 lbf ft)
Lug Bolts (5 Each) (C60Z and T5Z)
201 ±9 N•m (148 ±7 lbf ft)
Lug Nuts (5 Each) (C80Z, C80ZAC
,
T7Z, and T7ZAC
)
201 ±9 N•m (148 ±7 lbf ft)
BRAKE
Installation Allen-Head Capscrews (3 Each)
(C60Z, C60ZAC
, T5Z, and T5ZAC
)
10 N•m (89 lbf in)
Installation Allen-Head Capscrews (3 Each)
(C80Z, C80ZAC
, T7Z, and T7ZAC
)
17 N•m (13 lbf ft)
STEERING
Support to Frame Mounting Bolts (4 Each)
88 N•m (65 lbf ft)
Steer Bearing Locking Nut
27 N•m (20 lbf ft)
Control Handle Bracket to Control
Handle Arm (4 Each)
14 N•m (10 lbf ft)
Control Handle Head to Control Handle
Bracket (4 Each)
9 N•m (80 lbf in)
Directional Control Shaft to Control
Handle Bracket (2 Each)
42 N•m (31 lbf ft)
ELECTRICAL
Traction Motor Terminals (4 Each)
9 N•m (80 lbf in)
COUPLER (T5Z, T5ZAC
, T7Z, AND T7ZAC
)
Coupler (Jaw-Type) to Frame (4 Each)
102 N•m (75 lbf ft)
Coupler (Pin-Type) to Frame (2 Each)
203 N•m (150 lbf ft)
LIFT PUMP (C60Z, C60ZAC
, C80Z, AND
C80ZAC
)
Pressure Port Fitting
38 N•m (28 lbf ft)
4
8000 SRM 1033 Truck Weight
Travel Speeds
T5Z, T5ZAC
, T7Z, AND T7ZAC
No Load 200 lbs Drawbar Pull
300 lbs Drawbar
Pull
5000 lbs GTW
Level 5% Grade Level Level 5% Grade
Speed Speed Speed Speed Speed
Model
km/h mph
Batt.
Amp. km/h mph
Batt.
Amp. km/h mph
Batt.
Amp. km/h mph
Batt.
Amp. km/h mph
Batt.
Amp.
T5Z 12.6 7.8 98.3 5.9 3.7 176.0 7.1 4.4 135.6 N/A N/A N/A 4.7 2.9 259.0
T7Z 13.5 8.4 138.9 8.9 5.5 187.0 N/A N/A N/A 6.8 4.2 225.4 4.6 2.8 285.0
NOTE: Information applies to trucks equipped with rubber drive tire and 454 kg (1000 lb) battery with specific gravity 1.265 or higher.
C60Z, C60ZAC
, C80Z, AND C80ZAC
No Load Loaded to Capacity
Level 5% Grade Level 5% Grade
Speed Speed Speed Speed
Model
km/h mph
Batt.
Amp. km/h mph
Batt.
Amp. km/h mph
Batt.
Amp. km/h mph
Batt.
Amp.
C60Z 13.0 8.1 56.6 9.0 5.6 129.0 9.5 5.9 110.0 4.2 2.6 294.0
C80Z 12.6 7.8 95.3 8.0 5.0 132.0 7.4 4.6 145.4 3.9 2.4 251.0
NOTE: Information applies to trucks equipped with poly drive tire and 454 kg (1000 lb) battery with specific gravity
1.265 or higher.
Truck Weight
Less Battery With Battery
Unit
kg lb kg lb
T5Z and T5ZAC
541 1192 994 2192
T7Z and T7ZAC
587 1295 1041 2295
C60Z and C60ZAC
733 1616 1187 2616
C80Z and C80ZAC
836 1842 1289 2842
5
Battery Specifications and Adjustments 8000 SRM 1033
Battery Specifications and Adjustments
Figure 1. Battery Compartment
Battery and Battery Compartment Dimensions
Battery Compartment Battery
Dimensions Length (X) Width (Y) Capacity2
Weight
Model
Length
(X)
mm (in.)
Width
(Y)
mm (in.)
Height
Min1
mm (in.)
Max
mm (in.)
Min1
mm (in.)
Max
mm (in.)
Max
kwh
(amp hr)
Max
kg (lb)
T5Z and T5ZAC
794 (31.25) 340 (13.4) Open 648 (25.5) 785 (30.9) 218 (8.6) 330 (13) 11.9 (510) 469 (1035)
T7Z and T7ZAC
794 (31.25) 340 (13.4) Open 648 (25.5) 785 (30.9) 218 (8.6) 330 (13) 17.6 (750) 658 (1450)
C60Z and C60ZAC
794 (31.25) 340 (13.4) Open 663 (26.1) 785 (30.9) 325 (12.8) 330 (13) 11.9 (510) 469 (1035)
C80Z and C80ZAC
794 (31.25) 340 (13.4) Open 663 (26.1) 785 (30.9) 325 (12.8) 330 (13) 17.6 (750) 658 (1450)
1
Minimum battery dimensions allowed with standard battery spacer group.
2
6 hour rate.
NOTE: 24 Volt DC battery only.
Covered batteries required.
Battery connector type is 175 Amp, Red (Gray is optional).
Cable lead position B.
20-Inch cable length.
Maximum cable gauge of 1/0.
6
100 SRM 1030 General
General
DESCRIPTION
This section describes the frames for the C60Z,
C60ZAC
, C80Z, C80ZAC
, T5Z, T5ZAC
, T7Z, and
T7ZAC
lift trucks. Repair procedures for major sys-
tems/parts that fasten to the frame are found in
separate SRM sections.
C60Z, C60ZAC
, C80Z, and C80ZAC
lift trucks have a
main frame weldment and a fork frame weldment.
The main frame weldment has mounts for the mas-
ter drive unit (MDU), the lift pump and motor assem-
bly, and electrical system components. The mounting
holes for the casters are in the main frame weldment.
The fork frame weldment is fastened to the main
frame weldment by the links of the lifting mecha-
nism. The fork frame weldment is raised by a lift
cylinder connected to the main frame weldment and
fork frame weldment. The lift cylinder raises the bat-
tery end of the fork frame weldment and the linkage
mechanism moves the load wheels to raise the fork
tips at the rear of the fork frame weldment. See Fig-
ure 1.
T5Z, T5ZAC
, T7Z, and T7ZAC
trucks have a sin-
gle-frame weldment composed of the operator’s
compartment, battery compartment, and master
drive unit (MDU) compartment. The frame weld-
ment has mounts for the MDU and electrical system
components. See Figure 2.
Most truck repairs are performed on the individual
components that are bolted to the frame weldment
and not to the frame weldment itself.
1. MAIN FRAME WELDMENT 2. FORK FRAME WELDMENT
Figure 1. Frame Weldments (C60-80Z and C60-80ZAC
)
1
General 100 SRM 1030
Figure 2. Frame Weldment (T5-7Z and T5-7ZAC
)
2
100 SRM 1030 General
FEATURES
C60Z, C60ZAC
, C80Z, and C80ZAC
The C60Z, C60ZAC
, C80Z, and C80ZAC
frames have
mounts for:
• The Electrical System Parts
• The Lift Pump and Motor Assembly
• The Master Drive Unit
• Lift Cylinder
• Lift Linkage
Based on model and capacities, the main frame and
fork frame are available in combinations of the fol-
lowing:
1. Lifting Capacity
• C60Z and C60ZAC
: 2722 kg (6000 lb)
• C80Z and C80ZAC
: 3629 kg (8000 lb)
2. Battery Compartment Size
• 340 mm (13.40 in.)
3. Fork Width
• 230 mm (9.06 in.)
• 254 mm (10.00 in.)
4. Fork Spread (Outside to Outside)
• 686 mm (27.00 in.)
• 708 mm (27.88 in.)
5. Wheel Base and Fork Length
• See Table 1, Table 2, Table 3, and Table 4.
Table 1. Wheel Base and Fork Length
Forks C60Z
Length 908 mm (35.75 in.) 1060 mm (41.75 in.) 1213 mm (47.75 in.) 1365 mm (53.75 in.) 1518 mm (59.75 in.)
Raised
Wheel
Base
1770 mm (69.70 in.) 1923 mm (75.70 in.) 2075 mm (81.70 in.) 2228 mm (87.70 in.) 2380 mm (93.70 in.)
Lowered
Wheel
Base
1892 mm (74.50 in.) 2045 mm (80.50 in.) 2197 mm (86.50 in.) 2350 mm (92.50 in.) 2502 mm (98.50 in.)
Table 2. Wheel Base and Fork Length
Forks C80Z
Length
908 mm
(35.75 in.)
1060 mm
(41.75 in.)
1213 mm
(47.75 in.)
1365 mm
(53.75 in.)
1518 mm
(59.75 in.)
2127 mm
(83.75 in.)
2356 mm
(92.75 in.)
2432 mm
(95.75 in.)
Raised
Wheel
Base
1822 mm
(71.75 in.)
1969 mm
(77.50 in.)
2121 mm
(83.50 in.)
2273 mm
(89.50 in.)
2426 mm
(95.50 in.)
2654 mm (104.50 in.)
Lowered
Wheel
Base
1953 mm
(76.90 in.)
2106 mm
(82.90 in.)
2258 mm
(88.90 in.)
2410 mm
(94.90 in.)
2563 mm
(100.90 in.)
2791 mm (109.90 in.)
Table 3. Wheel Base and Fork Length
Forks C60ZAC
Length 908 mm (35.75 in.) 1060 mm (41.75 in.) 1213 mm (47.75 in.) 1518 mm (59.75 in.)
Raised
Wheel Base
1770 mm (69.70 in.) 1923 mm (75.70 in.) 2075 mm (81.70 in.) 2380 mm (93.70 in.)
Lowered
Wheel Base
1892 mm (74.50 in.) 2045 mm (80.50 in.) 2197 mm (86.50 in.) 2502 mm (98.50 in.)
3
General 100 SRM 1030
Table 4. Wheel Base and Fork Length
Forks C80ZAC
Length
908 mm
(35.75 in.)
1060 mm
(41.75 in.)
1213 mm
(47.75 in.)
1518 mm
(59.75 in.)
2127 mm
(83.75 in.)
2356 mm
(92.75 in.)
2432 mm
(95.75 in.)
3658 mm
(144 in.)
Raised
Wheel
Base
1822 mm
(71.75 in.)
1969 mm
(77.50 in.)
2121 mm
(83.50 in.)
2426 mm
(95.50 in.)
2654 mm (104.50 in.)
Lowered
Wheel
Base
1953 mm
(76.90 in.)
2106 mm
(82.90 in.)
2258 mm
(88.90 in.)
2563 mm
(100.90 in.)
2791 mm (109.90 in.)
T5Z, T5ZAC
, T7Z, and T7ZAC
The T5Z, T5ZAC
, T7Z, and T7ZAC
frames have
mounts for:
• The Electrical System Parts
• The Master Drive Unit
Based on model and capacities, the frame is available
in combinations of the following:
1. Battery Compartment Size
• 340 mm (13.4 in.)
2. Wheel Base
• T5Z and T5ZAC
: 942 mm (37.1 in.)
• T7Z and T7ZAC
: 996 mm (39.2 in.)
COVERS
The drive unit compartment is concealed behind a
contoured, front cover which fits securely around the
drive unit and steer support to the frame. A lower
cover fits around the base of the drive unit platform
and is secured in place with three screws after the
front cover has been installed.
To remove the covers, first remove the three screws
securing the lower cover and remove the lower cover
from the lift truck. Next, reach under the side of
the front cover, near the bottom, and find the grip
slot. With both hands, pull up and away from the
truck until the bottom of the cover kicks out from the
retaining clips. Repeat this for the other side of the
cover. Work around the edge of the cover until free
from the truck. See Figure 3.
To install the covers, place the bottom of the front
cover onto the operator platform and position the
lower edges partially into the lower retaining clips.
Push the top of the cover partially into the upper
retaining clips. Do not push either edge of the
cover completely in before starting all edges into
the proper place. When the cover is aligned and
started properly, press the cover completely into the
retaining clips. Position the lower cover around the
base of the front cover as removed. Make sure the
spring nut clips and the lower cover mounting holes
are aligned. Install the three screws to secure the
lower cover in place.
4
100 SRM 1030 General
1. FRONT COVER
2. LOWER COVER
3. SPRING NUT CLIPS
4. SCREWS
Figure 3. Drive Unit Compartment Covers
5
Special Precautions 100 SRM 1030
Special Precautions
WARNING
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. Verify that the key switch is in the OFF position
and the battery connector is completely discon-
nected.
2. 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. Remove the
200-ohm, 2-watt resistor before reconnecting the
battery. See Figure 4 or Figure 5.
1. POSITIVE CONNECTION
2. NEGATIVE CONNECTION
3. JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
Figure 4. Discharging the Capacitors (C60-80Z
and T5-7Z)
6
100 SRM 1030 Special Precautions
Figure 5. Discharging the Capacitors
(C60-80ZAC
and T5-7ZAC
)
Legend for Figure 5
1. POSITIVE CONNECTION
2. NEGATIVE CONNECTION
3. JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
7
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Painting Instructions 100 SRM 1030
Frame Separation and Assembly
C60Z, C60ZAC
, C80Z, AND C80ZAC
Frame Separation
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 overexposure
may occur without odor warning. Should work
be performed, utilize good industrial hygiene
practices, including removal of all paint (prime
and finish coats) to the metal around the area
to be welded, local ventilation, and/or supplied
air respiratory protection.
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 lift truck that needs re-
pairs. Report the need for repairs to your
supervisor immediately. If repair is necessary,
turn the key switch to the OFF position, dis-
connect the battery connector, and attach a
DO NOT OPERATE tag to the control handle.
In some cases a main frame weldment or a fork
frame weldment may be damaged, while the rest
of the truck is still usable. The two frames may be
separated from each other.
The main frame weldment is connected to the fork
frame weldment by the lift cylinder, upper links, and
rocker arms. Disconnect/connect these components
to separate/assemble the frames.
See the section Lifting Mechanism 4000 SRM 965.
Refer to Upper Link - Remove/Install, and Rocker
Arm - Remove/Install.
See the section Walkie Hydraulic Systems 1900
SRM 964. Refer to Lift Cylinder - Remove/Install.
Painting Instructions
WARNING
Always use solvents and paints in an area with
ventilation. DO NOT use solvents or paints
near heat or fire.
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Wear protection
for eyes and skin. When using cleaning sol-
vents, always follow the recommendations of
the manufacturer.
1. Remove all dirt from the surface to be painted.
Clean the area to be painted using a solvent for
painted surfaces. Remove all oil and grease.
2. Remove the top surface of paint and all rust from
the metal using sandpaper. Paint all metal sur-
faces where the paint is completely removed us-
ing primer. Apply the primer before applying the
color paint.
3. Protect all surfaces that will not be painted. DO
NOT paint cylinder rods, cables, labels, plates,
or controls.
4. Paint all the surfaces the original color, using
Hyster® paint. Follow the directions on the con-
tainer.
8
100 SRM 1030 Battery Compartment
Label Replacement
WARNING
Replace damaged WARNING or CAUTION la-
bels immediately.
If labels or information plates are missing or dam-
aged, they must be replaced. See Figure 6, Figure 7,
or Figure 8.
NOTE: The nameplate is installed using rivets. Re-
move old rivets before installing a new nameplate.
See your Hyster® lift truck dealer to make sure the
nameplate information is correct and complete before
installing a new nameplate. Fasten the nameplate
with the rivet heads outside.
1. Make sure the surface is dry and has no oil or
grease. DO NOT use solvent on new paint.
Clean the surface of old paint using a cleaning
solvent.
2. Remove the paper from the back of the label. DO
NOT touch the adhesive surface.
NOTE: The label cannot be moved after it touches the
surface.
3. Carefully hold the label in the correct position
above the surface. Put the label in the correct
position on the surface. Make sure all air is re-
moved from under the label and the corners and
edges are tight.
Battery Compartment
WARNING
Batteries are heavy. Use care to avoid injury.
Always use a battery roller stand or tray when
trucks are equipped with optional battery
rollers or slide. Always wear protective cloth-
ing and eye protection when working with or
near the battery.
The battery compartment must be kept clean to en-
sure proper operation and safety. Any fluids on or
around the battery is an indication that electrolyte
is spilling or leaking out. Leaking batteries must be
repaired or replaced and the battery compartment
must be cleaned. Spacers are available to secure bat-
teries that fit loosely in the battery compartment.
For instructions on changing the battery or adjusting
the battery spacers, see the section Periodic Main-
tenance 8000 SRM 1032 or Periodic Maintenance
8000 SRM 1368 - Battery Maintenance.
9
Battery Compartment 100 SRM 1030
Figure 6. Labels and Decals Location on C60Z and C80Z
10

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Hyster a479 (c80 z) forklift service repair manual

  • 2. 8000 SRM 1033 Hydraulic Oils Hydraulic System (C60-80Z and C60-80ZAC ) Specification C60Z and C60ZAC C80Z and C80ZAC Motor Power1 1.2 kW (1.6 hp) 1.5 kW (2.0 hp) Hydraulic Relief Pressure 2700 psi 3500 psi Lifting Speed With Load2 4.7 seconds 5.7 seconds Without Load 3.5 seconds 3.9 seconds Lowering Speed With Load2 1.2 seconds 2.4 seconds Without Load 1.8 seconds 6.5 seconds Pump Displacement 1.50 cm3 (0.092 in.3 )/rev 2.00 cm3 (0.122 in.3 )/rev Allowable Drift With Load 6.4 mm (0.25 in.) Maximum in 10 minutes @ 21 C (70 F) Oil Temperature Hydraulic Reservoir Capacity 0.71 liter (0.75 qt) 0.85 liter (0.90 qt) 1 24 Volts DC 2 Capacity Load Hydraulic Oils Operating Condition Standard CS/Freezer/Food Processing Arctic Truck Temperature Range 0 to 84 C (32 to 120 F) 18 to 84 C (0 to 120 F) 40 to 84 C ( 40 to 120 F) For All Hydraulically Actuated Equipment Specification ISO VG 46 Antiwear (HCE-140) Exxon Univis® HVI 26 Exxon Univis® HVI 26 Pour Point Maximum 15 C (5.0 F) 60 C ( 76.0 F) 60 C ( 76.0 F) Field Personnel Note: The product listed above is the approved source that meets or exceeds HYSTER specifications. The use of products other than that listed above is unauthorized. 1
  • 3. Gear Oils 8000 SRM 1033 Master Drive Unit Specifications Model Motor Power Gear Ratio Capacity Oil Specification T5Z and C60Z 2.0 kW (2.7 hp) 16:1 1.7 liter (1.8 qt) Gear Oil T7Z and C80Z 2.8 kW (3.8 hp) 17.8:1 2.0 liter (2.1 qt) Gear Oil T5ZAC and C60ZAC 4.0 kW (5.36 hp) 16:1 1.7 liter (1.8 qt) Gear Oil T7ZAC and C80ZAC 4.0 kW (5.36 hp) 17.8:1 2.0 liter (2.1 qt) Gear Oil Gear Oils Operating Condition Standard/CS/Freezer/Food Processing Arctic SAE Grade 80W-90 75W-90 Type Multipurpose EP Multipurpose EP Base Oil Conventional Petroleum Synthetic MIL-Specification No. MIL-L-2105C MIL-L-2105C API Service Classification GL-5 GL-5 Anticipated Ambient Temperature 18 to 49 C ( 15 to 100 F) Most HYSTER lift truck operations will fall within this temperature range. As low as 60 C ( 51 F) Primarily intended for cold storage and/or Arctic conditions; can be used as high as 90 C (32 F). Approved Sources Chevron Chevron Universal Gear Lube 80W/90 No Product Exxon Exxon Gear Oil GX 80W/90 No Product Mobil Mobilube HD 80W/90 Mobilube SHC 75W/90 Pennzoil Pennzoil MP 4092 No Product Phillips 66 Philube SMP Gear Oil 80W/90 No Product Solene Lub. Inc. Solene Gear Oil #905 No Product Sun Sunfleet GL-5 Gear Lube 80W/90 No Product Union 76 Unocal MP Gear Lube LS 80W/90 No Product Field Personnel Note: The products listed above are the approved sources that meet or exceed HYSTER specifications. The use of products other than that listed above is unauthorized. 2
  • 4. 8000 SRM 1033 Tire Specifications Grease Fittings and Bearings Application Standard/CS/Freezer Arctic/Food Processing Steer Bearings Approved Vendor Mobilgrease® 28 Amsoil GHD® Amsoil GHD® Oil Synthetic Synthetic Synthetic Thickener Clay Lithium Complex Lithium Complex Grade NGLI 1.5 2.0 2.0 Moly-Fortified No Yes Yes Dropping Pt. 310 C (590 F) 288 C (550 F) 288 C (550 F) Field Personnel Note: The product listed above is the approved source that meets or exceeds HYSTER specifications. The use of products other than that listed above is unauthorized. Tire Specifications Drive Tire Load Wheel Casters Lift Truck Model Size Composition Size Composition Size Composition T5Z and T5ZAC 10.0 × 5.0 in. Poly1 (Standard) Rubber2 (Optional) Siped-Poly1 (Optional) 8.0 × 5.0 in. Rubber2 (Standard) Poly3 (Optional) Not Available T7Z and T7ZAC 12.0 × 4.5 in. Poly1 8.0 × 5.0 in. Rubber2 (Standard) Poly3 (Optional) Not Available 3.25 × 6.50 in. Single/Poly4 (Standard) C60Z and C60ZAC 10.0 × 5.0 in. Rubber2 (Standard) Poly1 (Optional) Siped-Poly1 (Optional) 3.250 × 3.125 in. Dual/Poly4 (Optional) 4.0 × 2.5 in. Poly4 3.25 × 6.50 in. Single/Poly4 (Standard C80Z and C80ZAC 12.0 × 4.5 in. Poly1 3.250 × 3.125 in. Dual/Poly4 (Optional) 4.0 × 2.5 in. Poly5 1 Durometer 90 2 Durometer 65 3 Durometer 93 4 Durometer 95 5 Durometer 92 3
  • 5. Torque Specifications 8000 SRM 1033 Torque Specifications MASTER DRIVE UNIT Lower Nut on Motor Mounting Stud (4 Places) 26 N•m (19 lbf ft) Upper Nut on Motor Mounting Stud (4 Places) 20 N•m (15 lbf ft) Transmission to Frame Mounting Bolts (4 Each)(C60Z, C60ZAC , T5Z, and T5ZAC ) 201 N•m (148 lbf ft) Transmission to Frame Mounting Bolts (4 Each)(C80Z, C80ZAC , T7Z, and T7ZAC ) 300 N•m (221 lbf ft) Top Cover to Support Bracket 32 N•m (24 lbf ft) Pinion Gear to Shaft 180 N•m (133 lbf ft) Drive Shaft Gear Retaining Nut 300 N•m (221 lbf ft) Drain Plug 60 N•m (44 lbf ft) Fill Plug 45 N•m (33 lbf ft) Lug Bolts (5 Each) (C60Z and T5Z) 201 ±9 N•m (148 ±7 lbf ft) Lug Nuts (5 Each) (C80Z, C80ZAC , T7Z, and T7ZAC ) 201 ±9 N•m (148 ±7 lbf ft) BRAKE Installation Allen-Head Capscrews (3 Each) (C60Z, C60ZAC , T5Z, and T5ZAC ) 10 N•m (89 lbf in) Installation Allen-Head Capscrews (3 Each) (C80Z, C80ZAC , T7Z, and T7ZAC ) 17 N•m (13 lbf ft) STEERING Support to Frame Mounting Bolts (4 Each) 88 N•m (65 lbf ft) Steer Bearing Locking Nut 27 N•m (20 lbf ft) Control Handle Bracket to Control Handle Arm (4 Each) 14 N•m (10 lbf ft) Control Handle Head to Control Handle Bracket (4 Each) 9 N•m (80 lbf in) Directional Control Shaft to Control Handle Bracket (2 Each) 42 N•m (31 lbf ft) ELECTRICAL Traction Motor Terminals (4 Each) 9 N•m (80 lbf in) COUPLER (T5Z, T5ZAC , T7Z, AND T7ZAC ) Coupler (Jaw-Type) to Frame (4 Each) 102 N•m (75 lbf ft) Coupler (Pin-Type) to Frame (2 Each) 203 N•m (150 lbf ft) LIFT PUMP (C60Z, C60ZAC , C80Z, AND C80ZAC ) Pressure Port Fitting 38 N•m (28 lbf ft) 4
  • 6. 8000 SRM 1033 Truck Weight Travel Speeds T5Z, T5ZAC , T7Z, AND T7ZAC No Load 200 lbs Drawbar Pull 300 lbs Drawbar Pull 5000 lbs GTW Level 5% Grade Level Level 5% Grade Speed Speed Speed Speed Speed Model km/h mph Batt. Amp. km/h mph Batt. Amp. km/h mph Batt. Amp. km/h mph Batt. Amp. km/h mph Batt. Amp. T5Z 12.6 7.8 98.3 5.9 3.7 176.0 7.1 4.4 135.6 N/A N/A N/A 4.7 2.9 259.0 T7Z 13.5 8.4 138.9 8.9 5.5 187.0 N/A N/A N/A 6.8 4.2 225.4 4.6 2.8 285.0 NOTE: Information applies to trucks equipped with rubber drive tire and 454 kg (1000 lb) battery with specific gravity 1.265 or higher. C60Z, C60ZAC , C80Z, AND C80ZAC No Load Loaded to Capacity Level 5% Grade Level 5% Grade Speed Speed Speed Speed Model km/h mph Batt. Amp. km/h mph Batt. Amp. km/h mph Batt. Amp. km/h mph Batt. Amp. C60Z 13.0 8.1 56.6 9.0 5.6 129.0 9.5 5.9 110.0 4.2 2.6 294.0 C80Z 12.6 7.8 95.3 8.0 5.0 132.0 7.4 4.6 145.4 3.9 2.4 251.0 NOTE: Information applies to trucks equipped with poly drive tire and 454 kg (1000 lb) battery with specific gravity 1.265 or higher. Truck Weight Less Battery With Battery Unit kg lb kg lb T5Z and T5ZAC 541 1192 994 2192 T7Z and T7ZAC 587 1295 1041 2295 C60Z and C60ZAC 733 1616 1187 2616 C80Z and C80ZAC 836 1842 1289 2842 5
  • 7. Battery Specifications and Adjustments 8000 SRM 1033 Battery Specifications and Adjustments Figure 1. Battery Compartment Battery and Battery Compartment Dimensions Battery Compartment Battery Dimensions Length (X) Width (Y) Capacity2 Weight Model Length (X) mm (in.) Width (Y) mm (in.) Height Min1 mm (in.) Max mm (in.) Min1 mm (in.) Max mm (in.) Max kwh (amp hr) Max kg (lb) T5Z and T5ZAC 794 (31.25) 340 (13.4) Open 648 (25.5) 785 (30.9) 218 (8.6) 330 (13) 11.9 (510) 469 (1035) T7Z and T7ZAC 794 (31.25) 340 (13.4) Open 648 (25.5) 785 (30.9) 218 (8.6) 330 (13) 17.6 (750) 658 (1450) C60Z and C60ZAC 794 (31.25) 340 (13.4) Open 663 (26.1) 785 (30.9) 325 (12.8) 330 (13) 11.9 (510) 469 (1035) C80Z and C80ZAC 794 (31.25) 340 (13.4) Open 663 (26.1) 785 (30.9) 325 (12.8) 330 (13) 17.6 (750) 658 (1450) 1 Minimum battery dimensions allowed with standard battery spacer group. 2 6 hour rate. NOTE: 24 Volt DC battery only. Covered batteries required. Battery connector type is 175 Amp, Red (Gray is optional). Cable lead position B. 20-Inch cable length. Maximum cable gauge of 1/0. 6
  • 8. 100 SRM 1030 General General DESCRIPTION This section describes the frames for the C60Z, C60ZAC , C80Z, C80ZAC , T5Z, T5ZAC , T7Z, and T7ZAC lift trucks. Repair procedures for major sys- tems/parts that fasten to the frame are found in separate SRM sections. C60Z, C60ZAC , C80Z, and C80ZAC lift trucks have a main frame weldment and a fork frame weldment. The main frame weldment has mounts for the mas- ter drive unit (MDU), the lift pump and motor assem- bly, and electrical system components. The mounting holes for the casters are in the main frame weldment. The fork frame weldment is fastened to the main frame weldment by the links of the lifting mecha- nism. The fork frame weldment is raised by a lift cylinder connected to the main frame weldment and fork frame weldment. The lift cylinder raises the bat- tery end of the fork frame weldment and the linkage mechanism moves the load wheels to raise the fork tips at the rear of the fork frame weldment. See Fig- ure 1. T5Z, T5ZAC , T7Z, and T7ZAC trucks have a sin- gle-frame weldment composed of the operator’s compartment, battery compartment, and master drive unit (MDU) compartment. The frame weld- ment has mounts for the MDU and electrical system components. See Figure 2. Most truck repairs are performed on the individual components that are bolted to the frame weldment and not to the frame weldment itself. 1. MAIN FRAME WELDMENT 2. FORK FRAME WELDMENT Figure 1. Frame Weldments (C60-80Z and C60-80ZAC ) 1
  • 9. General 100 SRM 1030 Figure 2. Frame Weldment (T5-7Z and T5-7ZAC ) 2
  • 10. 100 SRM 1030 General FEATURES C60Z, C60ZAC , C80Z, and C80ZAC The C60Z, C60ZAC , C80Z, and C80ZAC frames have mounts for: • The Electrical System Parts • The Lift Pump and Motor Assembly • The Master Drive Unit • Lift Cylinder • Lift Linkage Based on model and capacities, the main frame and fork frame are available in combinations of the fol- lowing: 1. Lifting Capacity • C60Z and C60ZAC : 2722 kg (6000 lb) • C80Z and C80ZAC : 3629 kg (8000 lb) 2. Battery Compartment Size • 340 mm (13.40 in.) 3. Fork Width • 230 mm (9.06 in.) • 254 mm (10.00 in.) 4. Fork Spread (Outside to Outside) • 686 mm (27.00 in.) • 708 mm (27.88 in.) 5. Wheel Base and Fork Length • See Table 1, Table 2, Table 3, and Table 4. Table 1. Wheel Base and Fork Length Forks C60Z Length 908 mm (35.75 in.) 1060 mm (41.75 in.) 1213 mm (47.75 in.) 1365 mm (53.75 in.) 1518 mm (59.75 in.) Raised Wheel Base 1770 mm (69.70 in.) 1923 mm (75.70 in.) 2075 mm (81.70 in.) 2228 mm (87.70 in.) 2380 mm (93.70 in.) Lowered Wheel Base 1892 mm (74.50 in.) 2045 mm (80.50 in.) 2197 mm (86.50 in.) 2350 mm (92.50 in.) 2502 mm (98.50 in.) Table 2. Wheel Base and Fork Length Forks C80Z Length 908 mm (35.75 in.) 1060 mm (41.75 in.) 1213 mm (47.75 in.) 1365 mm (53.75 in.) 1518 mm (59.75 in.) 2127 mm (83.75 in.) 2356 mm (92.75 in.) 2432 mm (95.75 in.) Raised Wheel Base 1822 mm (71.75 in.) 1969 mm (77.50 in.) 2121 mm (83.50 in.) 2273 mm (89.50 in.) 2426 mm (95.50 in.) 2654 mm (104.50 in.) Lowered Wheel Base 1953 mm (76.90 in.) 2106 mm (82.90 in.) 2258 mm (88.90 in.) 2410 mm (94.90 in.) 2563 mm (100.90 in.) 2791 mm (109.90 in.) Table 3. Wheel Base and Fork Length Forks C60ZAC Length 908 mm (35.75 in.) 1060 mm (41.75 in.) 1213 mm (47.75 in.) 1518 mm (59.75 in.) Raised Wheel Base 1770 mm (69.70 in.) 1923 mm (75.70 in.) 2075 mm (81.70 in.) 2380 mm (93.70 in.) Lowered Wheel Base 1892 mm (74.50 in.) 2045 mm (80.50 in.) 2197 mm (86.50 in.) 2502 mm (98.50 in.) 3
  • 11. General 100 SRM 1030 Table 4. Wheel Base and Fork Length Forks C80ZAC Length 908 mm (35.75 in.) 1060 mm (41.75 in.) 1213 mm (47.75 in.) 1518 mm (59.75 in.) 2127 mm (83.75 in.) 2356 mm (92.75 in.) 2432 mm (95.75 in.) 3658 mm (144 in.) Raised Wheel Base 1822 mm (71.75 in.) 1969 mm (77.50 in.) 2121 mm (83.50 in.) 2426 mm (95.50 in.) 2654 mm (104.50 in.) Lowered Wheel Base 1953 mm (76.90 in.) 2106 mm (82.90 in.) 2258 mm (88.90 in.) 2563 mm (100.90 in.) 2791 mm (109.90 in.) T5Z, T5ZAC , T7Z, and T7ZAC The T5Z, T5ZAC , T7Z, and T7ZAC frames have mounts for: • The Electrical System Parts • The Master Drive Unit Based on model and capacities, the frame is available in combinations of the following: 1. Battery Compartment Size • 340 mm (13.4 in.) 2. Wheel Base • T5Z and T5ZAC : 942 mm (37.1 in.) • T7Z and T7ZAC : 996 mm (39.2 in.) COVERS The drive unit compartment is concealed behind a contoured, front cover which fits securely around the drive unit and steer support to the frame. A lower cover fits around the base of the drive unit platform and is secured in place with three screws after the front cover has been installed. To remove the covers, first remove the three screws securing the lower cover and remove the lower cover from the lift truck. Next, reach under the side of the front cover, near the bottom, and find the grip slot. With both hands, pull up and away from the truck until the bottom of the cover kicks out from the retaining clips. Repeat this for the other side of the cover. Work around the edge of the cover until free from the truck. See Figure 3. To install the covers, place the bottom of the front cover onto the operator platform and position the lower edges partially into the lower retaining clips. Push the top of the cover partially into the upper retaining clips. Do not push either edge of the cover completely in before starting all edges into the proper place. When the cover is aligned and started properly, press the cover completely into the retaining clips. Position the lower cover around the base of the front cover as removed. Make sure the spring nut clips and the lower cover mounting holes are aligned. Install the three screws to secure the lower cover in place. 4
  • 12. 100 SRM 1030 General 1. FRONT COVER 2. LOWER COVER 3. SPRING NUT CLIPS 4. SCREWS Figure 3. Drive Unit Compartment Covers 5
  • 13. Special Precautions 100 SRM 1030 Special Precautions WARNING 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. Verify that the key switch is in the OFF position and the battery connector is completely discon- nected. 2. 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. Remove the 200-ohm, 2-watt resistor before reconnecting the battery. See Figure 4 or Figure 5. 1. POSITIVE CONNECTION 2. NEGATIVE CONNECTION 3. JUMPER WIRES 4. 200-OHM, 2-WATT RESISTOR Figure 4. Discharging the Capacitors (C60-80Z and T5-7Z) 6
  • 14. 100 SRM 1030 Special Precautions Figure 5. Discharging the Capacitors (C60-80ZAC and T5-7ZAC ) Legend for Figure 5 1. POSITIVE CONNECTION 2. NEGATIVE CONNECTION 3. JUMPER WIRES 4. 200-OHM, 2-WATT RESISTOR 7
  • 15. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
  • 16. Painting Instructions 100 SRM 1030 Frame Separation and Assembly C60Z, C60ZAC , C80Z, AND C80ZAC Frame Separation 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 overexposure may occur without odor warning. Should work be performed, utilize good industrial hygiene practices, including removal of all paint (prime and finish coats) to the metal around the area to be welded, local ventilation, and/or supplied air respiratory protection. 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 lift truck that needs re- pairs. Report the need for repairs to your supervisor immediately. If repair is necessary, turn the key switch to the OFF position, dis- connect the battery connector, and attach a DO NOT OPERATE tag to the control handle. In some cases a main frame weldment or a fork frame weldment may be damaged, while the rest of the truck is still usable. The two frames may be separated from each other. The main frame weldment is connected to the fork frame weldment by the lift cylinder, upper links, and rocker arms. Disconnect/connect these components to separate/assemble the frames. See the section Lifting Mechanism 4000 SRM 965. Refer to Upper Link - Remove/Install, and Rocker Arm - Remove/Install. See the section Walkie Hydraulic Systems 1900 SRM 964. Refer to Lift Cylinder - Remove/Install. Painting Instructions WARNING Always use solvents and paints in an area with ventilation. DO NOT use solvents or paints near heat or fire. Cleaning solvents can be flammable and toxic and can cause skin irritation. Wear protection for eyes and skin. When using cleaning sol- vents, always follow the recommendations of the manufacturer. 1. Remove all dirt from the surface to be painted. Clean the area to be painted using a solvent for painted surfaces. Remove all oil and grease. 2. Remove the top surface of paint and all rust from the metal using sandpaper. Paint all metal sur- faces where the paint is completely removed us- ing primer. Apply the primer before applying the color paint. 3. Protect all surfaces that will not be painted. DO NOT paint cylinder rods, cables, labels, plates, or controls. 4. Paint all the surfaces the original color, using Hyster® paint. Follow the directions on the con- tainer. 8
  • 17. 100 SRM 1030 Battery Compartment Label Replacement WARNING Replace damaged WARNING or CAUTION la- bels immediately. If labels or information plates are missing or dam- aged, they must be replaced. See Figure 6, Figure 7, or Figure 8. NOTE: The nameplate is installed using rivets. Re- move old rivets before installing a new nameplate. See your Hyster® lift truck dealer to make sure the nameplate information is correct and complete before installing a new nameplate. Fasten the nameplate with the rivet heads outside. 1. Make sure the surface is dry and has no oil or grease. DO NOT use solvent on new paint. Clean the surface of old paint using a cleaning solvent. 2. Remove the paper from the back of the label. DO NOT touch the adhesive surface. NOTE: The label cannot be moved after it touches the surface. 3. Carefully hold the label in the correct position above the surface. Put the label in the correct position on the surface. Make sure all air is re- moved from under the label and the corners and edges are tight. Battery Compartment WARNING Batteries are heavy. Use care to avoid injury. Always use a battery roller stand or tray when trucks are equipped with optional battery rollers or slide. Always wear protective cloth- ing and eye protection when working with or near the battery. The battery compartment must be kept clean to en- sure proper operation and safety. Any fluids on or around the battery is an indication that electrolyte is spilling or leaking out. Leaking batteries must be repaired or replaced and the battery compartment must be cleaned. Spacers are available to secure bat- teries that fit loosely in the battery compartment. For instructions on changing the battery or adjusting the battery spacers, see the section Periodic Main- tenance 8000 SRM 1032 or Periodic Maintenance 8000 SRM 1368 - Battery Maintenance. 9
  • 18. Battery Compartment 100 SRM 1030 Figure 6. Labels and Decals Location on C60Z and C80Z 10