service repair manual

1. SERVICE REPAIR
T7ZAC [B477]

2. 1600 SRM 1031 Special Precautions
Introduction
GENERAL
This section provides a description of the steering
system used on the T5-7Z, T5-7ZAC
, C60-80Z, and
C60-80ZAC
lift trucks. Procedures for removal, dis-
assembly, repair, assembly, and installation of the
steering assembly are outlined in this section.
See the section Electrical System 2200 SRM 1052
or Electrical System 2200 SRM 1357 for informa-
tion on removal and disassembly of the control han-
dle.
See the section Master Drive Unit 630 SRM 961 for
information on the traction motor, drive unit, or drive
tire and wheel assembly.
See the section Periodic Maintenance 8000 SRM
1032 or Periodic Maintenance 8000 SRM 1368 for
instructions on removing and installing the Drive
Unit Compartment Covers.
DESCRIPTION OF OPERATION
The steering system consists of a top-mounted, fixed,
tower-type control handle assembly, a support as-
sembly, a steer plate, a Master Drive Unit (MDU),
and the drive tire and wheel assembly. The opera-
tor moves the control handle assembly left or right
to steer the truck. Direction and speed controls are
located on the control handle assembly which is at-
tached to the hub on the support assembly. The con-
trol handle assembly is adjustable. A spring-loaded
pin locks it into position. The support is attached
to the truck frame and houses a set of tapered roller
bearings. The hub is attached to the upper end of the
spindle. The steer plate connects the lower end of the
spindle to the MDU and turns the MDU left or right
when the control handle is moved to steer the truck.
Special Precautions
WARNING
To avoid personal injury and prevent electri-
cal shock, perform the following steps before
troubleshooting or adjusting and before con-
necting or disconnecting a handset or personal
computer.
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 the proper procedure
when servicing the controller.
1. Turn the key switch to the OFF position and dis-
connect the battery.
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. See Figure 1 or
Figure 2.
3. Remove the 200-ohm, 2-watt resistor before re-
connecting the battery.
1. POSITIVE CONNECTION
2. NEGATIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
Figure 1. Discharging the Controller (C60Z,
C80Z, T5Z, and T7Z)
1

3. Special Precautions 1600 SRM 1031
Figure 2. Discharging Controller (C60ZAC
,
C80ZAC
, T5ZAC
, and T7ZAC
)
Legend for Figure 2
1. CONTROLLER
2. POSITIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
5. NEGATIVE CONNECTION
2

4. 1600 SRM 1031 Control Handle
Control Handle
REMOVE
1. Move the lift truck to a safe, level area.
2. Block the wheels to prevent the lift truck from
moving. Refer to Periodic Maintenance 8000
SRM 1032 or Periodic Maintenance 8000 SRM
1368 - How to Put the Truck on Blocks.
3. Turn the key switch to the OFF position, set the
parking brake to the ON position, and disconnect
battery.
4. Remove drive unit compartment covers. See the
section Periodic Maintenance 8000 SRM 1032
or Periodic Maintenance 8000 SRM 1368 -
Drive Unit Compartment Covers.
WARNING
The capacitor in the transistor controller can
hold an electrical charge after the battery
is disconnected. To prevent electrical shock
and personal injury, discharge the capacitor
before inspecting or repairing any component
in the drive unit compartment. Wear safety
glasses. Make certain the battery has been
disconnected.
5. Discharge the capacitor. See Special Precautions
in this section.
For the following instructions, refer to Figure 3.
6. Raise handle to the upper adjustment position.
7. Remove three Allen-head screws (20) holding
cover to hub and remove cover to gain access to
control handle wiring harness.
NOTE: Pay special attention to where each wire tie
and terminal of the wiring harness was removed for
proper installation.
8. Label and disconnect control handle wiring har-
ness from the control handle interface module.
Label and disconnect the main wiring harness
from the contactor, MDU and horn.
9. Gently pull control handle wiring harness
through spindle and place wiring harness over
to one side.
10. Support the handle with a sling and overhead
lifting device. Remove roll pin (28) and pivot
shaft (30) from hub.
11. Disengage adjustment pin and remove control
handle arm from the hub.
NOTE: If the pivot shaft does not fit snugly in the
bushings, replace the bushings.
12. Remove bushings from hub if there is excessive
clearance between the pivot shaft and bushings.
INSTALL
1. Install bushings to hub, if removed. Pin should
fit snugly in bushings.
2. Align control handle arm to hub. Retract the ad-
justing pin and position lower end of control han-
dle between the lobes on the hub.
3. Insert pivot (shaft) and roll pin (28).
4. Pull control handle wiring harness through spin-
dle and route wiring harness through large wire
clamp on side of support and around back side of
support as removed.
5. Secure wiring harness to top of motor mounting
stud using wire clamp. Connect control handle
wiring harness to the control handle interface
module. Connect the main wiring harness to the
contactor, brake, and horn as removed. Refer to
the sections Electrical System 2200 SRM 1052
or Electrical System 2200 SRM 1357 and Dia-
grams 8000 SRM 1034 to aid in correct installa-
tion of control handle wiring harness.
6. Align cover to hub and install three Allen-head
screws (20).
7. Connect the battery, turn the key switch to the
ON position, and set the parking brake switch to
the OFF position.
8. Remove blocks from wheels and test truck for
proper operation.
9. Install the drive unit compartment cover. Re-
fer to the section Periodic Maintenance 8000
SRM 1032 or Periodic Maintenance 8000 SRM
1368 - Drive Unit Compartment Covers.
3

5. Control Handle 1600 SRM 1031
Figure 3. Control Handle and Support Assembly
4

6. 1600 SRM 1031 Support Assembly
Legend for Figure 3
1. STEER PLATE
2. CAPSCREW
3. CAPSCREW
4. WASHER
5. LOCKWASHER
6. NUT
7. KEY
8. NUT
9. LOCKWASHER
10. WASHER
11. CAPSCREW
12. DASH
13. CAPSCREW
14. SUPPORT
15. CONTROL HANDLE ARM
16. SPINDLE
17. BEARING RACE
18. BEARING
19. SPACER
20. SCREW
21. COVER
22. SLEEVE, WIRE GUARD
23. LOCK NUT
24. LOCKING WASHER
25. HUB
26. KNOB
27. REDUCING NUT
28. ROLL PIN
29. BUSHING
30. PIVOT (SHAFT)
31. PLUNGER, NUT, AND SPRING ASSEMBLY
Support Assembly
REMOVE
1. Remove the control handle. Refer to Control
Handle in this section.
2. Remove nuts, lockwashers, washers, and cap-
screws that hold the spindle to the steer plate.
3. Loosen capscrews securing the steer plate to the
drive unit.
4. Attach a sling and an overhead lifting device to
the support.
5. Remove nuts, lockwashers, washers, and cap-
screws that hold the support to the frame.
6. Remove the support using an overhead lifting de-
vice and place on a clean workbench.
DISASSEMBLE
1. Bend tabs on the locking washer (24) down, using
a flat screwdriver. Remove the bearing lock nut
(23) by turning counterclockwise. Remove the
locking washer.
2. Remove the hub and key (7).
3. Remove the spindle, wire guard sleeves, and
spacers (19).
CAUTION
To prevent damage to the bearings and bearing
races, always use a soft-metal punch and ham-
mer to lightly tap them out of the support.
NOTE: Under normal conditions it is not necessary
to remove the bearing races from the support.
4. Remove bearings from the support.
5. Inspect the bearing races and replace if neces-
sary. Remove using a soft-metal punch and ham-
mer. Lightly tap the races out using a criss-cross
pattern.
6. Clean all surfaces with solvent and replace any
damaged parts.
REPAIR
WARNING
Commercial cleaning solvents may be
flammable and toxic and can cause severe
skin irritation. When using commercial
cleaning solvents, always comply with the
solvent manufacturer’s recommended safety
precautions.
Clean the bearing assemblies by washing them in
solvent to remove all grease and dirt. When clean,
the bearings should ALWAYS roll smoothly. Place
the bearing inside the race. Turn the bearing while
applying pressure with your hand to check for places
where the bearing does not turn smoothly. Inspect
the bearing and race for pits or grooves. If any rough
places are found, replace with a new bearing assem-
bly.
5

7. Control Handle and Support Assembly (Complete) 1600 SRM 1031
ASSEMBLE
1. Install the bearing races into the support using
a driver and press. Install one, turn the support
over, and install the second.
2. Install the support to the frame using an over-
head lifting device and a sling. Secure using four
capscrews. Torque to 88 N•m (65 lbf ft). Install
the large wire clamp to the lower capscrew on the
side farthest from the controller as removed.
3. Pack the bearings with Hyster® synthetic grease,
P/N 2074114, using a standard bearing packing
device. Place a liberal coating of synthetic grease
on the surface of the bearing races.
4. Install the wire guard sleeves (22) on spindle.
5. Install the spacer (19) and lower bearing (18) (ta-
per up) on spindle.
6. Align the spindle with the support and insert
through the support, being careful not to dam-
age bearings.
7. Install the upper bearing (18) (taper down) and
spacer (19) on the spindle.
8. Place the hub over the spindle. Align the grooves
in hub and spindle and insert key (7).
9. Install the bearing locking washer (24) and bear-
ing lock nut (23) to top of the spindle.
10. Tighten the bearing lock nut to seat the bear-
ings, loosen the bearing lock nut, and torque to
27 N•m (20 lbf ft).
11. Bend the bearing locking washer tabs against the
bearing lock nut.
INSTALL
1. Position the support to the lift truck frame.
2. Install four capscrews. Torque to 88 N•m
(65 lbf ft).
3. Install the spindle to the steer plate.
4. Tighten the lower steer plate capscrews. Torque
to 55 N•m (41 lbf ft).
5. Install the control handle assembly. See Control
Handle.
6. Remove blocks, connect the battery, turn the key
switch to the ON position, and set the parking
brake to the OFF position.
7. Test for proper operation and install drive unit
compartment covers. See Periodic Mainte-
nance 8000 SRM 1032 or Periodic Mainte-
nance 8000 SRM 1368 - Drive Unit Compart-
ment Covers.
Control Handle and Support Assembly (Complete)
REMOVE
WARNING
The steering assembly and dash weighs ap-
proximately 30 kg (66 lb), and requires the use
of an overhead lifting device to hold it in place
during removal and installation. Be sure the
overhead lifting device has an adequate rated
capacity to lift at least 30 kg (66 lb).
The following instructions are for removing the
entire dash and control handle assembly without
dismantling the assembly. This procedure is useful
when the dash and control handle must be removed
for access to other parts of the lift truck.
1. Turn the key switch to the OFF position and dis-
connect the battery.
2. Remove the drive unit compartment covers. See
Periodic Maintenance 8000 SRM 1032 or Pe-
riodic Maintenance 8000 SRM 1368 - Drive
Unit Compartment Covers.
3. Discharge the capacitor. See Special Precautions
in this section.
6

8. 1600 SRM 1031 Control Handle and Support Assembly (Complete)
NOTE: Pay special attention to where each wire tie
and terminal of the wiring harness was removed for
proper installation.
4. Label and disconnect the control handle wiring
harness from the control handle interface. Label
and disconnect the main wiring harness from the
contactor, MDU, and horn.
5. Secure one end of a rope or cargo strap around
the steering assembly plate between the dash
and the Control Handle assembly. Secure the
other end to an overhead lifting device sufficient
to lift at least 30 kg (66 lb). See Figure 4.
6. Remove the four capscrews, nuts, and washers
that hold the steering support to the frame. Re-
move the two capscrews attaching the swivel to
the steer plate.
7. Using the overhead lifting device, carefully re-
move the steering assembly from the truck.
INSTALL
1. Secure one end of a rope or cargo strap around
the steering assembly plate between the dash
and the Control Handle assembly. Secure the
other end to an overhead lifting device sufficient
to lift at least 30 kg (66 lb).
2. Using the overhead lifting device, carefully in-
stall the steering assembly and dash onto the
truck.
3. Install the four capscrews, nuts, and washers
that hold the steering support to the frame.
Torque to 88 N•m (65 lbf ft).
4. Install the two screws attaching the dash to the
support bracket.
NOTE: Pay special attention to where each wire tie
and terminal of the wiring harness was removed for
proper installation.
5. Connect the control handle wiring harness to the
control handle interface module. Connect the
main wiring harness to the contactor, MDU, and
horn as removed.
6. Connect the battery and test for proper operation
before returning to service.
7. Install the drive unit compartment covers. See
Periodic Maintenance 8000 SRM 1032 or Pe-
riodic Maintenance 8000 SRM 1368 - Drive
Unit Compartment Covers.
7

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10. Control Handle and Support Assembly (Complete) 1600 SRM 1031
1. SUPPORT
2. ATTACHING HARDWARE
3. DASH
4. STRAPS
Figure 4. Control Handle and Support Assembly Removal
8

11. 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

12. General 100 SRM 1030
Figure 2. Frame Weldment (T5-7Z and T5-7ZAC
)
2

13. 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

14. 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

15. 100 SRM 1030 General
1. FRONT COVER
2. LOWER COVER
3. SPRING NUT CLIPS
4. SCREWS
Figure 3. Drive Unit Compartment Covers
5

16. 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