Hyster T5ZAC Service & Repair Manual
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Hyster T5ZAC Service & Repair Manual

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Hyster B476 (T5ZAC) Forklift Service Repair
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Summary of Contents for Hyster T5ZAC

  • Page 1 Hyster B476 (T5ZAC) Forklift Service Repair Manual...
  • Page 2 ELECTRICAL SYSTEM [B476]; [B477]; C60Z [B478]; C80Z [B479] PART NO. 1687930 2200 SRM 1357...
  • Page 3 • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

  • Page 4: Table Of Contents

    Lower Cover............................... Directional/Throttle Switch ........................Neutral Switches........................... Throttle Sensor............................Assemble ................................ Directional/Throttle Switch ........................Neutral Switches........................... Throttle Sensor............................Lower Cover............................... Handle Shaft.............................. Upper Cover............................... Hand-brake ..............................Lift Pump Motor (C60Z and C80Z Only)....................Remove ................................Install ................................Troubleshooting..............................©2008 HYSTER COMPANY...
  • Page 5 Thanks very much for your reading, Want to get more information, Please click here, Then get the complete manual NOTE: If there is no response to click on the link above, please download the PDF document first, and then click on it. Have any questions please write to me: admin@servicemanualperfect.com...
  • Page 6 Table of Contents Electrical System TABLE OF CONTENTS (Continued) General Troubleshooting ..........................This section is for the following models: [B476]; [B477]; C60Z [B478]; C80Z [B479]...

  • Page 7: General

    2200 SRM 1357 General General This section includes removal, disassembly, checks, See the section Periodic Maintenance 8000 SRM adjustments, assembly, installation, and trou- 1368 for instructions on removing and installing the bleshooting procedures for the electrical system drive unit compartment covers and for minimum mo- components on the T5-7Z and C60-80Z truck...
  • Page 8 General 2200 SRM 1357 A. RH SIDE C. FORWARD B. LH SIDE D. REVERSE Figure 1. Truck Orientation...

  • Page 9: Description Of Operation

    2200 SRM 1357 Description of Operation Description of Operation This section includes information on the following A two-stage hand brake assembly (see Figure 2) is components: mounted just below the control handle. The hand • Control Handle Switches brake assembly consists of two independent hand •...
  • Page 10 Description of Operation 2200 SRM 1357 1. KEY SWITCH 8. CONTROL MODULE 2. BATTERY DISCHARGE INDICATOR (BDI) 9. DIAGNOSTIC CONNECTOR 3. PARKING BRAKE SWITCH 10. CONTACTOR 4. PARKING BRAKE 11. CONTROLLER 5. TRACTION MOTOR 12. FUSE 6. HORN 13. BATTERY CONNECTOR 7.
  • Page 11 2200 SRM 1357 Description of Operation 1. KEY SWITCH 7. CONTROL MODULE 2. BATTERY DISCHARGE INDICATOR (BDI) 8. DIAGNOSTIC CONNECTOR 3. PARKING BRAKE SWITCH 9. CONTACTOR 4. PARKING BRAKE 10. CONTROLLER 5. TRACTION MOTOR 11. FUSE 6. HORN 12. BATTERY CONNECTOR Figure 4.

  • Page 12: Special Precautions

    Special Precautions 2200 SRM 1357 Special Precautions DISCHARGING THE CAPACITORS 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. Wear safety glasses.

  • Page 13: Electrical System Checks

    2200 SRM 1357 Electrical System Checks Electrical System Checks 4. Remove the drive unit compartment covers. See WARNING Periodic Maintenance 8000 SRM 1368. Disconnect the battery before opening the com- 5. Discharge the capacitor. See Special Precautions partment cover or inspecting or repairing the in this section.
  • Page 14 Electrical System Checks 2200 SRM 1357 Table 1. Voltage Checks LIFT TRUCK WILL NOT MOVE IN EITHER DIRECTION. NO FAULT IS DISPLAYED ON THE CONTROLLER. Possible Causes: 1. Battery not connected. 2. Control fuse is damaged. 3. Key switch or brake switch is damaged. 4.

  • Page 15: Repairs

    2200 SRM 1357 Repairs Repairs CONTROLLER, REPLACE WARNING DO NOT make repairs or adjustments unless Remove you have been properly trained and authorized to do so. Improper repairs and adjustments CAUTION can create dangerous operating conditions. DO NOT replace the controller until you have DO NOT operate a lift truck that needs re- thoroughly checked all other electrical compo- pairs.

  • Page 16: Install

    Repairs 2200 SRM 1357 5. Turn parking brake to the OFF position and test for proper operation. 6. Install the drive unit compartment covers. See the section Periodic Maintenance 8000 SRM 1368. CONTROL MODULE Check The control module converts analog signals from the control handle to digital signals for the controller to read.
  • Page 17 2200 SRM 1357 Repairs 1. CONTROL MODULE 3. OUTPUT CONNECTOR (J-5) 2. ATTACHING HARDWARE 4. INPUT CONNECTOR (J-4) Figure 8. Control Module Table 2. Input Connector (J4) Voltages Control Handle Function Connector None Lower Horn Reverse Lift Forward J4-1 J4-2 J4-3 J4-4 GND*...

  • Page 18: Remove

    Repairs 2200 SRM 1357 Remove 2. Remove the drive unit compartment covers. See the section Periodic Maintenance 8000 SRM 1. Turn the key switch to the OFF position and dis- 1368. connect the battery. 3. Discharge the capacitor. See Special Precautions 2.

  • Page 19: Install

    2200 SRM 1357 Key Switch Install 1. Position contactor assembly in place and install two mounting screws into the side of the contac- tor. 2. On EE units, install stand-off, buss-bar, and fuse to contactor panel and contactor as removed. 3.

  • Page 20: Install

    Key Switch 2200 SRM 1357 INSTALL Toggle switches may be used in place of key switches certain applications. The term "key switch" will be used for both types of switch in the following instruc- tions. See Figure 11 or Figure 12. 1.

  • Page 21: Parking Brake Switch

    2200 SRM 1357 Fuses Parking Brake Switch REMOVE NOTE: Position switch lever according to brake switch decal. For the following procedures, see Figure 13. 3. Install retaining nut to top of parking brake 1. Move lift truck to a safe area and block drive switch.

  • Page 22: Horn

    High Speed Switch Assembly 2200 SRM 1357 Horn REPLACE 5. Remove nuts and washers from studs securing horn to frame. Remove horn from studs. Posi- 1. Move the truck to a safe, level location; turn the tion new horn onto studs as removed and install key switch to the OFF position;...

  • Page 23: Control Handle

    2200 SRM 1357 Control Handle WARNING Move the truck to an area with plenty of room where top speeds can be checked safely. 11. Test the high speed switch for proper operation. 12. Install the floormat. 1. COVER 11. ACTUATOR 2.

This manual is also suitable for:

T7zacC60zacC80zacB476B477B478 ... Show all

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