Hyster T5ZAC Service & Repair Manual Download Page 4 | Manualshive

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©2016 HYSTER COMPANY

TABLE OF CONTENTS

General .....................................................................................................................................................................1
Description of Operation .........................................................................................................................................2
Special Precautions ................................................................................................................................................. 6

Discharging the Capacitors ................................................................................................................................ 6

Electrical System Checks ........................................................................................................................................7
Repairs ..................................................................................................................................................................... 9

Calibration Mode .................................................................................................................................................9
Controller, Replace ..............................................................................................................................................9

Remove ............................................................................................................................................................ 9
Install ............................................................................................................................................................ 10

Control Module ..................................................................................................................................................10

Check .............................................................................................................................................................10
Remove .......................................................................................................................................................... 12
Install ............................................................................................................................................................ 13

Contactor ........................................................................................................................................................... 13

Check .............................................................................................................................................................13
Remove .......................................................................................................................................................... 13
Install ............................................................................................................................................................ 14

Key Switch .............................................................................................................................................................14

Remove .............................................................................................................................................................. 14
Install .................................................................................................................................................................15

Parking Brake Switch ...........................................................................................................................................15

Remove .............................................................................................................................................................. 15
Install .................................................................................................................................................................16

Fuses ...................................................................................................................................................................... 16
Horn ....................................................................................................................................................................... 17

Replace ...............................................................................................................................................................17

High Speed Switch Assembly ............................................................................................................................... 17

Remove .............................................................................................................................................................. 17
Install .................................................................................................................................................................18

Control Handle ...................................................................................................................................................... 19

Disassemble .......................................................................................................................................................19

Hand-brake ................................................................................................................................................... 19
Upper Cover .................................................................................................................................................. 20
Handle Shaft .................................................................................................................................................20
Lower Cover .................................................................................................................................................. 20
Directional/Throttle Switch ..........................................................................................................................21

Neutral Switches ......................................................................................................................................21
Throttle Sensor .........................................................................................................................................21

Assemble ............................................................................................................................................................25

Directional/Throttle Switch ..........................................................................................................................25

Neutral Switches ......................................................................................................................................25
Throttle Sensor .........................................................................................................................................26

Lower Cover .................................................................................................................................................. 26
Handle Shaft .................................................................................................................................................26
Upper Cover .................................................................................................................................................. 27
Hand-brake ................................................................................................................................................... 27

Lift Pump Motor (C60ZHD and C80ZHD Only)...................................................................................................28

Remove .............................................................................................................................................................. 28
Install .................................................................................................................................................................28

Table of Contents

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Summary of Contents for T5ZAC

Page 1: ...Hyster C477 T5ZAC T7ZAC Forklift Service Repair Manual...

Page 2: ...ELECTRICAL SYSTEM C80ZHD A282 C60ZHD A373 T5ZAC C476 D476 T7ZAC C477 PART NO 4096001 2200 SRM 1632...

Page 3: ...dic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use HYSTER APPROVED parts when ma...

Page 4: ...move 14 Install 15 Parking Brake Switch 15 Remove 15 Install 16 Fuses 16 Horn 17 Replace 17 High Speed Switch Assembly 17 Remove 17 Install 18 Control Handle 19 Disassemble 19 Hand brake 19 Upper Cove...

Page 5: ...TABLE OF CONTENTS Continued Troubleshooting 28 General Troubleshooting 28 This section is for the following models C80ZHD A282 C60ZHD A373 T5ZAC C476 D476 T7ZAC C477 Table of Contents ii...

Page 6: ...ore 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 pl...

Page 7: ...0SRM1283 for general information on traction motor troubleshooting and repair for lift truck models T5 T7AC See the section A C Motor Repair S N A169N03000L S N A185N03000L S N H118N03000L S N E174N03...

Page 8: ...This section includes information on the following components Control Handle Switches Hall Effect Directional Speed Control Key Switch Parking Brake Switch High Speed Switch Hand Brake Assembly Brake...

Page 9: ...ee Figure 2 is mounted just below the control handle The hand brake assembly consists of two independent hand levers various linkages and three switches to per form two different braking functions Whe...

Page 10: ...DI 3 PARKING BRAKE SWITCH 4 PARKING BRAKE 5 TRACTION MOTOR 6 HORN 7 LIFT PUMP MOTOR 8 DIAGNOSTIC CONNECTOR 9 CONTACTOR 10 CONTROLLER 11 FUSE 12 BATTERY CONNECTOR Figure 3 Electrical Components C60 80Z...

Page 11: ...INDICATOR BDI 3 PARKING BRAKE SWITCH 4 PARKING BRAKE 5 TRACTION MOTOR 6 HORN 7 DIAGNOSTIC CONNECTOR 8 CONTACTOR 9 CONTROLLER 10 FUSE 11 BATTERY CONNECTOR Figure 4 Electrical Components T5 7ZAC 2200 SR...

Page 12: ...arge the capacitor and never put power to the controller with any power wire dis connected Never short any controller terminal or motor terminal to battery Make sure to use proper procedures when serv...

Page 13: ...mately 1 165 or less Refer to Indus trial Battery 2240SRM0001 4 Remove the drive unit compartment covers See Periodic Maintenance 8000SRM1635 5 Discharge the capacitor See Special Precau tions in this...

Page 14: ...ttery voltage at control fuse Connect battery or check wiring between battery and fuse 1 1 Check for battery voltage at control fuse terminal of key switch 1 1 1 Battery voltage at key switch Check fo...

Page 15: ...wear safety glasses or approved eye pro tection when making any repairs on lift truck All checks adjustments and repairs in the drive unit compartment are done with the compartment cover removed Remov...

Page 16: ...nstall the drive unit compartment covers See the section Periodic Maintenance 8000SRM1635 CONTROL MODULE Check The control module converts analog signals from the control handle to digital signals for...

Page 17: ...he control handle compo nents controller and wiring Make any neces sary repairs and recheck the input values 9 If the input values are correct replace the con trol module See Remove NOTE PC Service To...

Page 18: ...C2 AI1 First Analog Input C3 NPOT Negative of Analog Input C4 DI10 Tenth Digital Input Tilt Down C5 DI14 Fourteenth Digital Input Reach Out C6 DI11 Eleventh Digital Input Side Left C7 DI12 AI5 Twelfth...

Page 19: ...coil using an ohmmeter to measure the resistance Use the high est resistance indication The coil should read 52 ohms 10 Remove and replace contactor if re sistance readings indicate a short circuit i...

Page 20: ...Key Switch REMOVE Toggle switches may be used in place of key switches certain applications The term key switch will be used for both types of switches in the following instructions See Figure 11 or F...

Page 21: ...Connect battery and test the key switch by turning it to the ON and OFF positions Check for proper operation 7 Install drive unit compartment covers See Pe riodic Maintenance 8000SRM1635 Parking Brake...

Page 22: ...compartment covers See Pe riodic Maintenance 8000SRM1635 Fuses WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnec ted To prevent electrical...

Page 23: ...the lift truck to service High Speed Switch Assembly The high speed switch is mounted to the floor of the operator s compartment The operator depresses the switch using the right foot to increase the...

Page 24: ...actuator and actuator plate to switch by inserting screws 14 5 Place switch assembly into base as removed 6 Center the spring inside the base between the curved side and the actuator 7 Pull the switc...

Page 25: ...entify and disconnect all wires connect ing control handle to the hand brake assembly 3 Remove hand brake assembly from control han dle by removing two capscrews 43 washers 44 and nuts 45 NOTE No furt...

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