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Hyster B476 (T5ZAC) Forklift Service Repair
Manual

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Summary of Contents for B476

Page 1: ...Hyster B476 T5ZAC Forklift Service Repair Manual...

Page 2: ...ELECTRICAL SYSTEM T5ZAC B476 T7ZAC B477 C60ZAC B478 C80ZAC B479 PART NO 1687930 2200 SRM 1357...

Page 3: ...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 remov...

Page 4: ...e 13 Install 14 Parking Brake Switch 15 Remove 15 Install 15 Fuses 15 Horn 16 Replace 16 High Speed Switch Assembly 16 Remove 16 Install 16 Control Handle 17 Disassemble 17 Hand brake 18 Upper Cover 1...

Page 5: ...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 6: ...Table of Contents Electrical System TABLE OF CONTENTS Continued General Troubleshooting 26 This section is for the following models T5ZAC B476 T7ZAC B477 C60ZAC B478 C80ZAC B479 ii...

Page 7: ...information on troubleshooting fault codes adjusting parameters and testing the motor controller See the section AC Motor Repair 620 SRM 1283 for general information on traction motor troubleshoot in...

Page 8: ...General 2200 SRM 1357 A RH SIDE B LH SIDE C FORWARD D REVERSE Figure 1 Truck Orientation 2...

Page 9: ...the brake coil energizes disengaging the brake This pulls the brake pressure plate away from the friction disc allowing the drive motor to turn freely A two stage hand brake assembly see Figure 2 is m...

Page 10: ...BATTERY DISCHARGE INDICATOR BDI 3 PARKING BRAKE SWITCH 4 PARKING BRAKE 5 TRACTION MOTOR 6 HORN 7 LIFT PUMP MOTOR 8 CONTROL MODULE 9 DIAGNOSTIC CONNECTOR 10 CONTACTOR 11 CONTROLLER 12 FUSE 13 BATTERY...

Page 11: ...EY SWITCH 2 BATTERY DISCHARGE INDICATOR BDI 3 PARKING BRAKE SWITCH 4 PARKING BRAKE 5 TRACTION MOTOR 6 HORN 7 CONTROL MODULE 8 DIAGNOSTIC CONNECTOR 9 CONTACTOR 10 CONTROLLER 11 FUSE 12 BATTERY CONNECTO...

Page 12: ...ways disconnect the battery Discharge the capacitor and never put power to the controller with any power wire disconnected Never short any controller terminal or motor terminal to battery Make sure to...

Page 13: ...cific gravity of ap proximately 1 165 or less Refer to Industrial Battery 2240 SRM 1 4 Remove the drive unit compartment covers See Periodic Maintenance 8000 SRM 1368 5 Discharge the capacitor See Spe...

Page 14: ...e Check for open control fuse 1 02 No battery 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...

Page 15: ...partment cover removed Remove the drive unit compartment cover for access to the electrical components and discharge the capacitor See the section Periodic Maintenance 8000 SRM 1368 Replace the covers...

Page 16: ...the controller to read If the controller is reporting an input error fault code then the control module may be malfunc tioning Check the control module using the follow ing steps See Figure 8 1 Conne...

Page 17: ...2 Input Connector J4 Voltages Control Handle Function Connector None Lift Lower Horn Forward Reverse J4 1 X J4 2 5V J4 3 5V J4 4 GND GND GND GND GND GND J4 5 OPEN OPEN OPEN OPEN GND GND J4 6 24V J4 7...

Page 18: ...0 Check Disconnect coil wires Test contactor coil using an ohmmeter to measure the resistance Use the highest resistance indication The coil should read 52 ohms 10 Remove and replace contactor if resi...

Page 19: ...intenance 8000 SRM 1368 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 in stru...

Page 20: ...o proper terminals as identified during removal 2 Position the key switch through mounting hole in frame and adjust switch to proper height by turning lower jam nut 3 Install retaining nut to the key...

Page 21: ...ke switch decal 3 Install retaining nut to top of parking brake switch Make certain switch is properly aligned before tightening retaining nut 4 Connect battery and turn the key switch to the ON posit...

Page 22: ...moval steps necessary to repair switch and install Refer to Figure 14 for the following procedures REMOVE 1 Move the truck to a level area Turn the key switch to the OFF position and disconnect the ba...

Page 23: ...irs or adjustments unless you have both authorization and training Re pairs and adjustments that are not correct can create a dangerous operating condition DO NOT operate a lift truck that needs repai...

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