Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Hyster A476 – A479 (T5Z T7Z C60AZ C80Z T5ZAC T7ZAC C60ZAC C80AC) Service Manual – PDF DOWNLOAD
Original price was: $89.95.$29.95Current price is: $29.95.
Hyster A476 – A479 (T5Z T7Z C60AZ C80Z T5ZAC T7ZAC C60ZAC C80AC) Service Manual – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Hyster A476 – A479 (T5Z T7Z C60AZ C80Z T5ZAC T7ZAC C60ZAC C80AC) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster A476 – A479 (T5Z T7Z C60AZ C80Z T5ZAC T7ZAC C60ZAC C80AC) Service Manual – PDF DOWNLOAD
Language : English
Pages : 402
Downloadable : Yes
File Type : PDF
Size: 39.9 MB
TABLE OF CONTENTS:
Hyster A476 – A479 (T5Z T7Z C60AZ C80Z T5ZAC T7ZAC C60ZAC C80AC) Service Manual – PDF DOWNLOAD
AC Motor Controller................................................................ 1 toc............................................................................ 1 AC Motor Controller........................................................ 1 General.................................................................... 3 Discharging the Capacitors............................................. 3 Description................................................................ 4 Electrical System...................................................... 4 AC Traction Motor.................................................. 6 Controller......................................................... 6 Service PC Connection.............................................. 6 Parameters................................................................. 6 General................................................................ 6 Parameter Description...................................................... 7 Parameters............................................................. 7 Extended Shift..................................................... 7 Walk Speed (Both Directions)....................................... 7 Hi Speed (FWD)..................................................... 7 Hi Speed (REV)..................................................... 7 Minimum Acceleration............................................... 8 Maximum Acceleration............................................... 8 Plugging........................................................... 8 ADS-Neutral........................................................ 8 ADS-Throttle....................................................... 8 Pick Acceleration.................................................. 8 Pick Deceleration.................................................. 8 Battery Full Voltage............................................... 8 Lift Interrupt..................................................... 8 Service Hour Reminder.............................................. 8 Troubleshooting............................................................ 9 General................................................................ 9 Status Codes........................................................... 9 Dash Display............................................................... 62 General................................................................ 62 Startup................................................................ 62 Status LED............................................................. 62 Performance Mode Indicator............................................. 62 Hourmeter.............................................................. 63 Battery Charge Indicator............................................... 63 Fault Log.............................................................. 63 Connector Pin-Outs......................................................... 64 System Logic Diagram....................................................... 65 tables......................................................................... 1 Table 1. Parameter Default Values.......................................... 7 Table 2. Fault Codes....................................................... 10 AC Motor Repair.................................................................... 68 toc............................................................................ 68 AC Motor Repair............................................................ 68 General.................................................................... 70 Accessing the Drive Unit Compartment................................... 70 B60-80Z AC......................................................... 70 C60-80Z AC and T5-7Z AC............................................ 70 Special Precautions........................................................ 72 Discharging the Capacitors............................................. 72 Description................................................................ 73 AC Motor Repair............................................................ 73 Remove................................................................. 73 Disassemble............................................................ 73 Inspect................................................................ 75 Assemble............................................................... 75 Install................................................................ 75 Troubleshooting............................................................ 76 Brakes............................................................................. 79 toc............................................................................ 79 Brakes..................................................................... 79 General.................................................................... 81 Accessing the Drive Unit Compartment................................... 81 B60-80Z AC......................................................... 81 C60-80Z AC and T5-7Z AC............................................ 82 Description................................................................ 83 Special Precautions........................................................ 84 Brake Check................................................................ 85 Brake Release.......................................................... 85 Brake Apply............................................................ 85 Air Gap................................................................ 85 Hold On Grade Test..................................................... 87 Brake Assembly Repair...................................................... 87 B60Z AC, C60Z AC, and T5Z AC .......................................... 87 Remove............................................................. 87 Repair............................................................. 88 Install............................................................ 89 B80Z AC, C80Z AC, and T7Z AC .......................................... 89 Remove............................................................. 89 Repair............................................................. 90 Install............................................................ 91 Troubleshooting............................................................ 92 tables......................................................................... 79 Table 1. Stator Resistance................................................. 85 Table 2. Adjustment Specifications......................................... 86 Capacities and Specifications...................................................... 94 toc............................................................................ 94 Capacities and Specifications.............................................. 94 Hydraulic System (C60-80Z and C60-80Z AC )................................. 96 Hydraulic Oils............................................................. 96 Master Drive Unit Specifications........................................... 97 Gear Oils.................................................................. 97 Grease..................................................................... 98 Tire Specifications........................................................ 98 Torque Specifications...................................................... 99 Master Drive Unit...................................................... 99 Brake.................................................................. 99 Steering............................................................... 99 Electrical............................................................. 99 Coupler ( T5Z, T5Z AC, T7Z, and T7Z AC )............................... 99 Lift Pump ( C60Z, C60Z AC, C80Z, and C80Z AC )......................... 99 Travel Speeds..............................................................100 T5Z, T5Z AC, T7Z, and T7Z AC...........................................100 C60Z, C60Z AC, C80Z, and C80Z AC.......................................100 Truck Weight...............................................................100 Battery Specifications and Adjustments.....................................101 Diagrams...........................................................................103 toc............................................................................103 Diagrams...................................................................103 Electrical System..................................................................132 toc............................................................................132 Electrical System..........................................................132 General....................................................................135 Description of Operation...................................................137 Special Precautions........................................................140 Discharging the Capacitors.............................................140 Electrical System Checks...................................................141 Repairs....................................................................143 Calibration Mode.......................................................143 Controller, Replace....................................................143 Remove.............................................................143 Install............................................................144 Control Module.........................................................144 Check..............................................................144 Remove.............................................................146 Install............................................................146 Contactor..............................................................146 Check..............................................................146 Remove.............................................................146 Install............................................................147 Key Switch.................................................................147 Remove.................................................................147 Install................................................................148 Parking Brake Switch.......................................................149 Remove.................................................................149 Install................................................................149 Fuses......................................................................149 Horn.......................................................................150 Replace................................................................150 High Speed Switch Assembly.................................................150 Remove.................................................................150 Install................................................................150 Control Handle.............................................................151 Disassemble............................................................151 Hand-brake.........................................................152 Upper Cover........................................................152 Handle Shaft.......................................................152 Lower Cover........................................................153 Directional/Throttle Switch........................................153 Neutral Switches...............................................153 Throttle Sensor................................................153 Assemble...............................................................157 Directional/Throttle Switch........................................157 Neutral Switches...............................................157 Throttle Sensor................................................157 Lower Cover........................................................158 Handle Shaft.......................................................158 Upper Cover........................................................158 Hand-brake.........................................................159 Lift Pump Motor (C60Z AC and C80Z AC Only).................................159 Remove.................................................................159 Install................................................................159 Troubleshooting............................................................160 General Troubleshooting................................................160 tables.........................................................................132 Table 1. Voltage Checks....................................................142 Table 2. Input Connector (J4) Voltages.....................................145 Frame..............................................................................162 toc............................................................................162 Frame......................................................................162 General....................................................................164 Description............................................................164 Features...............................................................166 C60Z, C60Z AC, C80Z, and C80Z AC...................................166 T5Z, T5Z AC, T7Z, and T7Z AC.......................................167 Covers.................................................................167 Special Precautions........................................................169 Frame Separation and Assembly..............................................171 C60Z, C60Z AC, C80Z, and C80Z AC.......................................171 Frame Separation...................................................171 Painting Instructions......................................................171 Label Replacement..........................................................172 Battery Compartment........................................................172 tables.........................................................................162 Table 1. Wheel Base and Fork Length........................................166 Table 2. Wheel Base and Fork Length........................................166 Table 3. Wheel Base and Fork Length........................................166 Table 4. Wheel Base and Fork Length........................................167 Industrial Battery.................................................................179 toc............................................................................179 Industrial Battery.........................................................179 General....................................................................181 Lead-Acid Batteries........................................................181 Specific Gravity...........................................................182 Chemical Reaction in a Cell................................................182 Electrical Terms...........................................................183 Battery Selection..........................................................184 Battery Voltage............................................................185 Battery as a Counterweight.................................................185 Battery Ratings............................................................186 Kilowatt-Hours.........................................................186 Battery Maintenance........................................................186 Safety Procedures......................................................186 Maintenance Records....................................................187 New Battery............................................................187 Cleaning Battery.......................................................187 Adding Water to Battery................................................189 Hydrometer.............................................................190 Battery Temperature....................................................190 Charging Battery.......................................................191 Types of Battery Charges...........................................192 Methods of Charging................................................193 Troubleshooting Charger............................................194 Knowing When Battery Is Fully Charged..............................194 Where to Charge Batteries..............................................194 Equipment Needed...................................................194 Battery Connectors.....................................................195 Battery Care...........................................................195 tables.........................................................................179 Table 1. Battery Capacity Terms............................................186 Master Drive Unit..................................................................198 toc............................................................................198 Master Drive Unit..........................................................198 General....................................................................200 Check Oil Level........................................................200 Change Gear Oil ( T5-7Z AC, B60-80Z AC, and C60-80Z AC )...............201 Safety Precautions.........................................................201 Drive Tire.................................................................204 Remove.................................................................204 Install................................................................204 Master Drive Unit..........................................................204 Remove.................................................................204 Install................................................................212 Troubleshooting............................................................214 tables.........................................................................198 Table 1. Drive Unit Specifications.........................................200 Metric and Inch (SAE) Fasteners....................................................217 toc............................................................................217 Metric and Inch (SAE) Fasteners............................................217 General....................................................................219 Threaded Fasteners.....................................................219 Nomenclature, Threads..................................................219 Strength Identification................................................220 Cotter (Split) Pins....................................................220 Fastener Torque Tables.................................................225 Conversion Table.......................................................227 tables.........................................................................217 Table 1. Bolts and Screws..................................................221 Table 2. Studs and Nuts....................................................222 Table 3. Torque Nuts.......................................................223 Table 4. Torque Nuts With Nylon Insert.....................................224 Table 5. Torque Values for Metric Fasteners*...............................225 Table 6. Torque Values for Inch Fasteners*.................................226 Table 7. Conversion Table for Metric and English Units.....................227 Table 8. Cotter Pin Dimensional Data.......................................228 Table 9. Cotter Pin Dimensional Data.......................................229 Table 10. Cotter Pin Dimensional Data......................................230 Table 11. Cotter Pin Dimensional Data......................................232 Periodic Maintenance...............................................................236 toc............................................................................236 Periodic Maintenance.......................................................236 Introduction...............................................................239 General................................................................239 Drive Unit Compartment Covers..........................................241 Remove.............................................................241 Install............................................................241 How to Move a Disabled Truck...........................................242 How to Tow the Truck...............................................242 How to Put the Truck on Blocks.........................................243 How to Raise Drive/Steer Tire......................................243 How to Raise the Load Wheels.......................................243 Special Precautions........................................................244 Maintenance Schedule.......................................................245 Maintenance Procedures Every 8 Hours or Daily..............................249 Checks With the Key Switch OFF.........................................249 Safety Labels......................................................249 Battery............................................................250 Frame..............................................................250 Drive Tire, Casters (Optional), and Trail Wheels or Load Wheels....251 Lift Linkage ( C60-80Z AC )........................................251 Coupler ( T5-7Z AC )...............................................251 Steering Operation.................................................251 Checks With the Key Switch ON..........................................251 Control Handle.....................................................251 Gauges.............................................................252 Fuses..............................................................252 High Speed Switch..................................................252 Hydraulic ( C60-80Z AC )...........................................252 Hand Brake.........................................................253 Maintenance Procedures Every 250 Hours or Every 6 Weeks....................253 Caster Lubrication.....................................................253 Maintenance Procedures Every 500 Hours or Every 3 Months ..................254 Hydraulic System.......................................................254 Hydraulic Oil......................................................255 Hydraulic Reservoir Breather.......................................255 Steering System........................................................255 Steer Column and Tilt Mechanism....................................255 Lift Linkage and Load Wheels (C60-80Z AC ) ............................255 Casters................................................................255 Caster Shim Check..................................................255 Caster Shim Adjust.................................................256 Master Drive Unit......................................................257 Change Gear Oil....................................................257 Check Oil Level....................................................257 Drive Tire Check.......................................................258 Maintenance Procedures Every 2000 Hours or Yearly..........................258 Trail Wheel Bearings ( T5-7Z AC )......................................258 Remove.............................................................258 Inspect............................................................258 Install............................................................259 Hydraulic System (C60-80Z AC ).........................................260 Changing the Hydraulic Oil.........................................260 Master Drive Unit......................................................264 Drive Unit Gear Oil................................................264 Brakes.............................................................264 Welding Repairs............................................................265 Battery Maintenance........................................................265 How to Charge Battery..................................................265 How to Change Battery..................................................266 Adjusting the Battery Spacers......................................266 Changing Battery With Rollers......................................266 Remove.........................................................267 Install........................................................267 Remove Battery Using Overhead Crane................................267 Install Battery Using Overhead Crane...............................268 Battery Specifications.................................................268 tables.........................................................................236 Table 1. Maintenance Schedule..............................................246 Table 2. Specific Gravity Corrections......................................266 Table 3. Battery Specifications (C60Z AC ).................................268 Table 4. Battery Specifications (C80Z AC ).................................269 Table 5. Battery Specifications (T5Z AC )..................................269 Table 6. Battery Specifications (T7Z AC )..................................270 Steering Mechanism.................................................................271 toc............................................................................271 Steering Mechanism.........................................................271 Introduction...............................................................273 General................................................................273 Description of Operation...............................................273 Special Precautions........................................................273 Control Handle.............................................................275 Remove.................................................................275 Install................................................................275 Support Assembly...........................................................277 Remove.................................................................277 Disassemble............................................................277 Repair.................................................................277 Assemble...............................................................278 Install................................................................278 Control Handle and Support Assembly (Complete).............................278 Remove.................................................................278 Install................................................................279 Troubleshooting............................................................281 Troubleshooting and Adjustments Using the AC Controls Program (ETACC)..............283 toc............................................................................283 Troubleshooting and Adjustments Using the AC Controls Program (E...........283 General....................................................................286 Computer Requirements..................................................286 Software, Install......................................................286 Language Selection.....................................................286 Demo Mode..............................................................287 Connect PC to Lift Truck...............................................291 Starting AC Controls Program...........................................293 Lift Truck Control Setup...................................................297 Change Lift Truck Serial Number or Hourmeter...........................297 Setting Factory Default Values or Changing Lift Truck Parameters.......299 Create New Custom Lift Truck Configuration.............................305 Lift Truck Configuration Properties....................................308 Import New Lift Truck Configuration From Disk..........................311 Delete Custom Lift Truck Configuration or Password File................313 Dash Display...............................................................316 Custom Display Languages...............................................316 Download Display Language..............................................318 Clear Operator Log.....................................................318 Password Functions.........................................................321 Enable/Disable Password and Lift Truck Inspection Functions............321 Truck Inspection Checklist.........................................321 Password...........................................................321 Password Properties....................................................321 Create New Password File...............................................326 Download Passwords.....................................................328 Upload Passwords.......................................................328 Reports Menu...............................................................332 Devices Report.........................................................332 Custom Report..........................................................332 Password Report........................................................332 Operator Report........................................................339 Current Settings Report................................................342 Status Code Report.....................................................345 Status Codes Log.......................................................348 Troubleshooting............................................................350 Diagnostics............................................................350 Help Menu..................................................................353 General................................................................353 Contents...............................................................353 Technical Support......................................................353 About Electric Truck AC Controls Program...............................353 User Interface (2).................................................................359 toc............................................................................359 User Interface.............................................................359 General....................................................................361 Description............................................................361 Dash Display Menu Access...............................................361 Menu Navigation............................................................362 Dash Display...............................................................364 Technician Menu............................................................364 View Versions..........................................................366 Hourmeters.............................................................366 Diagnostics............................................................366 Fault Log..........................................................367 Controller Inputs..................................................368 Control Handle Inputs..............................................369 Run Diagnostics....................................................370 Traction Motor.................................................371 Pump Motor and Valve...........................................371 Control Handle.................................................372 Traction Temps.................................................372 Service Reminder.......................................................372 Change Supervisor Password.............................................373 Operator Modes.........................................................374 Set Performance........................................................374 Extended Shift.....................................................376 Walk Speed.........................................................376 High Speed (FWD)...................................................376 High Speed (REV)...................................................377 Minimum Acceleration...............................................377 Maximum Acceleration...............................................377 Plugging...........................................................378 ADS-Neutral........................................................378 ADS-Throttle.......................................................378 Battery Full.......................................................378 Lift Interrupt.....................................................379 Defaults...........................................................379 Save and Exit......................................................379 Exit Without Saving................................................380 Set General Items......................................................380 A/V Alarm (Audible/Visual).........................................381 Clear Fault Log........................................................381 Calibrations...........................................................382 Throttle...........................................................382 Change Service Technician Password.....................................382 Exit to Run Mode.......................................................383 tables.........................................................................359 Table 1. Technician Menu...................................................365 Table 2. Diagnostics Menu..................................................367 Table 3. Controller Inputs.................................................368 Table 4. Control Handle Inputs.............................................369 Table 5. Run Diagnostics Menu..............................................370 Table 6. Performance Parameters............................................374 Table 7. Set Performance Menu..............................................375 Table 8. Set General Items Menu............................................380 Table 9. Calibrations Menu.................................................382 User Interface.....................................................................386 toc............................................................................386 User Interface.............................................................386 General....................................................................388 Description............................................................388 Dash Display Menu Access...............................................388 Dash Display...............................................................389 Menu Navigation............................................................390 Supervisor Menu............................................................392 View Versions..........................................................393 Hourmeters.............................................................393 Diagnostics............................................................393 Fault Log..........................................................394 Controller Inputs..................................................395 Control Handle Inputs..............................................395 Run Diagnostics....................................................396 Traction Motor.................................................397 Pump Motor and Valve...........................................397 Control Handle.................................................397 Temperatures...................................................398 Service Reminder.......................................................398 Change Supervisor Password.............................................399 Operator Modes.........................................................399 Exit to Run Mode.......................................................400 tables.........................................................................386 Table 1. Supervisor Menu...................................................392 Table 2. Diagnostics Menu..................................................394 Table 3. Controller Inputs.................................................395 Table 4. Control Handle Inputs.............................................395 Table 5. Run Diagnostics Menu..............................................396
HYSTER A476 – A479 (T5Z T7Z C60AZ C80Z T5ZAC T7ZAC C60ZAC C80AC) SERVICE MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
S.V
