Hyster C476 Operating instructions

Hyster C476 (T5ZAC, T7ZAC) Forklift Service
Repair Manual

USER INTERFACE
SERVICE TECHNICIAN
C60ZHD [A373];
C80ZHD [A282];
T5ZAC [C476/D476];
T7ZAC [C477]
PART NO. 4096000 2200 SRM 1631

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
•When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
•DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
•Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic 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 making repairs. Replacement parts must meet or ex-
ceed 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.
•Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
•Be sure to follow the WARNING and CAUTION notes in the instructions.
•Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
•Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

©2016 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Introduction .........................................................................................................................................................1
Description .......................................................................................................................................................... 1
Button Keypad ................................................................................................................................................1
LED Indicator Lights ..................................................................................................................................... 1
LCD Screen .....................................................................................................................................................2
Dash Display Menu Access .................................................................................................................................2
Menu Navigation .....................................................................................................................................................2
Dash Display Menu Operation ...........................................................................................................................3
Nodes ...................................................................................................................................................................3
Menu Structure ...................................................................................................................................................3
Service-Level Menu .................................................................................................................................................4
Hour Meters ........................................................................................................................................................5
H1 Truck Hours ..............................................................................................................................................6
H2 Traction Hours ..........................................................................................................................................6
H3 Pump Hours ..............................................................................................................................................6
H5 Odometer Hours ........................................................................................................................................6
H10 Display Hours .........................................................................................................................................6
H32 Combinatin Node Hours .........................................................................................................................6
Performance ........................................................................................................................................................ 6
Performance Level 1 .......................................................................................................................................7
P1.1 Forward ..............................................................................................................................................8
P1.2 Reverse ............................................................................................................................................... 8
P1.3 Acceleration ........................................................................................................................................8
P1.4 Plug .....................................................................................................................................................8
P1.5 Coast ...................................................................................................................................................8
P1.6 Lift Speed ........................................................................................................................................... 8
P1.7 Lower Speed .......................................................................................................................................8
Operator Passwords ............................................................................................................................................8
Add Password ..................................................................................................................................................9
Delete Password ..............................................................................................................................................9
Edit Password .................................................................................................................................................9
Operator Password .........................................................................................................................................9
Clear Log .........................................................................................................................................................9
Operator Logs ......................................................................................................................................................9
Operator 1-150 ..............................................................................................................................................10
Information ........................................................................................................................................................10
I1 Model .........................................................................................................................................................11
I3 Serial Number ..........................................................................................................................................11
I5 Truck Voltage ...........................................................................................................................................11
Settings ..............................................................................................................................................................11
S1 Metric .......................................................................................................................................................11
S2 User Performance ....................................................................................................................................11
S3 Timeout ....................................................................................................................................................11
S4 Battery Type ............................................................................................................................................11
S5 BDI Startup Full .....................................................................................................................................12
S6 BDI Full ...................................................................................................................................................12
S7 BDI Empty ...............................................................................................................................................12
S8 BDI Reset .................................................................................................................................................12
S9 Lift Interrupt ...........................................................................................................................................12
Table of Contents
i

TABLE OF CONTENTS (Continued)
S10 Audible Warning ................................................................................................................................... 12
S11 Visual Warning ......................................................................................................................................12
S12 Checklist ................................................................................................................................................13
S13 Maint Reminder .................................................................................................................................... 13
S14 Restore Default ......................................................................................................................................13
S15 Truck Lockout ........................................................................................................................................13
S61 Extended Shift .......................................................................................................................................13
S63 Walk Speed Accel .................................................................................................................................. 13
S64 Walk Speed Decel ..................................................................................................................................13
S65 Pick Accel ...............................................................................................................................................13
S66 Pick Decel ...............................................................................................................................................13
S67 Min Steer Assist F .................................................................................................................................13
S68 Min Steer Assist R .................................................................................................................................13
Software Versions .............................................................................................................................................14
Error Log ...........................................................................................................................................................14
(E1) Error Log 1 ............................................................................................................................................14
Error 1.1 (E1.1) .........................................................................................................................................14
Error 1.2 (E1.2) .........................................................................................................................................14
Error 1.3 (E1.3) .........................................................................................................................................14
Error 1.4 (E1.4) .........................................................................................................................................14
Diagnostics .............................................................................................................................................................16
Diagnostics ........................................................................................................................................................16
D1 Status .......................................................................................................................................................16
D2 Input ........................................................................................................................................................16
D3 Output ..................................................................................................................................................... 16
D1 Status ...........................................................................................................................................................16
D1.1 CAN ......................................................................................................................................................18
D1.2 Contactor ..............................................................................................................................................18
D1.3 Full Traction ........................................................................................................................................ 18
D1.4 Limp Traction .......................................................................................................................................18
D1.6 Lift ........................................................................................................................................................18
D1.7 Lower ....................................................................................................................................................18
D2 Inputs ...........................................................................................................................................................18
D2.10 Display ................................................................................................................................................19
D2.10.1 Bus Error .................................................................................................................................... 19
D2.10.2 Bus Max Error ............................................................................................................................19
D2.10.32 Combination Controller ............................................................................................................19
D2.10.60 CTRL Hand ...............................................................................................................................19
D2.32 Combination Controller .....................................................................................................................19
D2.32.1 Target Speed ...............................................................................................................................22
D2.32.2 Motor Speed ................................................................................................................................22
D2.32.3 Motor Encoder ............................................................................................................................ 22
D2.32.4 Controller Temperature .............................................................................................................22
D2.32.5 Motor Temperature ....................................................................................................................23
D2.32.6 Motor Current .............................................................................................................................23
D2.32.7 Cap Voltage .................................................................................................................................23
D2.32.8 Cap Maximum Voltage ...............................................................................................................23
D2.32.9 Cap Minimum Voltage ............................................................................................................... 23
D2.32.10 Key Voltage ...............................................................................................................................23
D2.32.11 Key Max Voltage .......................................................................................................................23
Table of Contents
ii

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TABLE OF CONTENTS (Continued)
D2.32.12 Key Minimum Voltage ............................................................................................................. 23
D2.32.16 MC Connct ................................................................................................................................ 23
D2.32.17 MC Current ...............................................................................................................................23
D2.32.18 Horn Switch ..............................................................................................................................23
D2.32.19 Brake Switch .............................................................................................................................23
D2.32.20 Horn Connect ............................................................................................................................23
D2.32.22 Pump Current ...........................................................................................................................23
D2.32.22 Rabbit Switch ............................................................................................................................23
D2.32.26 Regen Switch ............................................................................................................................ 23
D2.32.27 Lift Switch .................................................................................................................................24
D2.32.28 Lower Switch ............................................................................................................................24
D2.32.31 Load Hold Connect ...................................................................................................................24
D2.32.32 Load Hold Current ................................................................................................................... 24
D2.32.33 SOC ........................................................................................................................................... 24
D2.60 Control Handle ...................................................................................................................................24
D2.60.1 Horn Switch ................................................................................................................................24
D2.60.2 Lift Switch ...................................................................................................................................24
D2.60.4 Lower Switch ..............................................................................................................................24
D2.60.10 Tilt Up SW ................................................................................................................................24
D2.60.11 Tilt Down SW ............................................................................................................................25
D2.50.14 4th Aux IN SW ..........................................................................................................................25
D2.50.15 4th Aux OUT SW ......................................................................................................................25
D2.60.19 Trac Input .................................................................................................................................25
D3 Output ..........................................................................................................................................................25
D3.10 Display ................................................................................................................................................25
D3.10.10 Display Com ..............................................................................................................................25
D3.10.32 Combination Com .....................................................................................................................25
D3.10.60 Handle Com ..............................................................................................................................25
D3.32 Traction ..............................................................................................................................................25
D3.32.1 U-V Line DC Curr ...................................................................................................................... 28
D3.32.2 U-W Line DC Curr ......................................................................................................................28
D3.32.3 V-W Line DC Curr ......................................................................................................................28
D3.32.6 Pump DC Current ...................................................................................................................... 28
D3.32.7 Pump Motor Short ......................................................................................................................28
D3.32.9 Load Hold ....................................................................................................................................28
D3.32.10 Backup Alarm ...........................................................................................................................28
D3.32.11 Strobe ........................................................................................................................................28
D3.32.12 Horn ...........................................................................................................................................28
Calibration .............................................................................................................................................................29
C4 Throttle ....................................................................................................................................................29
This section is for the following models:
(C60ZHD ) [A373];
(C80ZHD ) [A282];
(T5ZAC ) [C476/D476];
(T7ZAC ) [C477]
Table of Contents
iii

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS

General
INTRODUCTION
The Common Control System (CCS) was developed
to achieve a commonality of programming traits
and display menus across a wide range of fork lift
products. The ability to use one common
programming method increases the effectiveness of
the technician through similarity of functions when
using the display interface and display menus and
sub-menus. Whenever differences in menu
structures appear between products they will be
noted in the applicable service manual for that
product. Proper use of the Common Control System
should only be attempted by factory trained
technicians. Some terms and descriptions in this
manual may be generic in scope and not represent
the actual truck being serviced. Any questions
regarding this manual should be directed to the
factory service representative.
DESCRIPTION
The User Interface Service Technician Manual
describes the functions of the display panel that are
available to the service technician. With a proper
service-level password, a service technician can
access menu items that are not visible at operator
or supervisor-level access.
NOTE: The initial set up of supervisor passwords
must be performed by a service technician
accessing the menu system with a service-level
password. The supervisor password must be set up
before a supervisor can access the menu functions.
The factory default 55555 password should be
changed to a different number during initial setup.
The dash display is a multifunction device. It
contains a button keypad, a series of LED indicator
lights, and an LCD screen. See Figure 1.
Figure 1. Dash Display
Button Keypad
The button keypad is located on the right side of
the display. It consists of four buttons arranged in
a circle with a fifth button in the center. The
buttons are numbered 1 through 5, starting with
button 1 at the top and continuing clockwise and
ending with button 5 situated in the center of the
keypad.
LED Indicator Lights
The LED indicator lights are located on the display
below the LCD screen and to the left of the button
keypad. The lights illuminate to notify the operator
of certain conditions. The function of each light (in
order from left to right) is as follows:
• Battery
• Wrench
• Thermometer
• Operator Pedal
• Warning
2200 SRM 1631 General
1

LCD Screen
The LCD screen displays the following when the
key is in the ON position:
1. Battery Charge Indicator
2. Hourmeter (Hours)
3. Throttle Command
4. Actual Speed
5. Run Direction
6. Performance Mode
DASH DISPLAY MENU ACCESS
To access the dash display menu system:
1. Turn the key or keyless switch to the ON
position.
2. Depress the center button (#5) on the display
two times.
3. The Enter Password screen will now appear
on the LCD. Enter your five-digit Service
Technician password. The factory default
service-level password is 55555.
To enter your password at the ENTER
PASSWORD screen, enter the appropriate digit in
the highlighted area of the display. Use the
appropriate button on the display keypad to enter
any digit between 1 and 5. The cursor will
automatically move to the next position after a
number has been entered. Repeat until all five
digits of your password have been entered. Upon
successful entry of your service-level password, the
display will enter the Service Menu system. If an
incorrect password is entered, the display will ask
for the password to be entered again. The menu
system can be exited at any time by pressing the
LEFT (#4) button repeatedly.
Menu Navigation
NOTE: The display menus are revolving and will
repeat when you scroll beyond the last menu item.
Upon successful entry of your service-level pass-
word, the service menu screen will appear on the
dash display LCD screen. Menu navigation is ac-
complished by using the display buttons. From in-
side the menu, the buttons function as follows:
1. UP
- Scroll up within a menu, or increase the
value of a setting when making a parameter
adjustment.
2. RIGHT
- Scroll right within a menu. Will move you
into the next submenu or activate the high-
lighted parameter to allow parameter value
adjustments.
3. DOWN
- Scroll down within a menu, or decrease the
value of a setting when making a parameter
adjustment.
4. LEFT
- Scroll left within a menu. Will move you to
the previous menu when depressed. Press re-
peatedly to exit the menu system.
5. ENTER
- Press to accept parameter value adjust-
ments. Press twice to access the Enter Pass-
word screen.
General 2200 SRM 1631
2