Hyster C477 Operating instructions

Hyster C477 (T5ZAC, T7ZAC) Forklift Service
Repair Manual

ELECTRICAL SYSTEM
C80ZHD [A282];
C60ZHD [A373];
T5ZAC [C476/D476];
T7ZAC [C477]
PART NO. 4096001 2200 SRM 1632

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
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
i

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

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General
This section includes removal, disassembly, checks,
adjustments, assembly, installation, and
troubleshooting procedures for the electrical system
components on the T5-7ZAC and C60-80ZHD truck
models. Components covered in other sections, such
as motors and industrial batteries, are not included
in this section.
See the section Controller Diagnostics
9000SRM1657 for additional information on the AC
motor controller and for information on
troubleshooting fault codes, adjusting parameters,
and testing the motor controller.
See the section AC Motor Repair *(With EPAS)
0620SRM1283 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 E174N03000L=>
0620SRM1621 for general information on traction
motor troubleshooting and repair for lift truck
models:
• C60-80ZHD
See the section Periodic Maintenance
8000SRM1635 for instructions on removing and
installing the drive unit compartment covers and
for minimum motor brush length specifications.
See the section Diagrams 8000SRM1634 for the
wiring diagrams and schematics.
Throughout this section the terms right, left, front,
rear, forward, and reverse relate to the viewpoint of
an operator riding on the truck with the forks
trailing. See Figure 1.
2200 SRM 1632 General
1

A. RH SIDE
B. LH SIDE C. FORWARD D. REVERSE
Figure 1. Truck Orientation
Description of Operation
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 and Regen
Switches)
•Battery Discharge Indicator/Hourmeter
(BDI)
• Fuses
General 2200 SRM 1632
2

• Control Module
• AC Motor Controller
• Brake Coil
• Drive Motor
•Lift Pump Motor (C60-80ZHD)
• Contactor
ON/OFF switches are used for:
• Key Switch
•Lift and Lower Functions (C60-80ZHD)
• Horn
• Fast Speed (Foot Switch)
• Brake and Regen Switches
• Throttle Neutral Signal
• Parking Brake
A directional/throttle control, neutral switches, and
push-button function switches are housed in the
control handle.
The Hall effect throttle control is used to provide a
directional/speed signal. The neutral switches ver-
ify the throttle is in neutral position during the
self-check at startup. The horn switch (and lift and
lower switches on the C60-80ZHD) are mounted in
the top cover of the control handle. These switches
send signals to the controller activating each indi-
vidual function.
The control module converts analog signals from
the control handle to digital signals for the control-
ler to read.
The main contactor opens to remove power from
the traction and lift circuits in the event of an elec-
tric failure.
A spring applied/electrically released brake is
mounted to the top of the traction motor. When the
key switch is in the ON position and the parking
brake switch is in the OFF position, the brake coil
energizes, disengaging the brake. This pulls the
brake pressure plate away from the friction disc al-
lowing the drive motor to turn freely.
A two-stage hand brake assembly (see 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. When both
levers are released (Position One), no braking is ap-
plied. If either hand lever is placed in the second
position, the controller places the traction motor
into regen mode.
The brake coil releases the pressure plate mechani-
cally engaging the brake when either hand lever is
placed in the third position, the parking brake
switch is in the ON position, or when the key
switch is in the OFF position.
1. BRAKES DISENGAGED (POSITION ONE)
2. REGENERATIVE BRAKING (POSITION TWO)
3. MECHANICAL BRAKING (POSITION THREE)
Figure 2. Hand Brake Position
On the C60-80ZHD trucks, the motor controller en-
ergizes the lift pump motor when the lift button is
depressed. The motor controller activates the sole-
noid coil opening the lowering valve (located at the
pump), when the lower switch is depressed. Refer
to Figure 3 or Figure 4. The controller protects the
lift pump and motor assembly, eliminating the
need for a height limit switch. The controller will
stop the lift pump motor 0.6-0.8 seconds after cur-
rent flow to the lift pump motor exceeds the preset
limit. This occurs when the lift truck has reached
the maximum lift height, when lifting more than
the specified load capacity, or if an electrical fault
occurs. The controller will interrupt power to the
lift pump motor immediately and resets when the
lift button is released.
2200 SRM 1632 Description of Operation
3

1. KEY SWITCH
2. BATTERY DISCHARGE INDICATOR (BDI)
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 (C60-80ZHD)
Description of Operation 2200 SRM 1632
4

1. KEY SWITCH
2. BATTERY DISCHARGE 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 SRM 1632 Description of Operation
5

Special Precautions
DISCHARGING THE CAPACITORS
WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted. To prevent electrical shock and personal in-
jury, discharge the capacitor before inspecting or
repairing any component. Wear safety glasses.
Make certain the battery has been disconnected.
DO NOT use a screwdriver to discharge the trac-
tion motor controller.
WARNING
To avoid personal injury and prevent electrical
shock, perform the following steps before per-
forming any troubleshooting or adjustments, and
connecting or disconnecting a handset or PC.
CAUTION
To avoid controller damage, always disconnect
the battery. Discharge 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 servicing the controller.
1. Move the truck to a safe, level area. Turn the
key switch to the OFF position and disconnect
the battery.
2. Remove the drive unit compartment cover to
access the drive unit compartment.
3. Discharge the capacitors in the controllers by
connecting a 200-ohm, 2-watt resistor across
the controller's B+ and B−terminals. See Fig-
ure 5. DO NOT short across the motor control-
ler terminals with a screwdriver or jumper
wire.
1. CONTROLLER
2. POSITIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
5. NEGATIVE CONNECTION
Figure 5. Discharging Controller
4. Remove the 200-ohm, 2-watt resistor before re-
connecting the battery.
Special Precautions 2200 SRM 1632
6

Electrical System Checks
WARNING
Disconnect the battery before opening the com-
partment cover or inspecting or repairing the elec-
trical system. If a tool causes a short circuit, the
high current flow from the battery can cause per-
sonal injury or property damage.
The capacitor in the controller can hold an electri-
cal charge after the battery is disconnected. To
prevent electrical shock, disconnect the battery
and discharge the capacitor before inspecting or
repairing any component in the drive unit com-
partment. Always wear safety glasses.
CAUTION
The correct meter polarity is necessary for the
checks. The voltage checks are made between the
point indicated and battery negative. Connect the
meter negative to battery negative.
Always disconnect the battery and discharge the
capacitor before disconnecting cables from the
controller. Never put power to the controller with
any cables or wires disconnected. Never short
any controller or motor terminal to the battery. Al-
ways follow proper procedure when working in
the electrical system.
1. Turn the key switch to the OFF position.
2. Disconnect and separate the battery connec-
tors.
NOTE: The battery does not have to be removed to
check the specific gravity.
3. Check the specific gravity of the battery. If the
specific gravity is less than 1.260, the battery is
not fully charged or is damaged. A fully charged
battery has a specific gravity of 1.270 to 1.290.
A discharged battery has a specific gravity of
approximately 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 section.
6. The electric lift truck has a two-wire system.
The frame must not be a common electrical
path. Using an ohmmeter, check for 50,000
ohms or more between each terminal of the bat-
tery connector (truck end) and a clean connec-
tion on the frame. Remove any electrical paths
between the controller and the frame of the lift
truck. Carbon dust in a motor or other parts
can cause an electrical path. Check for addi-
tional equipment that may provide an electrical
path to the frame.
7. Check for voltage between each terminal of the
battery connector (battery end) and a clean con-
nection on the frame. Normally there is small
voltage (less than 30% of the battery voltage)
between the battery and the frame, even
though the resistance is very high. A higher
voltage can indicate a dirty or damaged battery.
Clean battery and battery compartment as nec-
essary.
8. Visually check for parts or wires that are loose
or damaged.
WARNING
Some checks require the battery to be reconnec-
ted. Do not connect the battery until the point of
the procedure when you are directed to do so.
Raise the drive wheel of the truck and position on
solid hardwood blocks to prevent unexpected
movement when working with the battery connec-
ted.
9. Always follow proper procedure when working
in the electrical system. See Table 1.
NOTE: Make an identification of any wires before
you disconnect them. The wires must be connected
correctly after checks or repairs.
2200 SRM 1632 Electrical System Checks
7

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. Transistor controller connector unplugged.
5. Transistor controller is damaged.
1.0 Check for battery voltage on the bat-
tery side of control fuse. ------▸ ------ 1.01 Battery voltage at control fuse. 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. ------▸
------ 1.1.1 Battery voltage at key switch. Check for
damaged key switch. Check connector.
|
|
|------▸
1.1.2 No voltage at key switch. Wire to key
switch or connections is damaged.
1.3 Key switch closed. Brake switch
closed. Check for battery voltage at
B+ terminal of transistor controller. ------▸
------
1.3.1 Battery voltage at B+ terminal. Check
fault code. If no fault code, possible dam-
aged control handle card.
|
|
|------▸
1.3.2 No voltage at B+ terminal. Check B- ter-
minal. Check fault code.
Electrical System Checks 2200 SRM 1632
8

Repairs
WARNING
DO NOT make repairs or adjustments unless you
have been properly trained and authorized to do
so. Improper repairs and adjustments can create
dangerous operating conditions. DO NOT operate
a lift truck that needs repairs. Report the need for
repairs to your supervisor immediately. If repair is
necessary, turn the key switch to the OFF posi-
tion, disconnect the battery, and attach a DO NOT
OPERATE tag to the control handle.
Disconnect the battery before opening the drive
unit compartment cover or inspecting or repairing
the electrical system. If a tool causes a short cir-
cuit, the high current flow from the battery can
cause personal injury or property damage.
The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted. To prevent electrical shock and personal in-
jury, discharge the capacitor before inspecting or
repairing any component in the drive unit com-
partment. See Special Precautions in this section.
Always 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. Remove the drive unit compartment
cover for access to the electrical components and
discharge the capacitor. See the section Periodic
Maintenance 8000SRM1635. Replace the covers
when service has been completed.
CALIBRATION MODE
In Calibration Mode, service screens can be ac-
cessed through the battery discharge indicator
LCD. Instructions for the various calibration proce-
dures can be found in the sections:
•User Interface 2200SRM1354
or •User Interface 2200SRM1353
.
CONTROLLER, REPLACE
Remove
CAUTION
DO NOT replace the controller until you have thor-
oughly checked all other electrical components
and are sure the controller is malfunctioning.
1. Move the truck to a safe, level location. Turn
the key switch to the OFF position, disconnect
the battery, and block the drive tire to prevent
unexpected movement.
2. Remove the drive unit compartment covers. See
the section Periodic Maintenance
8000SRM1635.
3. Discharge the capacitor. See Special Precau-
tions in this section.
2200 SRM 1632 Repairs
9

4. Tag and disconnect wires from the controller.
See Figure 6.
1. B– TERMINAL
2. B+ TERMINAL (POS CONNECTION STD)
3. MAIN FUSE (STD LOCATION)
4. + TERMINAL (POS CONNECTION EE)
5. MAIN CONNECTOR
6. TRACTION MOTOR POS (TERMINAL U)
7. TRACTION MOTOR POS (TERMINAL W)
8. TRACTION MOTOR POS (TERMINAL V)
9. PUMP MOTOR POS (TERMINAL P)
10. LABEL (PART NUMBER)
Figure 6. Controller Wiring
5. Remove mounting screws and remove control-
ler.
Install
1. Install replacement controller on lift truck us-
ing mounting hardware.
2. Connect wires and cables to the proper termi-
nals as identified during the removal proce-
dure.
3. Connect battery and turn the key switch to the
ON position.
4. Turn parking brake to the OFF position and
test for proper operation.
5. Install 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 the control-
ler to read. If the controller is reporting an input
error fault code, then the control module may be
malfunctioning. Check the control module using the
following steps.
1. Remove drive unit compartment covers for ac-
cess to the electrical components, and raise the
drive tire off the floor to prevent unexpected
movement. See the section Periodic Mainte-
nance 8000SRM1635.
2. Connect the battery and turn the key switch to
the ON position. Make sure the parking brake
switch is in the OFF position.
3. Connect the negative voltmeter lead to the neg-
ative battery cable connection at the controller.
4. Disconnect 6way connector B, check pin 3 (on
the harness side) for +24V. See Figure 7.
Repairs 2200 SRM 1632
10

1. CONTROL MODULE
2. MOUNTING HARDWARE
3. CONNECTOR A = 16WAY
4. CONNECTOR B = 6WAY
5. CONNECTOR C = 8WAY
Figure 7. Control Module Connectors
5. Reconnect 6way connector B, check pin 9 on
connector A for +5V.
6. If there is no voltage at A9 (+5V), then trouble-
shoot the module. See the Troubleshooting
Manual section.
7. If the voltages are proper readings (in Step 4
and Step 55), then check inputs at connector A
while activating each function.
NOTE: Voltage should be present at A3, A4, A5, A6
and ONLY while activating the corresponding
function. See Table 2.
8. If the input values differ from those in the ta-
ble, troubleshoot the 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 Tool may be used to check com-
munication between control handle, control module,
and traction controller. See the Troubleshooting
Manual section.
Table 2. Input Connector A
16 Pin Connector A
A1 DI1 First Digital Input BS
A2 DI2 Second Digital Input SR
A3 DI3 Third Digital Input Horn
A4 DI4 Fourth Digital Input FWD
A5 DI6 Fifth Digital Input REV
A6 DI6 Sixth Digital Input Raise
A7 DI7 Seventh Digital Input Los1
A8 DI8 Eighth Digital Input Los2
A9 PPOT Positive of AI1, AI2, AI3,
AI4, AI5, AI6
A10 AI2 Second Analog Input
A11 AI3 Third Analog Input
A12 NPOT Negative of Analog Inputs
2200 SRM 1632 Repairs
11

Table 2. Input Connector A (Continued)
16 Pin Connector A
A13 AI4 Fourth Analog Input
A14 +BATT +Battery, Short Circuit to
CNB#5
A15 COMMON Positive of all the Digital
Inputs Common Microswitch
A16 -BATT -Battery Battery Negative
Table 3. Input Connector B
6 Pin Connector B
B1 CAN LOW Low Level CAN-BUS Voltage I/O
B2 -BATT -Battery
B3 +KEY Key Input
B4 CAN HIGH High Level CAN-BUS Voltage I/O
B5 +BATT +Battery, Short Circuit to CNA#14
B6 SAS Internal Connected to DI1 With a
100 Ohm Resistance
Table 4. Input Connector C
8 Pin Connector C
C1 DI9 Ninth Digital Input Tilt Up
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 Digital Input /
Fifth Analog Input Side Right
C8 DI13 / AI6 Thirteenth Digital Input /
Sixth Analog Input Reach In
Remove
1. Turn the key switch to the OFF position and
disconnect the battery.
2. Remove drive unit compartment covers for ac-
cess to the electrical components. See the sec-
tion Periodic Maintenance 8000SRM1635.
3. Discharge the capacitors. See Discharging the
Capacitors in this section.
4. Disconnect all connectors from the control mod-
ule.
5. Remove capscrews, lock nuts, and washers se-
curing control module to the frame. See Fig-
ure 8.
Repairs 2200 SRM 1632
12

1. CONTROL MODULE
2. CAPSCREWS 3. WASHERS 4. LOCK NUTS
Figure 8. Control Module Mounting
Install
NOTE: Install new control module with the 16way
connector (A) orientation toward the floor mat.
1. Position new control module frame.
2. Install capscrews, washers, and lock nuts to se-
cure module to frame. Tighten to
3.5 N•m (31.0 lbf in).
3. Install connectors to control module.
4. Connect the battery and turn the key switch to
the ON position. Test truck for proper opera-
tion.
5. Install the drive unit compartment covers. See
the section Periodic Maintenance
8000SRM1635. Test the lift truck for proper op-
eration, and return the truck to service.
CONTACTOR
NOTE: Tag and identify wires before disconnecting
them. The wires must be connected correctly after
checks or repairs. See Figure 10.
Check
Disconnect coil wires. Test contactor 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 in both di-
rections or if there is an open circuit in both direc-
tions. Make sure coil wires are connected to the
proper terminals.
Remove
1. Move the truck to a safe location, turn the key
switch to the OFF position and disconnect the
battery.
2. Remove the drive unit compartment covers. See
the section Periodic Maintenance
8000SRM1635.
3. Discharge the capacitor. See Special Precau-
tions in this section.
4. If the lift truck has an EE rating, remove cover
of the contactor box for access to the contactor
terminals. See Figure 9.
1. CONTACTOR (POWER OUT)
2. CONTACTOR (TO BATTERY POS)
3. CONTACTOR (POWER IN)
4. GROMMETS
5. CONTACTOR (TO CONTROLLER)
6. TO CONTROLLER B+
7. FUSE
8. BUS BAR
9. ENCLOSURE BOX
Figure 9. Contactor (EE Enclosure)
5. Label and disconnect the wires and cables from
the contactor assembly.
2200 SRM 1632 Repairs
13

6. On EE units, remove fuse, buss-bar, and stand-
off to access the contactor mounting screws.
7. Remove two mounting screws located on the
side of the contactor and remove contactor as-
sembly. See Figure 10.
Install
1. Position contactor assembly in place and install
two mounting screws into the side of the con-
tactor.
2. On EE units, install stand-off, buss-bar, and
fuse to contactor panel and contactor as re-
moved.
3. Install wires and cables to the contactor assem-
bly as removed.
4. Connect the battery, turn the key switch to the
ON position and test for proper operation.
5. Install the drive unit compartment covers. See
the section Periodic Maintenance
8000SRM1635.
1. CONTACTOR (TO CONTROLLER)
2. CONTACTOR (POWER OUT)
3. CONTACTOR (POWER IN)
4. CONTACTOR (TO BATTERY POS)
Figure 10. Contactor
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 Fig-
ure 12.
1. Move lift truck to a safe area and block drive
wheel to prevent unexpected movement.
2. Disconnect battery and turn the key switch to
the OFF position.
3. Remove drive unit compartment covers. See
Periodic Maintenance 8000SRM1635 .
4. Remove three capscrews holding dash display
to frame mount.
5. Lift dash display off frame and disconnect wir-
ing from display unit and ignition switch.
6. Discharge the capacitor. See Special Precau-
tions in this section.
NOTE: Make note of the orientation of the key
switch for proper installation.
7. Remove retaining nut from top of the key
switch.
8. Remove the key switch from mounting hole in
dash display.
9. Tag and identify all wires and connections for
reference during reassembly. Disconnect wires
from switch.
Repairs 2200 SRM 1632
14