General
The removal and replacement procedures for the
following electrical components are covered in this
service manual:
• Display panel
• Manual hydraulic and E-Hydraulic control
components
• Motor controllers
• Sensors and switches
• Lights
• Fuses, alarm and horn
• Battery
• Vehicle System Manger (VSM)
For adjustment procedures of switches located on
the linkage for the manual control valve, or for
switches located on the E-Hydraulic control valve,
see Main Control Valves 2000SRM1520.
See AC Motor Repair 0620SRM1515 for
information on servicing and maintaining the AC
hydraulic pump and traction motors and
Industrial Battery 2240SRM0001 for information
on the battery.
If any of the wire harnesses need to be repaired, see
the section Wire Harness Repair 2200SRM1128
for repair procedures.
Some of the components used are made of plastic.
When using screws to replace and install plastic
components, the screws should be rotated
counterclockwise until screw thread turns over the
last thread in the plastic part. The screw can then
be turned clockwise to make a connection. This
prevents "cutting" new threads and damaging the
existing thread in the plastic part.
If any welding must be done, obtain proper
authorization from a Resident Service Engineer. If
authorization is given, be sure to follow the
procedures in the WARNING and CAUTIONS
below.
WARNING
Forklift frames and components may be painted
with a catalyzed paint such as polyurethane or a
two-part primer. Welding, burning, or other heat
sufficient to cause thermal decomposition of the
paint may release isocyanates. These chemicals
are allergic sensitizers to the skin and respiratory
tract and overexposure may occur without odor
warning. Should work be performed, utilize good
industrial hygiene practices including removal of
all paint (prime and finish coats) to the metal
around the area to be welded, local ventilation,
and/or supplied-air respiratory protection.
CAUTION
When an arc welder is used, always disconnect
the battery connector on the lift truck. This action
will prevent damage to the motor controllers.
Connect the ground clamp for the arc welder as
close as possible to the weld area. This action will
prevent damage to a bearing from the large
current from the welder.
Before performing arc welding repairs, disconnect
the motor controller and VSM connections to
prevent damage to motor controllers and VSM. See
sections Motor Controllers Replacement and
Vehicle Systems Manager for procedures.
2200 SRM 1524
General
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