CONTROLLER, REPLACE
WARNING
Some checks require the battery to be connected.
DO NOT connect the battery until the procedure
tells you to do so. Make sure the drive wheel is
raised to prevent movement and possible injury.
Raise the drive wheel. See the section Periodic
Maintenance 8000SRM1644 - How to Put a Lift
Truck on Blocks. The blocks must prevent the lift
truck from falling and causing personal injury or
property damage.
DO NOT
replace the controller until you have thoroughly
checked all other electrical components and are sure the
controller is malfunctioning. .
Remove
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.
3.
Discharge the capacitor. See Discharging the Internal
Capacitors in this section.
4.
Tag and disconnect wires from the controller. See Fig-
ure 6.
5.
Remove nuts securing shield box to controller if equip-
ped.
6.
Remove mounting screws and remove controller.
Install
1.
Install replacement controller on lift truck using
mounting hardware.
2.
Connect wires and cables to the proper terminals as
identified during the removal procedure.
3.
Connect battery and turn the key switch to the
ON
po-
sition. Test the brake for proper operation.
Turn the key switch to the
OFF
position and discon-
nect the battery again to continue installation.
4.
Install the drive unit compartment covers.
1. B+ CONTROLLER TERMINAL
2. MAIN FUSE
3. MAIN CONNECTOR
4. TRACTION MOTOR POS (TERMINAL U)
5. TRACTION MOTOR POS (TERMINAL W)
6. CABLE CLAMP
7. TRACTION MOTOR POS (TERMINAL V)
8. MAIN CONTACTOR (IN)
9. BATTERY POS
10. MAIN CONTACTOR (OUT)
11. BATTERY NEG
12. PUMP MOTOR POS (TERMINAL P)
13. IN-LINE FUSE
14. BATT POS (FROM CONTACTOR)
15. BATT NEG (FROM CONTROLLER)
16. B– CONTROLLER TERMINAL
Figure 6. Controller Wiring (Manual Steer Shown)
Repairs
2200 SRM 1640
8
