CONTACTOR TIPS
CAUTION
NEVER manually close the main power
contactor. Damage to the system controller
and/or the amplifiers may occur.
CAUTION
To avoid damage to the system controller and
amplifiers, follow the CAPACITOR
DISCHARGE PROCEDURE at the beginning of
this section.
Removal
1. Disconnect the battery and discharge the
capacitors (refer to CAPACITOR
DISCHARGE PROCEDURE in this section).
2. Remove the top cover (refer to TOP COVER
Removal procedure in the FRAME section).
3. Note the location of all power cables and
wires for correct replacement. Disconnect the
cables and wires from the bus bars on the
contactor. Use a backup wrench to prevent
bending the bus bars.
4.
Remove the nylon lock nuts securing the
upper contactor tips in place.
5.
Remove the insulators and springs from the
armature. Remove the contactor tips.
6.
Remove the lock nuts securing the insulator
block to the contactor body. Remove the
insulator and the bus bars.
Replacement
1.
Install the bus bars on the insulating base.
Be sure the holes in the bus bars engage the
locators on the insulating base.
2.
Install the insulator on the bus bars and
secure with the lock nuts.
3.
Install the upper tips over the insulators
attached to the armature.
4.
Install the springs and insulating washers
and secure with the lock nuts.
NOTE
DO NOT over-tighten the nuts securing the
cables and wires to the bus bars of the
contactor. Over-tightening the nuts can
cause the bus bars to bend, resulting in
misalignment of the contactor tips and
overheating. Use a backup wrench to prevent
bending the bus bars.
5.
Connect the power cables and wires as noted
during Step 3 of Removal.
6.
Install the top cover (refer to TOP COVER
Replacement procedure in the FRAME
section).
7.
Connect the battery.
MAIN POWER CONTACTOR
CAUTION
NEVER manually close the main power
contactor. Damage to the system controller
and/or the amplifiers may occur.
CAUTION
To avoid damage to the system controller and
amplifiers, follow the CAPACITOR
DISCHARGE PROCEDURE at the beginning of
this section.
Removal
1.
Disconnect the battery and discharge the
capacitors (refer to CAPACITOR
DISCHARGE PROCEDURE in this section).
2.
Remove the top cover (refer to TOP COVER
Removal procedure in the FRAME section).
3.
Disconnect the B+ and capacitor supply
cables from the bus bar of the main power
contactor (the bus bar toward the front of the
truck).
4.
Remove the bus bar between the contactor
and the fuses.
5.
Label and disconnect the wires from the main
power contactor.
6.
Remove the bus bar between the contactor
and the lift (600 amp) fuse.
7.
Remove the nuts securing the panel to the
frame of the truck and rotate the panel to
access the contactor mount screws.
8. Remove the screws holding the contactor to
the bracket and remove the contactor.
Replacement
1. Align the mounting holes in the contactor with
the holes in the panel and install the screws.
E
lectric
C
ounterbalance
H
igh
O
utput
Electrical
4/3/00
8.4
