• Control Module
• AC Motor Controller
• Brake Coil
• Drive Motor
• Lift Pump Motor (C60-80Z
HD
)
• Contactor
ON/OFF switches are used for:
• Key Switch
• Lift and Lower Functions (C60-80Z
HD
)
• 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 C60-80Z
HD
) 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 C60-80Z
HD
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
