Special Precautions
WARNING
DO NOT make repairs or adjustments unless you
have both authorization and training. Repairs and
adjustments that are not correct can create dan-
gerous operating conditions. DO NOT operate a
lift truck that needs repairs. Report the need for
repairs to your supervisor immediately. If repair is
necessary, attach a DO NOT OPERATE tag to the
control handle.
WARNING
Disconnect the battery and separate the connec-
tor before opening the drive unit compartment
cover or inspecting or repairing the electrical sys-
tem. If a tool causes a short circuit, the high cur-
rent flow from the battery can cause personal in-
jury or property damage.
WARNING
Some checks and adjustments are done with the
battery connected. DO NOT connect the battery
until the procedure tells you to do so. Never have
any metal on your fingers, arms, or neck. Metal
items can accidentally make an electrical connec-
tion and cause injury.
WARNING
Before doing any tests or adjustments, raise the
vehicle off the ground and block the lift truck to
prevent unexpected movement. See the section
Periodic Maintenance 8000YRM1048, Periodic
Maintenance 8000YRM1009, or Periodic Mainte-
nance 8000YRM1379 for your lift truck. Refer to
How to Put a Lift Truck on Blocks.
WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted. To prevent an electrical shock and personal
injury, discharge the capacitor before inspecting
or repairing any component in the drive unit com-
partment. Wear safety glasses. Make certain that
the battery has been disconnected.
CAUTION
To avoid controller damage, always disconnect
the battery, discharge the capacitor, and never
put power to the controller while any power wires
are disconnected. Never short any controller ter-
minal or motor terminal to the battery. Make sure
to use proper procedure when servicing the con-
troller.
1. Block load wheels to prevent lift truck from mov-
ing. See the section Periodic Maintenance
8000YRM1048, Periodic Maintenance
8000YRM1009, or Periodic Maintenance
8000YRM1379 for your lift truck.
2. Turn the key switch to the OFF position and dis-
connect the battery.
3. Discharge the capacitors in the controllers by con-
necting a 200-ohm, 2-watt resistor across the
controller's B+ and B- terminals. DO NOT short
across the motor controller terminals with a
screwdriver or jumper wire. See Figure 3 or Fig-
ure 4.
4. Remove the 200-ohm, 2-watt resistor before re-
connecting the battery.
2200 YRM 1007 Special Precautions
5
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