Repairs; Controller, Replace; Remove; Install - Yale 524150797 Maintenance Manual

2200 YRM 1508
WARNING
DO NOT make repairs or adjustments unless you
have been properly trained and authorized to do
so. Improper repairs and adjustments can create
dangerous 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 and disconnect the battery.
Disconnect the battery and separate the connector
before opening the drive unit compartment cover
or inspecting or repairing the electrical system. If a
tool causes a short circuit, the high current flow
from the battery can cause personal injury or
property damage.
The capacitor in the controller can hold an
electrical charge after the battery is disconnected.
To prevent electrical shock and personal injury,
discharge the capacitor before inspecting or
repairing any component
compartment. See Special Precautions in this
section.
All checks, adjustments, and repairs in the drive unit
compartment are done with the compartment cover
removed. Remove the drive unit compartment cover
for access to the electrical components and discharge
the capacitor.

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 - How to Put
a Lift Truck on Blocks. The blocks must prevent
the lift truck from falling and causing personal
injury or property damage.
•
Periodic Maintenance 8000YRM1510
for lift truck model A249
•
Periodic Maintenance 8000YRM1666
for lift truck model A245

Repairs

in the drive unit
NOTE: Although the controller is factory programmed,
any custom parameters must be uploaded or re-
entered into the controller when replacing. See the
section User Interface.
DO NOT replace the controller until you have
thoroughly checked all other electrical components
and are sure the controller is malfunctioning. For the
following procedures, refer to Figure 3.

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 cover. Refer
to AC Motor Repair 0620YRM1513, Accessing
the Drive Unit Compartment.
3. Discharge the capacitor. See Special Precautions
in this section.
4. Tag and disconnect wires from the controller.
5. Remove the 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, turn the key switch to the ON
position, and turn parking brake to the OFF
position.
4. Test for proper operation.
5. Install the drive unit compartment cover.
Repairs
5