Hyster Forklift W45-HD

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 discharge the internal or external capacitors before opening any compartment covers or inspecting or repairing the electrical system. DO NOT place tools on top of the battery. If a tool causes a short circuit, the high current flow from the battery can cause personal injury or property damage.

Some checks and adjustments are performed with the battery connected. DO NOT connect the battery until the procedure instructs you to do so. Never wear jewelry or other metallic items on your fingers, arms, or neck when working near electrical components. Metal items can accidentally make an electrical connection and cause injury.

Before performing any tests or adjustments, block the lift truck to prevent unexpected movement.

The capacitors in the transistor controllers can hold an electrical charge after the battery is disconnected. To prevent an electrical shock andpersonal injury, discharge the internal or external capacitors before inspecting or repairing any component in the electrical compartments. Make certain that the battery has been disconnected.

DO NOT short across the motor controller terminals with a screwdriver or jumper wire.

To avoid controller damage, always disconnect the battery, discharge the internal or external capacitors, and never put power to the controller while any power wires are disconnected. Never short any controller terminal or motor terminal to the battery. Make sure to use proper procedure when servicing the controller.

Does status code display if truck does not respond to lift and lower command?

YES- Proceed to status code description section within this manual to address the status code.

NO- Inspect lift and lower switches at tiller head.

If the lower function is inoperative and no code has been displayed, perform the following troubleshooting procedures:

1. Open tiller head assembly and inspect tiller card.

Are lower switches connected to tiller card connectors JP12 and JP15?

Warning: This procedure requires trained personnel with PPE!

Measure voltage between terminal before FU1 and B(-)

Measure resistance between truck frame and each of the following test points: Battery postivie wire after FU1, B(+) and B(-), U-Phase cable, V-Phase cable, W-Phase cable, Pump positive cable, Pump negative cable

Measure battery voltage between terminal after FU1 and B(-)

The ohmmeter is used to measure a circuit or device's resistance in ohms. Ohmmeters use low internal voltage and current which flow through an isolated circuit or device being tested. The voltage of the meter battery and the amount of current flow in the circuit are used to calculate the circuit’s resistance. It is necessary to disconnect or isolate the circuit being test so not to damage the vehicle’s electrical system or the ohmmeter.

An ohmmeter is used to perform:

• Operation of variable resistors

Measure voltage between the coil's positive terminal and B(-)

Is voltage same as truck's battery voltage?

If NO, inspect the Coil's battery B(+) input circuit for open or short.

Disconnect coil's ground control circuit.

Measure resistance between ground circuit terminal and B(-)

Actuate coil ground control to determine if controller is sending activation signal to coil.

If NO, inspect ground control circuit. Verify that controller is receiving device input signal.