Model 6210 Maintenance Manual

Section 7.Component Procedures

Electrical Components Traction Amplifier

Traction Amplifier Removal

1.If equipped with the optional keypad, press the red OFF ( O ) key. Place the Main ON/OFF Switch in the OFF position. Disconnect the battery connector from the truck.

2.Remove the tractor covers.

3.Discharge the capacitors in the traction amplifier by connectin g a load (such as a contactor coil or a horn) across the amplifier’s TA B+ and TA B– terminals.

4.Push the locking tab and disconnect the J1 connector from the traction amplifier. See Figure7-64.

5.Disconnect the power cables (terminals TA B+ and TA B–) on the traction amplifier. Do not stress the power cable connections. Disconnect the traction motor cables (terminals U, V, and W) at the traction amplifier.

6.Remove the screws securing the traction amplifier to the elect rical panel. Remove the traction amplifier.

Traction Amplifier Installation

NOTE: All traction amplifiers are preset to factory default specifications.

1.Secure the traction amplifier to the electrical panel with the previously removed hex head cap screws. Torque screws to 11 ft. lbs. (14.9 Nm).

2.Connect the power cables (terminals TA B+ and TA B–) on the traction amplifier. Torque screws to 80 to 100 in.lb. (9.1 to 11.3Nm) maximum. Do not stress the cable connections and put strain on internal components.

3.Connect the J1 connector and traction motor connectors (terminals U, V, and W) to the traction amplifier.

4.Connect the battery connector.

5.Place the Main ON/OFF Switch in the ON position. If equipped with the optional keypad, enter your PIN-key code and then press the green ON ( | ) key.

6.Test operation of the truck.

7.If equipped with the optional keypad, press the red OFF ( O ) key. Place the Main ON/OFF Switch in the OFF position.

8.Install the tractor covers.

Publication: 1146947, Revised: 12 Jan 2017 7-53

Contactors

The main contactor (MPC) controls battery power to both the traction and lift motors. The lift pump contactor (LPC) provides power to the lift motor to control the hydraulics.

Visually inspect the contactors for any signs of burning or physical damage. These are sealed contactors; therefore, th e entire contactor must be replaced if there are any signs of damage.

Resistance Testing

1.If equipped with the optional keypad, press the red OFF ( O ) key. Place the Main ON/OFF Switch in the OFF position. Disconnect the battery connector from the truck.

2.Remove the tractor covers to access the contactor panel.

3.Disconnect the wires from the contactor coil.

4.Connect the ohmmeter to the wire connectors on the contactor coil.

5.The reading should be 22 to 24.2 Ohms for standard contactor (76. 5 to 93.5 Ohms for cold storage contactor). If resistance is outside that range, replace the contactor.

NOTE: Replace the main contactor (MPC) and/or lift pump contactor (LPC) if coil resistance is not 22 to 24.2 Ohms for standard contactor (76.5 to 93.5 Ohms for cold storage contactor).

Contactor Removal

1.If equipped with the optional keypad, press the red OFF ( O ) key. Place the Main ON/OFF Switch in the OFF position. Disconnect the battery connector from the truck.

2.Remove the tractor covers to access the contactor panel.

3.Disconnect the wires from the MPC-X and MPC-Y or LPC-X and LPC-Y terminals on the contactor.

4.Remove the nuts securing the cables and fuse (FU2) to the contactor, noting the locations for assembly later.

5.Remove screws and flat washers holding the contactor to the bracket.

Contactor Installation

1.Secure the contactor to the bracket with flat washers and screws. Torque the screws to 39 in.lb. (4.4 Nm).

2.Secure the cables and fuse to the contactor with jam nuts. Torque the nuts to 70 to 84 in. lb. (8 to 9.5 Nm).

3.Connect the wires to the MPC-X and MPC-Y or LPC-X and LPC-Y terminals.

4.Install the tractor covers.

5.Reconnect the battery connector to the truck.

6.Place the Main ON/OFF Switch in the ON position. If equipped with the optional keypad, enter your PIN-key code and then press the green ON ( | ) key.

7.Test the truck for correct operation before returning to service.