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Service Manual Chassis, Mast & Options ESR15N-36V ESR18N-36V ESR20N-36V ESR23N-36V EDR13N-36V EDR15N-36V ESS15N-36V ESS20N-36V

2SR3800900-up 4SR3800900-up 5SR3800900-up 7SR3800900-up 1DR3800900-up 2DR3800900-up 2SS3800900-up 5SS3800900-up

99759-7D100

TABLE OF CONTENTS

MAST INSTALLATION INSTRUCTIONS Truck How the Truck is Shipped ........................................................................... Uprighting a Cradled Truck ......................................................................... Option 1: Uprighting with Two Chain Hoist.................................................. Option 2: Uprighting with One Chain Hoist and a Forklift Truck ..................

1-1 1-1 1-2 1-3

Mast Installation Instructions Truck System Requirements ....................................................................... Mast Inspection........................................................................................... Chain Lubrication........................................................................................ Upright and Carriage Position, Chain Tension ............................................ Channel Lubrication.................................................................................... Mast Mounting Bolts and Torque Specifications.......................................... Overhead Guard Mounting Bolts and Torque Specifications ....................... Hydraulic Fluid Level................................................................................... Hydraulic Functions .................................................................................... Pump Intake Coupling (Bleed Points) .........................................................

1-3 1-3 1-3 1-3 1-4 1-5 1-6 1-7 1-7 1-7

GENERAL INFORMATION FEATURES Glossary ........................................................................................................

2-1

Reach Truck Serial Number Definition ........................................................

2-3

General Overview..........................................................................................

2-4

Jacking Truck ................................................................................................

2-8

Load Wheel Replacement Guide..................................................................

2-9

Caster Adjustment ........................................................................................ 2-10 Brake Assembly Inspection and Adjustment ............................................. 2-11 Adjustment of Air Gap with Brake Applied................................................. 2-11 Friction Disc Replacement ........................................................................... 2-11 Transmission................................................................................................. 2-13 THEORY OF OPERATIONS Solenoid Activation Chart ............................................................................

3-1

Main Hydraulic Manifold...............................................................................

3-1

Theory of Operation ..................................................................................... Plugging in the Battery ............................................................................... B+ Feed to .................................................................................................. B-Feed to .................................................................................................... Additional Safety Circuit (Emergency Power Off)........................................ Turning Key Switch (S2) On........................................................................ Can Bus Communication ............................................................................

3-2 3-2 3-2 3-2 3-2 3-2 3-3

TABLE OF CONTENTS

THEORY OF OPERATIONS (continued) Stepping on the Operator Presence Pedal ................................................. 3-3 Steer Request............................................................................................. 3-3 Electric Steer Controller “APS” ................................................................... 3-4 Travel Request ............................................................................................ 3-4 Plugging Request ....................................................................................... 3-6 Regenerative Braking ................................................................................. 3-6 Lift / Lower Request.................................................................................... 3-6 Lift Activation .............................................................................................. 3-7 Lower Activation.......................................................................................... 3-7 Auxiliary Functions...................................................................................... 3-7 Tilt Request ................................................................................................ 3-8 Tilt Activation .............................................................................................. 3-8 Reach / Retract Request ............................................................................ 3-8 Sideshift Request........................................................................................ 3-8 Reach / Retract and Sideshift Activation..................................................... 3-8 Reach / Retract Activation .......................................................................... 3-8 Sideshift Activation ..................................................................................... 3-8 Lift Pressure Adjustment............................................................................. 3-9 Max. Lowering Speed Adjustment (Mechanical) ......................................... 3-9 Emergency Lowering .................................................................................. 3-10 Electrical Lowering Speed Adjustment ....................................................... 3-10 OPERATOR DISPLAY Operator Display ...........................................................................................

4-1

General Information ...................................................................................... ESC (Escape) Button.................................................................................. Scroll Left Button ........................................................................................ Scroll Up Button.......................................................................................... Scroll Down Button ..................................................................................... Scroll Right Button ...................................................................................... Enter Key .................................................................................................... Battery State of Charge .............................................................................. Parking Brake ............................................................................................. Clock........................................................................................................... Mode of Operation (Optional) ..................................................................... Travel Direction ........................................................................................... Travel Speed Indicator ................................................................................ Text Messaging ........................................................................................... Shelf Selector (Option) ............................................................................... Load Weight Display ...................................................................................

4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-3 4-3 4-3

Turn KEY On..................................................................................................

4-4

Under General Settings ................................................................................

4-4

History Folder ...............................................................................................

4-5

TABLE OF CONTENTS

OPERATOR DISPLAY (continued) Shelf Height (Option) ....................................................................................

4-5

To Change Self Height Option .....................................................................

4-6

Mode of Operation (Performance Modes I, II, III and IV) ............................

4-6

Thermal Monitoring ......................................................................................

4-7

SelfTest ..........................................................................................................

4-7

Operation Hours............................................................................................

4-7

Battery State of Charge ................................................................................

4-7

OPERATOR DISPLAY INFORMATION & PROGRAMMING Password Protected Mode Management Mode ..................................................................................... How to Enter “Management” Mode .......................................................... Service Mode.............................................................................................. How to Enter “Service Mode”...................................................................

5-1 5-1 5-1 5-1

Display Enabled Functions General Settings ......................................................................................... History Folder ............................................................................................. Password Manage ...................................................................................... Parameters ................................................................................................. Display Parameters .................................................................................. Configuration Settings..............................................................................

5-2 5-2 5-2 5-2 5-2 5-2

5-3 5-3 5-4 5-4 5-5 5-5 5-6 5-6 5-7 5-7 5-8 5-8 5-9 5-9 5-10 5-10 5-11 5-11 5-11

iii

TABLE OF CONTENTS

OPERATOR DISPLAY INFORMATION & PROGRAMMING (continued) Low Batt ............................................................................................... Maintenance Warning........................................................................... Stand-by-Timer..................................................................................... Travel Alarm ......................................................................................... Max Speed Fwd ................................................................................... Max Speed Bwd ................................................................................... Release Braking ................................................................................... Inverse Braking..................................................................................... Steer Sensitivity.................................................................................... Forward Steering .................................................................................. Lower Stop / Batt Lock ......................................................................... Cutback Linear ..................................................................................... Cutback 1 Speed .................................................................................. Cutback 2 Height / Cutback 2 Speed ................................................... Cutback 3 Height / Cutback 3 Speed ................................................... PreSensor Low ..................................................................................... PreSensor Low ..................................................................................... Real Load Weight ................................................................................. Max Lift................................................................................................. FreeLift ................................................................................................. LiftLimit ................................................................................................. Reach 2 ................................................................................................ Retract 2............................................................................................... Reach2 / Retr2 ..................................................................................... 2nd Pump ............................................................................................. E Cushion............................................................................................. Wheel Centering...................................................................................

5-11 5-11 5-11 5-11 5-11 5-12 5-12 5-12 5-12 5-12 5-12 5-12 5-12 5-12 5-12 5-13 5-13 5-13 5-13 5-13 5-13 5-14 5-14 5-14 5-14 5-14 5-14

Diagnostics Diagnostics *Service Mode Only* ............................................................... How to Access “Onboard Diagnostics”..................................................... Digital Inputs ........................................................................................ Analog Inputs ....................................................................................... Outputs................................................................................................. Temperatures........................................................................................ Motor Controls......................................................................................

5-15 5-15 5-15 5-16 5-16 5-17 5-17

Service Service *Service Mode Only* ..................................................................... How to Access “Service”.......................................................................... Set Maintenace Intervals ...................................................................... Clear History Folder ............................................................................. Reset Pre-Height Select ....................................................................... Restore Truck Param ............................................................................ Restore Perf Mode ............................................................................... Restore Passwords...............................................................................

5-18 5-18 5-18 5-18 5-19 5-19 5-19 5-19

TABLE OF CONTENTS

OPERATOR DISPLAY INFORMATION & PROGRAMMING (continued) Height Detection (Option) Height Detection Overview ......................................................................... Height Detection Installation ....................................................................... Pre_Selected Shelf Height Option .............................................................. To Change the Shelf Height .....................................................................

5-20 5-21 5-22 5-22

Cold Storage Option ..................................................................................... 5-24 Operator Mode Entering Chart .................................................................... 5-25 Management Mode Entering Chart .............................................................. 5-27 Service Mode Entering Chart....................................................................... 5-29 MAST Where to Find Serial Number on Mast ........................................................

6-1

Hydraulic Manifold with Cover.....................................................................

6-1

Hydraulic Manifold with Cover Removed....................................................

6-1

Contents ........................................................................................................

6-2

Periodic Maintenance ...................................................................................

6-2

Inspection......................................................................................................

6-2

500 Hour Inspection .....................................................................................

6-2

Troubleshooting ............................................................................................

6-3

Mast Removal................................................................................................

6-4

Cylinders Main Lift Cylinder ........................................................................................ Description............................................................................................... Free Lift Cylinder ........................................................................................ Description............................................................................................... Cylinder Operation ...................................................................................... Cylinder Raising....................................................................................... Cylinder Lowering .......................................................................................

6-4 6-4 6-5 6-5 6-6 6-6 6-6

Main Lift Cylinder Service Main Lift Cylinder Disassembly................................................................... Cleaning and Inspection ............................................................................. Main Lift Cylinder Reassembly ................................................................... Piston Rod and Piston ............................................................................. Retainer / Retainer Assembly ..................................................................

6-7 6-7 6-8 6-8 6-8

TABLE OF CONTENTS

MAST (continued) Piston Rod and Piston ............................................................................. 6-10 Retainer / Retainer Assembly .................................................................. 6-10 Mast Uprights Upright Desciption ...................................................................................... Outer Upright Assembly........................................................................... Intermediate Upright Assembly ................................................................ Inner Upright Assembly............................................................................

6-11 6-11 6-11 6-11

Upright Chain Inspection Elongation................................................................................................... Edge Wear .................................................................................................. Turning or Protruding Pins .......................................................................... Cracked Plates............................................................................................ Fatigue Cracking ...................................................................................... Stress-Corrosion Cracking ....................................................................... Corrosion Fatigue .................................................................................... Ultimate Strength Failure ............................................................................ Tight Joints ................................................................................................. Chain Length Adjustment............................................................................

6-12 6-12 6-12 6-13 6-13 6-13 6-13 6-13 6-13 6-14

Periodic Inspection Triple-Stage Upright (TSU) Chain Length Adjustment ................................ 6-14 Chain Lubrication........................................................................................ 6-16 General Guidelines ..................................................................................... 6-16 Chain Removal and Replacement Lift Chains (Standard & TSU) ..................................................................... 6-17 Primary Cylinder / Carriage (TSU’s) ........................................................... 6-17 Other Chain Service Notes ......................................................................... 6-17 Periodic Inspection—Upright & Lift Bracket Removal & Replace Roller Shim Adjustments Lift Bracket Removal Preperation ............................................................... Removal & Replace Roller Shim................................................................. Upright & Lift Bracket Removal ................................................................... Upright Removal ...................................................................................... Preparation .............................................................................................. Disconnect Battery......................................................................................

6-18 6-19 6-23 6-23 6-23 6-23

Upright Disassembly Rail Cylinders ............................................................................................. Rollers and Shims.................................................................................... Cable, Hose and Chain Sheaves ................................................................ Free Lift Cylinder ........................................................................................ Cable and Chain Sheaves ..........................................................................

6-25 6-25 6-27 6-27 6-28

Lift Bracket Assembly Shimming.................................................................................................... 6-30 Pantograph Carriage Roller ........................................................................ 6-30 vi

TABLE OF CONTENTS

MAST (continued) Checks and Adjustments ............................................................................ Roller Clearance Inspection........................................................................ Service..................................................................................................... Checking Lower Roller Clearance with Upright 6" from Fully Retracted Position ..................................................... When Using a Pry Bar ................................................................................ “C” Clamp Method....................................................................................... Checking Upper Roller Clearance with Upright Extended Approx. 1/2 Full Extension ............................................. Checking Upper Roller Clearance with Upright Extended Approx. to Full Extension ............................................... Checking Lower Roller clearance with Upright Extended Approx. Within 6” of Full Extension.................................

6-30 6-35 6-35 6-35 6-35 6-36 6-37 6-39 6-40

Fork Removal Lift Bracket Service..................................................................................... Fork Carriage Removal ............................................................................ Models Equipped with Sideshift Only ................................................... Models Equipped with Tilt Only ............................................................ Servicing Lift Bracket Arm Rollers ........................................................... Tilt Cylinder Overhaul .............................................................................. Cylinder Removal .................................................................................

6-43 6-43 6-43 6-44 6-45 6-47 6-47

ITA Lift Brackets ITA Lift Bracket with Sidesifter .................................................................... ITA Lift Bracket without Sideshifter ............................................................. Cylinder Removal..................................................................................... Preparation and Cleaning ........................................................................ Disassembly............................................................................................. Retainer Assembly ............................................................................... Piston Rod and Assembly .................................................................... Cleaning and Inspection ....................................................................... Reassembly ............................................................................................. Retainer Assembly ...............................................................................

6-47 6-48 6-48 6-48 6-49 6-49 6-49 6-50 6-50 6-50

Reach Cylinder Overhaul Cylinder Removal........................................................................................ Remove Forks.......................................................................................... Remove the Fork Carriage....................................................................... Preparation, Cleaning and Inspection ......................................................... Disassembly ............................................................................................... Retainer Assembly ................................................................................... Piston Rod and Piston ............................................................................. Cleaning and Inspection .......................................................................... Reassembly ................................................................................................ Retainer Assembly......................................................................................

6-50 6-50 6-51 6-51 6-53 6-53 6-53 6-53 6-54 6-54

vii

TABLE OF CONTENTS

MAST (continued) Sideshift Cylinder Overhaul Cylinder Removal—Lift Bracket .................................................................. Remove Forks.......................................................................................... Preparation Cleaning and Inspection .......................................................... Disassembly ............................................................................................... Retainer Assembly ...................................................................................

6-55 6-55 6-55 6-55 6-55

Lift Bracket Service Cleaning and Inspection ............................................................................. 6-57 Reassembly ................................................................................................ 6-57 Reach and Sideshift Selector Valve Preparation ................................................................................................. 6-57 Mast Hydraulic Schematic............................................................................ 6-59 Reach and Tilt Selector Valve Removal...................................................................................................... Disassembly ............................................................................................... Mounting Selector Valve ............................................................................. Connecting Hydraulic Plumbing ..................................................................

6-60 6-60 6-60 6-61

Sideshifter Solenoid Control Valve Removal...................................................................................................... Installation .................................................................................................. Mount Selector Valve ............................................................................... Install Hoses ............................................................................................ Connect Coils ..........................................................................................

6-62 6-63 6-63 6-63 6-63

Servicing a Double Reach Lift Bracket ....................................................... 6-64 Installing Reach Cylinders ........................................................................... 6-66 Reach and Tilt Selector Valve Service Disassembly ............................................................................................... Cleaning ..................................................................................................... Reassembly—Solenoid Valves.................................................................... Reassembly—Counterbalance Valves ........................................................ Installation ..................................................................................................

6-67 6-68 6-69 6-71 6-71

Sideshifter Selector Valve Disassembly ............................................................................................... 6-72 Cleaning ..................................................................................................... 6-72 Reassembly ................................................................................................ 6-73 Mast Triline Hose / Cable Routing ............................................................... 6-74 Field Replacement of Mast Triline Harness ................................................ 6-75 Mast “Auxiliary” Hydraulic Flushing Procedure ......................................... 6-77

viii

TABLE OF CONTENTS

HYDRAULIC SCHEMATICS Legend ...........................................................................................................

7-1

Standard Performance with Tilt ...................................................................

7-2

Standard Performance with Tilt and Sideshift ............................................

7-3

High Performance with Tilt ...........................................................................

7-4

High Performance with Tilt and Sideshift ...................................................

7-5

CONTROLLER System Configuration and Outline .............................................................. 8-1 System Configuration.................................................................................. 8-1 Outline ........................................................................................................ 8-2 Logic Unit................................................................................................. 8-2 Inverter..................................................................................................... 8-2 Output Unit (RIO)..................................................................................... 8-3 Display Unit.............................................................................................. 8-3 APS (Advanced Power Steering) Unit ...................................................... 8-3 External Logic............................................................................................. 8-4 Logic Unit................................................................................................. 8-4 Inverter..................................................................................................... 8-5 Output Unit............................................................................................... 8-6 Display Unit.............................................................................................. 8-7 Controller Area Network (CAN)................................................................... 8-8 AC Motor System Basics ............................................................................ 8-9 Feature of AC Motor ................................................................................ 8-9 Speed Control of Induction Motor ............................................................ 8-9 Inverter..................................................................................................... 8-10 Function......................................................................................................... Traction Control Function ............................................................................ Powering .................................................................................................. Limitation of Maximum Travel Speed........................................................ Regeneration ........................................................................................... Controlled Roll Back ................................................................................ Steering ................................................................................................... Stall Timer................................................................................................ Free Lift.................................................................................................... Hydraulic Control Function.......................................................................... Hydraulic Controller ................................................................................. Priority ..................................................................................................... Inhibition of Simultaneous Operation ....................................................... Attachments 2 and 3................................................................................ Steering Control Function ........................................................................... OPP (Operator Presence Pedal) Function .................................................. Preventing Operator’s Absence................................................................ Other Functions .......................................................................................... ix

8-11 8-11 8-11 8-12 8-13 8-13 8-14 8-14 8-14 8-16 8-16 8-17 8-17 8-17 8-18 8-19 8-19 8-20

TABLE OF CONTENTS

CONTROLLER (continued) BDI (Battery Discharge Indicator) ............................................................ Service Indicator ...................................................................................... Hour Meter Function ................................................................................ Chime Control Function ........................................................................... Battery Voltage Monitor............................................................................ Display Function (See Display Section) ...................................................... Normal Operation Display ........................................................................ Error Display ............................................................................................ Password Display.....................................................................................

8-20 8-20 8-20 8-21 8-21 8-22 8-22 8-23 8-23

Removal and Installation.............................................................................. Inspecting Before Replacing Controllers..................................................... Checking Inverter and DSP Card............................................................. Checking Logic Card................................................................................ Checking Power Supply Card .................................................................. Checking Output Unit............................................................................... Checking Display Unit .............................................................................. Discharging Electric Charges from Inverters and APS Unit ........................ Replacing Inverter....................................................................................... Replacing DSP (Digital Signal Processor) Card ......................................... Replacing Logic Unit................................................................................... Replacing Logic Card ................................................................................. Replacing Power Supply Card .................................................................... Replacing Output Unit................................................................................. Replacing APS (Advanced Power Steering) Unit ........................................

8-24 8-24 8-24 8-25 8-26 8-27 8-28 8-29 8-30 8-32 8-34 8-35 8-36 8-37 8-38

Basic .............................................................................................................. Basic Items ................................................................................................. Testing Tools ............................................................................................... Pin by Pin Voltage Measurement ................................................................ Pin by Pin Measurement Chart................................................................... Coil Resistances .........................................................................................

8-38 8-38 8-38 8-39 8-40 8-50

Checking Contactor ...................................................................................... 8-51 Checking Contactor Coil ............................................................................. 8-51 Checking Contactor Tip .............................................................................. 8-51 Checking Inverter.......................................................................................... 8-52 Regeneration Check ..................................................................................... 8-52 TROUBLESHOOTING FOR CONTROL CIRCUITS General Information ...................................................................................... Before Replacing Devices........................................................................... Connection of the Service Tool ................................................................... How to Clean Harness Connectors and System Components...................... CAN-BUS Reach Truck AC .........................................................................

9-1 9-1 9-1 9-2 9-3

TABLE OF CONTENTS

TROUBLESHOOTING FOR CONTROL CIRCUITS (continued) Troubleshooting ............................................................................................ 9-4 E0 Traction Motor, Overheating.................................................................. 9-4 E2 Pump Motor 1, Overheating ................................................................. 9-8 E3 Pump Motor 2, Overheating ................................................................. 9-11 E4 Steer Motor, Overheating ..................................................................... 9-14 E5 Traction Inverter, Overheating............................................................... 9-17 E7 Pump Inverter 1, Overheating .............................................................. 9-20 E8 Pump Inverter 2, Overheating .............................................................. 9-23 E9 Steer Inverter, Overheating .................................................................. 9-26 A5 Traction Motor, Over-Current ............................................................... 9-29 14 Traction Motor Current Sensor Fault ..................................................... 9-32 15 Traction Motor, Over-Current................................................................. 9-34 16 Traction Motor, Stall Timer Speed Fault ................................................ 9-37 34 Pump Motor 1, Current Sensor Fault .................................................... 9-39 35 Pump Motor 1, Over-Current ................................................................ 9-41 40 Line Contactor Fault ............................................................................. 9-44 45 Traction Motor Open ............................................................................. 9-46 47 Pump Motor 1, Open ............................................................................ 9-49 48 Pump Motor 2, Open ............................................................................ 9-52 49 Steer Motor, Open ................................................................................ 9-55 51 Traction Lever Sensor Fault .................................................................. 9-58 52 Traction Motor Pulse Input Fault ........................................................... 9-61 55 FC Solenoid Fault ................................................................................. 9-64 56 FC Solenoid Current Leak .................................................................... 9-67 57 Pump Motor 1 Pulse Input Fault ........................................................... 9-69 58 Pump Motor 2 Pulse Input Fault ........................................................... 9-72 59 Steer Motor Pulse Input Fault ............................................................... 9-75 60 Display Communication Fault ............................................................... 9-78 61 Parameter Write Fault ........................................................................... 9-81 62 Logics Fault .......................................................................................... 9-82 63 Traction Inverter Fault ........................................................................... 9-83 65 Pump Inverter 1 Fault ........................................................................... 9-86 66 Pump Inverter 2 Fault ........................................................................... 9-89 68 Output Unit Fault .................................................................................. 9-92 71 APS Controller Fault ............................................................................. 9-94 78 Battery Voltage Too Low ....................................................................... 9-96 79 Battery Voltage Too High ...................................................................... 9-98 81 Pressure Sensor Fault .......................................................................... 9-100 82 Steer Stepper Motor Fault .................................................................... 9-103 85 Brake Switch Fault ................................................................................ 9-105 86 Height Sensor Fault .............................................................................. 9-107 88 Logic Fault Multipurpose Output #1, Travel Alarm ................................ 9-110 88 Logic Fault Multipurpose Output #2, Horn ............................................ 9-112 94 Pump Motor 2, Current Sensor Fault .................................................... 9-114 95 Pump Motor 2, Over-Current ............................................................... 9-116 xi

TABLE OF CONTENTS

TROUBLESHOOTING FOR CONTROL CIRCUITS (continued) (E) Incorrect Start ...................................................................................... 9-119 (H1) Lift Lever, Faulty Setting .................................................................... 9-121 (H2) Tilt Switch, Faulty Setting................................................................... 9-123 (H3) Reach Switch, Faulty Setting ............................................................. 9-125 (H4) Sideshift Switch, Faulty Setting.......................................................... 9-127 (Lo) Battery Low ........................................................................................ 9-129 Component Identification............................................................................. 9-131 Electrical Diagrams....................................................................................... 9-135 Wiring Schematic Wiring Diagram PLANNED MAINTENANCE Maintenance Locations ................................................................................ 10-1 Maintenance Intervals .................................................................................. 10-2 Service Data Recommended Lubricants .......................................................................... 10-3 Fluid Capacities .......................................................................................... 10-3

xii

1-1 1-1 1-2 1-3

1-3 1-3 1-3 1-3 1-4 1-5 1-6 1-7 1-7 1-7

MAST INSTALLATION INSTRUCTIONS

Truck

Uprighting a Cradled Truck This section includes instructions for uprighting a cradled truck. Generally, when the OAL (Overall Lowered Height) of a truck is 107 in. (2717.8 mm) or higher, it will be secured to a cradle and shipped lying down (with the mast horizontal).

How the Truck is Shipped Before doing the inspection, take note of how the truck was prepared for shipping from the factory: •

•

The Mast/Tractor Assembly is laid down on a skid (this is known as cradling). Usually if the Overall Lowered Height (OAL) is 107 in. (2717.8 mm) or more, the truck will be secured to a cradle and shipped lying down (with its mast horizontal). Instructions for uncradling a truck are detailed in “Uprighting a Cradled Truck” on this page.

! CAUTION Two technicians are required for erecting and assembling the unit.

The carriage is strapped to the truck’s baselegs (for cradled trucks).

In the battery compartment. •

A glass mast guard is installed (if used).

•

Two battery doors are strapped in place.

! CAUTION Remove all jewelry from hands and wrists before doing the installation.

! WARNING To prevent possible injury or damage to the unit, use extreme caution when handling a cradled forklift truck. Place the mast, truck, and pallets in an open area where it will be safe to work. The truck components are heavy, unstable, and difficult to handle. Use extreme care when lifting and assembling this truck. Proceed with extreme caution.

Warnings and Cautions Be sure to follow these important warnings and cautions before uprighting a cradled truck: •

Anyone involved in setting up this unit should wear gloves, safety glasses, steel-toed boots, and a safety helmet.

•

There should be no distractions during setup of this truck.

•

Do not allow observers to stand nearby.

Items Needed To upright the truck, you will need: •

1-1

A hoist with a minimum working capacity of 5 tons (4536 kg).

MAST INSTALLATION INSTRUCTIONS

•

An assembly area with a ceiling clearance in excess of the truck’s collapsed height.

•

A hoist sling for the mast.

12. Lift the cradle up and away from the truck and slowly lower it to the floor.

Option 1: Uprighting with Two Chain Hoists Use this procedure when two chain hoists of suitable weight capacities are available. 1. Before lifting the truck into the upright position, remove the forks from the cradle. Use a lifting device to prevent personal injury because the forks weigh more than 50 lbs. (23 kg) each. 2. Position the cradled truck so it is lying directly beneath and parallel to the chain hoist rail.

! WARNING

While performing the next step, be sure that the chain on the baselegs does not lift the cradle off the floor. Also, be sure not to let it become slack as this will allow the truck to lower too quickly.

Once the forks are positioned under the cradle, attach a safety chain between the fork carriage of the lifting truck and the upper cross piece of the cradle. This prevents the cradle from slipping off the forks during the uprighting procedure.

3. Attach the first chain hoist to the upper cross piece of the cradled truck’s mast. 4. Attach the second chain hoist to the baselegs of the cradled truck. 5. Slowly raise each chain until all slack is gone.

! WARNING

6. Begin lifting the chain attached to the upper cross piece of the cradled truck’s mast.

7. Once the lifting chain reaches a certain point, the center of gravity will shift, causing the weight of the cradled truck to shift to the chain hoist attached to the baselegs. 8. Once the weight has shifted, continue to lower the truck with the baseleg chain hoist until it is standing on the floor in the upright position. 9. Remove the chains from the base legs. 10. Remove the chain from the upper cross piece of the truck’s mast and attach it to the upper cross piece of the cradle. 11. Remove the bolts from the bottom cradle cross piece that secures the cradle to the truck’s front bumper. 1-2

MAST INSTALLATION INSTRUCTIONS

Mast Installation Instructions

Option 2: Uprighting with One Chain Hoist and a Forklift Truck

Truck System Requirements

Use this procedure when one chain hoist is available. This procedure uses a forklift truck and a chain hoist, both of suitable weight capacity.

IMPORTANT: The mast is compatible with SAE 10W petroleum base oil per Mil. Spec. MIL-0-5606 or MIL-0-2104B only. Use of synthetic or aqueous base hydraulic oil is not recommended. The recommended hydraulic oil is Caterpillar HYDO. See service data chart in section 12 of the Planned Maintenance Section for oils required for non-standard applications.

1. Before lifting the truck into the upright position, remove the forks from the cradle. Use a lifting device to prevent personal injury because the forks weigh more than 50 lbs. (23 kg) each. 2. Position the cradled truck so it is lying directly beneath and parallel to the chain hoist rail. 3. Position the forks of the forklift truck you’re using to upright the truck under the upper cross piece of the cradle.

Mast Inspection

4. Attach the chain hoist to the baselegs of the cradled truck.

1. Inspect all chains for lubrication.

Check each of the following before using the Mast for the first time. 2. Inspect all chains for any visible damage.

5. Slowly raise the chain hoist until all slack is gone.

3. Inspect the main lift chain adjustment for proper tension and upright position.

6. Begin to raise the upper end of the cradle with the forks of the lifting truck.

4. Inspect the free lift chain adjustment for proper tension and carriage position.

7. Once the forks have lifted the cradle to a certain point, the center of gravity will shift. This causes the weight of the cradled truck to shift to the chain hoist.

5. Inspect for lubrication in the Mast upright channels.

8. Once the weight has shifted, continue to lower the truck with the chain hoist until the truck is standing on the floor in the upright position.

6. Check for Mast skewing.

9. Remove the chain between the lifting truck carriage and the upper cross piece of the cradle. Back the lifting truck away.

The main and free lift chains have been factory lubricated using heat and pressure to force the lubrication thoroughly into the chain links. Avoid removal or contamination of this factory-applied lubrication. Do not wash, sand blast, etch, steam clean, or paint the chains for initial Mast installation. If chains need lubrication, refer to Page 6-16 Chain Lubrication.

Chain Lubrication

10. Remove the chain from the baselegs and attach it to the upper cross piece of the cradle. 11. Loosen and remove the nuts holding the wooden cradle cross piece to the mast, then remove the wooden cross piece.

Upright and Carriage Position, Chain Tension

12. With the chain still attached to the cradle, lift the cradle up and away from the truck and slowly lower it to the floor.

The main lift chains should be adjusted so that when the unloaded mast is fully lowered, the uprights are flush at the bottom. The free lift chains should be adjusted so that when the unloaded mast is fully lowered, the carriage is properly positioned depending on the truck type.

1-3

MAST INSTALLATION INSTRUCTIONS

Mast Skewing

All chains should also be adjusted for equal tension of the pairs to ensure proper load distribution and mast operation.

To adjust the Mast to eliminate skewing, perform the Mast Skewing Adjustment as described below.

Chains are adjusted at the chain anchors (see Section 6, page 6-14). To determine equal tension, extend the unloaded mast to put the chains under tension. Then press the center of the strand with your thumb. Then press at the same place on the other chain of the pair. Each chain in a pair should have equal “give.” If the uprights or carriage are not in correct adjustment, or if the chain pairs do not have equal tension, perform the Main Lift and Free Lift Chain Adjustments.

•

Extend the mast to full lift height and inspect for mast skewing.

•

If the mast bends to the right at full extension, a shim(s) needs to be removed from the left main lift cylinder rod.

•

If the mast bends to the left at full extension, a shim(s)needs to be installed on the left main lift cylinder rod. Snap Ring Washer

Channel Lubrication Inspect the upright channels for lubrication. If necessary, lubricate the full length of each upright channel with chassis lube or Kendall SR-12X.

Intermediate Upright

Shim

Cylinder Alignment Pin Tab

MA0980.eps

Alignment Pin

Figure 1.1 Shimming ML Cylinders

1-4

MAST INSTALLATION INSTRUCTIONS

Mast Mounting Bolts and Torque Specifications

Figure 1.2

Mast is mounted with M16 bolts from top and with M20 bolts from below. The M16 bolts are assembled from the mast side and the M20 bolts are assembled from the chassis side.

Bolt type

Torque [Nm]

Quantity [pcs]

M16 x 45 DIN 912 8.8

200(147.5122ft lbs.)

Mast from the top

Washer 16 DIN 127

Mast from the top

M20 x 40 DIN 933 8.8

400(295.02 ft. lbs.)

Mast from below

Washer 20 DIN 127

Mast from below

1-5

MAST INSTALLATION INSTRUCTIONS

Overhead Guard Mounting Bolts and Torque Specifications

Figure 1.3

Bolt type M20 x 40 DIN 933 10.9

Torque [Nm]

Quantity [pcs]

400 (292.0244 ft. lbs.)

Washer, Lock 20

1-6

MAST INSTALLATION INSTRUCTIONS

Hydraulic Fluid Level

Hydraulic Functions

Refer to Service Data—Planned Maintenance for recommended oils and fluid capacities.

Trucks that are transported laying down have the hydraulic oil removed. New oil must be added and air will be trapped in the system, resulting in no hydraulic function. Bleed out the air from the hydraulic system before putting into service. The bleed points can be found in the battery compartment as shown in the following picture. The battery will have to be pushed aside to get to this area.

NOTE The mast must be in the fully lowered position before filling the hydraulic tank or bleeding the hydraulic system.

Oil Tank, filling hole

Pump Intake Coupling (Bleed Points) The picture below shows the pumps intake couplings, labeled bleed point A (standard and high performance model) and bleed point B (high performance model only), which are located in the battery compartment. To make sure the pump receives oil immediately and doesn’t run dry the first time it is turned on—loosen nut A and wait until you see oil dripping out of it. Then retighten the nut. On the high performance models, both A and B need to be loosened until oil is dripping out of them. Then both nuts should be retightened.

Oil Level

1. Start by filling the hydraulic tank with 33 liters (8.7 U.S. gallons) of hydraulic oil. 2. Fill the mast hydraulic system and bleed it. 3. Finally fill the hydraulic tank to the level shown in the picture above.

1-7

GENERAL INFORMATION & FEATURES Glossary ........................................................................................................

2-1

Reach Truck Serial Number Definition ........................................................

2-3

General Overview..........................................................................................

2-4

Jacking Truck ................................................................................................

2-8

Load Wheel Replacement Guide..................................................................

2-9

GENERAL INFORMATION & FEATURES

Glossary

Contact Tips or Contacts The portion of a switch, relay or contactor where the circuit can be opened or closed.

Activate A component or circuit that is “activated” from its normal condition because of an application of force or electricity.

Contactor Assembly An electrical component consisting of an electromagnetic coil and a set of heavy contact tips.

Auxiliary Function A vehicle function other than lift/lower or travel. These include reaching, retracting, tilting and sideshifting.

Contactor Coil An electromagnet used to close or open contact tips in a contactor assembly. Continuity The ability to allow current flow.

Battery Two or more cells connected together to a supply of electric current.

Control Circuits Wires and components carrying low current used to signal the controllers, turn on main components, or support optional components.

BDI (Battery Discharge Indicator) An electrically controlled display showing the operator the state of battery charge.

Controller A device with multiple inputs and outputs used to control a particular system or sub-system.

Bus A data path shared by many devices (e.g., multipoint line) with one or more conductors for transmitting signals, data, or power.

Controller Area Network (CAN) A communication protocol developed for “noisy” environments. It is used to establish an open communication system between intelligent devices.

Bus Bar A heavy electrical conductor that carries high current from one point to another and other smaller wires are connected.

Current The movement or flow of electricity through a conductor. A circuit must be complete for current to flow.

Circuit A way for current to flow from the positive (+) side of an electrical power source to the negative (–) side of an electrical power source. This can be through wires and electrical components.

Deactivate To change from the activated condition back to the normal (deactivated) condition. It can be caused by the application of force, the removal of force, or the removal of electricity.

Closed Circuit Wiring or components in a circuit that have a continuous path for current.

Digital Signal A signal in which the elements may be either of two distinct values. For example high voltage, low voltage.

Coil A component made from many circles or turns of wire used to concentrate a magnetic field.

Display An electrical device that converts voltage inputs to a visual output.

Conduct To allow the flow of current. Conductor A material that provides a path for current flow.

Electric Motor A device that changes electrical energy into mechanical energy to do work.

Connector Part of a wire assembly or harness that connects with another wire assembly or harness. Used for ease of assembly and disassembly.

Electrical Braking Electrically trying to rotate the drive motor opposite to the direction of truck movement.

2-1

GENERAL INFORMATION & FEATURES

Electromagnet A coil of wire, most often wound on an iron core, which produces a strong magnetic filed when current is sent through the coil.

Microprocessor A small computer chip preprogrammed to control the various electrical functions on a forklift truck. Normal Condition Words used with a switch or relay. Their normal condition is their condition when they are not controlled by the application of force, temperature, pressure, or electricity.

Electromotive Force (EMF) The force that causes an electric current to flow in a circuit. This force is measured in volts. Encoder Is a sensor of mechanical motion. It translates motion (such as speed, direction, and shaft angle) into electrical signals.

Normally Closed (N.C.) A switch or relay whose contacts are closed in the normal condition.

Filter An electrical device or component for restriction or suppression of undesired voltage spikes.

Normally Open (N.O.) A switch or relay whose contacts are open in the normal condition.

Fuse A component in an electrical circuit that will open the circuit if too much current goes through it.

Ohm The unit of measurement of resistance. The amount of resistance that will let one volt push only one ampere of current through it.

Harness An assembly made of two or more wires that are held together.

Open Circuit Wiring or components of a circuit that have no continuity.

Hour Meter An electrically activated device used to record the amount of usage a truck receives.

Output The current flow from a component which initiated from a voltage change at the component’s input.

Indicator A lamp or LED that gives an indication of some vehicle condition when it turns on or flashes.

Potentiometer A device that converts mechanical movement into a voltage pattern for a variable request.

Input A voltage change at the incoming connection of a component.

Power Circuits The cables and components carrying high current used to provide power to the motor controllers and motors themselves.

Insulator A material that has a very large resistance so that it will not let current flow through it.

Resistance Opposition to the flow of current in a circuit. The unit of electrical resistance is the OHM. The lower the resistance, the greater the current flow for a given voltage.

Inverter A circuit used to convert DC to AC and/or AC to DC Lift/Lower The method in which the reach truck raises and lowers the product to be removed or deposited within the warehouse.

Rotor The rotating component of a motor. Stator That part of an AC induction motor’s magnetic structure, which does not rotate. It usually contains the primary winding.

Magnetic Field The area around a magnet where magnetic forces can be detected.

2-2

GENERAL INFORMATION & FEATURES

Steering The method in which the reach truck turns the vehicle while transporting product within the warehouse Terminal An electrical connection point on an electrical component.

Watt The unit of measurement of power. The amount of power used when one volt pushes one ampere of current through a resistance of one ohm. The result of amperes (current) multiplied by volts (voltage) is watts (power).

Travel Method in which the reach truck transports product within the warehouse.

Wire A conductor used to provide a path for current to flow to and from electrical components.

Varistor An electrical filter that eliminates voltage spikes when the mechanical horn is activated. Filter device is terminated across from the horn device.

Zener Diode A special diode used to regulate voltage or as an over voltage protector.

Volt The unit of measurement of electromotive force. One volt is the force needed to make one ampere of current flow through one ohm of resistance in a circuit.

Mitsubishi Forklift Trucks Reach Truck Serial Number Definition 2 SR 3 3 11 9 01

Serial Number Character

Definition

Defines Mast/Chassis Combination

Chassis Type

Voltage

Chassis MFG Year

Chassis Planned MFG Week

Chassis Family (Orion) Indicator

Chassis Sequence Within MFG Week

SR • Single Reach

2 • 24V

3 • 2003

11 • Week 11 7 • Orion

01 • 1st Build

DR • Deep Reach

3 • 36V

4 • 2004

Range 1 • 2.5K Standard 2 • 3K Standard 4 • 3.5K Standard 5 • 4K Standard 7 • 4.5K Standard

SS • Straddle

5 • 2005 6 • 2006 7 • 2007 8 • 2008

2-3

9 • Orion TC

(01-99)

GENERAL INFORMATION & FEATURES

General Overview

The Display Unit controller (Sicos) is the interface between the control handle and the controllers responsible for carrying out the request (See Figure 2.1). The Display Unit controller analyzes the information from the control handle along with the operator presence switches to determine if the request will be honored. Operating limits may occur if the reach vehicle enters a low battery state, a lift cut out has been reached or if the traction or lift motor has overheated. Other optional equipment may also limit the operation of the reach vehicle.

The general overview section is designed to give the technician a basic operational understanding of the vehicle. The following information pertains to how the operator requests a particular function and how the vehicle reacts. There are many internal and external safety checks that take place during vehicle operation. In the general overview section we are assuming the vehicle is powered up and has passed all safety checks.

Figure 2.1 Control System Overview (Standard Performance Vehicle Shown)

2-4

GENERAL INFORMATION & FEATURES

Communications

eling too slow. This feedback allows for the control system to maintain an exact speed regardless of whether the vehicle is empty or loaded. Travel speed is indicated to the operator through the Display Unit.

The vehicle has several “intelligent modules.” The modules are tied together for the means of communicating. It is commonly referred to as a Controller Area Network or CAN. Because there are several devices in the system communicating to the main module, the vehicle communications share a common “Bus”. The communications for the vehicle will be referred to as the “CAN Bus” system. Several messages may travel over the CAN Bus system at any given moment. The vehicle’s internal software will determine the message priority and respond accordingly.

(Refer to the operator display section of this manual for a full description of information provided by the operators display). This process will continue until the operator releases the handle or an alarm occurs forcing the traction controller to cease operation and apply the brakes. If while traveling the control handle is released to the neutral position, the vehicle electronics will react accordingly. The traction controller will reverse the phasing and slows or “plugs” the motion of the motor. The brake is applied once the traction con-

Travel A travel request begins with the battery plugged in, emergency disconnect raised, the key switch on and the operator depressing the operator presence pedal

NOTE The operational characteristics of the traction system can be modified. (Refer to the “programming through the handset” section of this manual for additional information).

NOTE If the control handle is engaged prior to the operator presence pedal becoming activated, the Display Unit controller will indicate to the operator incorrect start.

troller senses no movement from the traction speed encoder.

prior to requesting travel from the control handle. (See Figure 2.1). If the sequence is correct, the Display Unit controller will send a message over the CAN Bus to the traction controller for travel including direction and desired speed. Once the traction controller receives the message from the Display Unit controller indicating travel direction and speed it will also verify that the operator presence switch has been activated. (See Figure 2.1) Before engaging the drive motor the traction controller will need to release the electric brake. The traction controller through the electric steer controller (internal relay) and operator presence switch #2 powers the electric brake. Once the brake is released the traction controller will begin to pulse the traction motor. The duration of on time will increase or decrease depending on the feedback from the traction speed encoder. If the motor is traveling too fast the on time will decrease and vice versa if the motor is trav-

2-5

GENERAL INFORMATION & FEATURES

Lift

NOTE

A lift begins with the battery plugged in, emergency disconnect raised, and the key switch on. Depressing the operator presence pedal prior to requesting a lift or lower function is not required. (See Figure 2.1).

The CAN Bus is a noise immune two-wire communication line that allows the connection and communication between controllers.

The Display Unit controller will require the lift/lower potentiometer to be in the neutral position upon key up or an alarm will occur. Rotating the lift/lower potentiometer within the control handle to the lift position will indicate a request to lift. The Display Unit controller will then determine if there are constraints put on the vehicle such as a lift cut out or lift interrupt. If there are lift constraints, the operator display will indicate why the lift request is being ignored. If there are no lift constraints then the Display Unit controller will send the lift request along with a percentage of the maximum lift speed to the pump controller. Additional information will be sent via the CAN Bus to the valve controller to request the lift/lower solenoid be put in the lift position.

Lower A lower request begins with the battery plugged in, emergency disconnect raised, and the key switch on. Depressing the operator presence pedal prior to requesting a lift or lower function is not required. (See Figure 2.1). The Display Unit controller will require the lift/lower potentiometer to be in the neutral position upon key up or an alarm will occur. The Display Unit controller will gather this information and send a request to the valve controller to engage the lowering and load holding solenoid. The amount of voltage across the proportional valve will vary with the lowering rate requested and open the valve accordingly. The fluid flow through the proportional valve will control the lowering speed.

NOTE The CAN Bus is a noise immune two-wire communication line that allows the connection and communication of many controllers.

NOTE The lift/lower, load holding and proportional solenoids are located on the tractor manifold.

NOTE

The lift/lower solenoid is located on the tractor manifold. (See Figure 2.1)

The operational characteristics of the lift and lower system can be modified. Refer to section 7 of this manual for additional information.

The pump controller will then begin to pulse the lift motor through the three phases (U, V & W). Velocity is related to the width and frequency of the pulse being sent to the motor. The longer the on time the longer the current will flow through the motor. The duration of the on time will increase or decrease depending on the feedback from the lift speed encoder. If the motor is traveling too fast the on time will decrease and vice versa if the motor is traveling too slow. This feedback allows for the control system to maintain an exact speed regardless of whether the vehicle is empty or loaded. This process will continue until the operator releases the handle or an error occurs forcing the pump controller to cease operation.

2-6

GENERAL INFORMATION & FEATURES

Steering

Auxiliary Function:

The request to steer the vehicle originates from the steering wheel. The steering wheel is attached to a stepper motor. Manually rotating the steering wheel will generate a signal from the motor. The steer controller interprets this signal and determines the rate and direction of the steering request. If the Display Unit controller has not sent a message to the steer controller that the operator presence pedal has been depressed then the steer controller will not honor the steer request. Steer direction is indicated to the operator through the display. Refer to the operator display section of this manual for a full description of information provided by the operators display. The two proximity switches located in the drive unit are used to determine the location of the drive unit wheel. When both switches are engaged the drive unit is centered.

The request for an auxiliary function originates from the control handle. The information is gathered from the Display Unit controller and is distributed via the CAN Bus to both the valve and pump controller. Depressing the operator presence switch is not required for auxiliary functions. Auxiliary functions consisting of reaching, retracting, tilt up, tilt down, sideshift left, and sideshift right require the displacement of hydraulic fluid to the carriage. For this reason a pair of manifolds are mounted on the carriage. (See Figure 2.1) Carriage hydraulic manifold #1 directs the hydraulic fluid to the tilt cylinders. Carriage hydraulic manifold #2 directs the hydraulic fluid to either the reach or sideshift cylinders. The direction of the fluid used to tilt up or down, sideshift left or right, reach or retract is determined by the directional solenoids located on the tractor hydraulic manifold. A message from the Display Unit controller indicating an auxiliary request will engage the lift motor along with the required solenoids associated with the auxiliary func-

NOTE The operational characteristics of the steer system can be modified. Refer to section 5 of this manual for additional information.

NOTE The operational characteristics of the auxiliary system can be modified. Refer to section 7 of this manual for additional information.

tion. This system utilizes the lift motor and pump assembly to control lift and auxiliary requirements.

2-7

GENERAL INFORMATION & FEATURES

Jacking Truck Anytime the truck is jacked up for any reason, the service technician should take extra time and caution to ensure that the truck will not tip over or pose a hazard to himself or others.

Only jack in this area no more than 2 in. (50.8 mm) off the floor

Only jack this area no more than 0.5 in. (13 mm) off floor. Figure 2.2

The diagram illustrates the correct jacking points on the truck frame. Whenever the truck is jacked up, there should not be any load on the forks. The forks should be lowered all the way to the lowest possible point. Disconnect the battery and remove the key. Always use solid blocks to support the vehicle. Never rely on jacks or chains to hold the vehicle. When the truck is jacked up at the chassis-end of the vehicle, it should not be lifted more than two inches (50.8 mm) off the floor. When jacking on the side of the truck, the load wheels should not be lifted off the floor more than one-half inch (13 mm).

! WARNING

Attach a chain to the top of the mast and an overhead hoist to stabilize the mast if jacking higher than described in this procedure.

Before jacking truck, check the caster assembly. It should be securely in place. Make sure that the caster travel limiting bolts are properly adjusted.

2-8

GENERAL INFORMATION & FEATURES

Load Wheel Replacement Guide Load wheel replacement procedure for 4", 5" and 6" Diameter Wheels (See figures that follow): Jack the vehicle up. Removal: 1. Remove the M20 wheel plate mounting bolts, on closed (Straddle) front style wheel plates, remove the M12 bolt in front as well. 2. Carefully remove the sideplates and tandem wheels. 3. Using a driver, remove 2 of the spring pins from one side of the tandem joints, and remove it from the shafts.

Figure 2.3 Open Front Load Wheel Plates

4. Slide the plate, and two washers off from the shafts. 5. Remove the load wheel.

M12 Front Bolt

Installation: 1. Check to make sure there is one washer on each shaft prior to installing the replacement load wheels. Install replacement load wheels onto the shafts.

M20 Mounting Bolts

Figure 2.4 Closed (Straddle) Front Load Wheel Plates

2. Insert one more washer on each shaft. 3. Slide the plate and joint onto the shafts. 4. Insert the 2 spring pins. 5. Slide the wheel plate mounting bolts through one side of the plates, and insert them into the baseleg assemblies.

Washer

Spring pin

6. Carefully slide the tandem wheels and the other plate into position. 7. For closed front style vehicles, install the front bolt loosely then on both types, torque the sideplate mounting bolts to 550 [Nm](405.66 ft.lbs.). If equipped, tighten the front bolt to [80 Nm] (59 ft.lbs.).

Joint

Plate

Figure 2.5 Tandem wheel assembly

2-9

GENERAL INFORMATION & FEATURES

Load Wheel Replacement Procedure for 10.5" Diameter Wheels (See Figure 2.6): Jack the vehicle up.

! CAUTION Use extreme care whenever the truck is jacked up for any reason. Never block the truck between the telescopic mast and the floor. Use a suitable hoist to stabilize the mast. Keep hands and feet clear from beneath vehicle while jacking. Use jack stands or solid blocks to support truck do not rely on jacks.

Removal: 1. Remove the M20 wheel plate mounting bolts. 2. Carefully remove the sideplates and wheel. Installation: 1. Slide the wheel plate mounting bolts through one side of the plates, and insert them into the baseleg assemblies. 2. Carefully slide the wheel and the other plate into position. 3. Torque the sideplate mounting bolts to 550 [Nm}(405.66 ft.lbs.).

1. Caster wheel load setting Adjustment can be done by hook wrench with nose end DIN 1810 A (size 58-62). Rocla item number is RL472467.

M20 Mounting Bolts Seal

Shaft

•

More load to caster wheel—turn adjustment nut to + direction

•

Less load to caster wheel—turn adjustment nut to – direction

Bearing Ring Screw

Retainer

Figure 2.6 10.5" Diameter Wheel Assembly

Spring Load Setting

Caster Adjustment NOTE Caster height adjustment differs, depending upon the mast on the truck. Refer to the following for caster height adjustment instructions. All adjustments should be done with the rated capacity battery installed and on a level surface.

1/2"

•

2-10

Adjust nut 1/2" for top and bottom bolt for a total 1" deflection of caster assembly.

GENERAL INFORMATION & FEATURES

Brake Assembly Inspection and Adjustment Inspections a. Friction disc thickness: 1. Measure the Figure 2.7)

disc

thickness

(See

2. Minimum thickness is 8.0 mm (5/16 inch).

Figure 2.7

3. If necessary, replace the friction disc. b. Air gap (See Figure 2.8) brake applied 1. Measure the air gap between the armature plate and stator using a feeler gauge

Friction Disk Min. Air Gap

Torque

8.0 mm

0.3–0.4 mm

23.0 (Nm) 31.4 ohms

5/16 inch

(.012–.016) inches 17 ft. lbs.

2. Air gap should be 0.3–0.4 mm (.012–.016 inch).

Adjustment Of Air Gap (See Figure 2.8) Brake Applied 1. Unbolt screws (10) 2. Slightly turn threaded sleeve (9). •

If the air gap is too large, screw them into the stator (7).

•

If the air gap is too small, screw them out of the stator (7).

•

1/6 turn changes the air gap by approx. 0.15 mm (.006 inch) Figure 2.8

3. Tighten screws (10) 9.2 (N•m) 6.78 ft. lbs. 4. Check air gap again and if necessary, repeat the adjustment.

Friction Disc Replacement 1. Loosen the screws (10) evenly and remove them. 2. Remove the stator (7) from the endshield. 3. Pull friction disc from hub. 4. Check hub splining, if it is worn it must be replaced. 5. Install the new disc and adjust the brake.

2-11

Coil Resistance

GENERAL INFORMATION & FEATURES

Transmission

2-12

GENERAL INFORMATION & FEATURES

ITEM

DESCRIPTION

BEARING

GEAR WHEEL

BEARING

CIRCLIP

SEAL

SCREW

PAD

BEARING

RING

PLATE

FITTING RING

O-RING

PLUG

SEAL

PLATE

SCREW

COVER

GEAR WHEEL

FITTING RING

BUSH

FITTING RING

CHASSIS

BEARING

NUT

O-RING

GEAR WHEEL

SCREW

NOTES

SECURE WITH LOCTITE 307 AND CAULK

SECURE WITH LOCTITE 243 AND TORQUE TO 97 FT/LBS

SECURE INNER RING WITH LOCTITE 620

SECURE WITH LOCTITE 243 AND TORQUE TO 207 FT/LBS

2-13

THEORY OF OPERATIONS Solenoid Activation Chart ............................................................................

3-1

Main Hydraulic Manifold...............................................................................

3-1

Theory of Operation ..................................................................................... 3-2 Plugging in the Battery ............................................................................... 3-2 B+ Feed to .................................................................................................. 3-2 B-Feed to .................................................................................................... 3-2 Additional Safety Circuit (Emergency Power Off)........................................ 3-2 Turning Key Switch (S2) On........................................................................ 3-2 Can Bus Communication ............................................................................ 3-3 Stepping on the Operator Presence Pedal ................................................. 3-3 Steer Request............................................................................................. 3-3 Electric Steer Controller “APS” ................................................................... 3-4 Travel Request ............................................................................................ 3-4 Plugging Request ....................................................................................... 3-6 Regenerative Braking ................................................................................. 3-6 Lift / Lower Request.................................................................................... 3-6 Lift Activation .............................................................................................. 3-7 Lower Activation.......................................................................................... 3-7 Auxiliary Functions...................................................................................... 3-7 Tilt Request ................................................................................................ 3-8 Tilt Activation .............................................................................................. 3-8 Reach / Retract Request ............................................................................ 3-8 Sideshift Request........................................................................................ 3-8 Reach / Retract and Sideshift Activation..................................................... 3-8 Reach / Retract Activation .......................................................................... 3-8 Sideshift Activation ..................................................................................... 3-8 Lift Pressure Adjustment............................................................................. 3-9 Max. Lowering Speed Adjustment (Mechanical) ......................................... 3-9 Emergency Lowering .................................................................................. 3-10 Electrical Lowering Speed Adjustment ....................................................... 3-10

THEORY OF OPERATIONS

Solenoid/Valve Activation Chart Valve / Solenoid

Lift

Function

Lower

S10

X X

Tilt Up

Tilt Down

Reach

Retract

Sideshift Left

Sideshift Right

Table 3.1

NOTE All functions other than the lower function will require the pump motor to be engaged. Also M1 is the only valve (proportional) that the on time will vary, this will vary depending on the lowering speed requested.

Figure 3.1

3-1

THEORY OF OPERATIONS

Additional Safety Circuit (Emergency Power Off)

Theory of Operation Every connection will not be addressed in the theory of operation. To troubleshoot a particular component you will need to locate the component on the schematic, and check the circuitry associated with it. You will need to have the schematic handy as a reference while reading the text.

If the emergency power off switch is in the normally closed position B+ will continue to flow to the key switch (S2). B+ will also flow to the main power contactor K11 (K11-1). Should at any time the operator need to remove power to the system, the emergency power off switch may be depressed. With the switch depressed (down), the normally closed switch will open and remove B+ from the main contactor coil (K11).

Plugging In the Battery Upon plugging in the battery, B+ will flow through connector X12:1 To the contactor connections and fuses listed. From the fuses it will feed several areas of the vehicle. It will also go to the emergency power off switch.

Turning Key Switch (S2) ON Refer to Schematic in Electrical Section Upon turning on the key switch (S2) B+ will flow to the Traction Motor Controller and to the B+ terminal of the K11 coil. This will cause the energizing of the K11 contactor. B+ will now feed to the K12 contactor tip. B+ will also flow to the control fuses 10F1 and 11F1 which feed B+ to the other controllers.

B+ Feed to Component(s) 1F1 Fuse 3F1 Fuse

The individual controllers Display, Pump Controller, 2nd Pump Controller, Electric Steer Controller, and Traction Controller will begin their internal checks to verify all internal hardware is functioning properly. After all internal checks have passed the following controllers will engage their respective safety circuits.

K11 Contactor K11 Relay Pin 4 S1 Emergency Disconnect B- will connect to several fuses, several motor controllers, the horn, the strobe light, the steering feedback sensor, and to optional features such as the fan as listed:

The vehicle Controller Area Network (see CAN Bus communication on next page) will now be operational and the controllers will communicate status and fault conditions.

B- Feed to

If everything checks out ok, the logics unit will activate the K12 contactor coil and the K12 contactor tips will provide B+ to the power fuses for the motor controllers.

Component(s) 1F2 3F2

Should an error occur causing the K12 contactor to become de-energized, all power to the three AC motors (Traction Motor, Pump Motor and Electric Steer Motor) will be removed.

Connection (Reference Feed To Controllers) Cold Storage Option Connection Connection 12F2 Fuse

3-2

THEORY OF OPERATIONS

CAN Bus Communication

Steer Request

CAN stands for Controller Area Network. CAN is a communication protocol developed for “noisy” environments. A CAN uses two digital signal lines referred to as Bus+ and Bus-. The CAN Bus technology allows for easy expansion of additional equipment so long as they are CAN ready. The only method of determining the functionality of the CAN Bus is with an oscilloscope. Both the Bus+ and Bus- signals will remain at 2.5v until a message is sent. The message is very short in time duration therefore making it very difficult to monitor utilizing a digital voltmeter. All controllers or “nodes” connected to the bus have the ability of communicating with each other.

Refer to Schematic in Electrical Section. Prior to a steer request being accepted, the battery must be plugged into the truck, the emergency power off switch must be raised, the key switch must be turned on and the control system must have passed self-test. If all internal checks pass the electric steer controller will close the contacts of the internal relay. The contacts will exit the Steer Motor Controller on connector XA3_1 Pin 21. Once the operator presence switch is depressed the Display Unit controller will send a message on the CAN Bus notifying all controllers attached to the bus that the operator presence switch has been depressed. The Steer Motor Controller will then gather information from the steer wheel sensor. As the steering wheel is rotated, the steering wheel motor will generate a sinusoidal wave through connector X11 pins 1,3, 4 and 6. The signals from the steering wheel motor will terminate at the steer controller connector XA3_1 pins 10 and 11. The amplitude and frequency of these signals will increase the faster the steering wheel is turned. See Figure 3.2 below.

The communication connections are shown on the schematic. The connections used for communications are run as a twisted pair to help reduce “noise”. There is also a terminating resistor at the beginning and the end of the communication loop.

Stepping on the Operator Presence Pedal Upon stepping on the operators presence pedal, two switches located underneath the pedal will be activated. S11 will apply B+ to the electric brake coil. The brake coil activation will now be controlled by the Steering Motor Controller and Logics Unit

Steering Motor

S12 will apply B+ to the Logics Unit which is used to determine the status of the Operator Presence Switch.

Figure 3.2 Sinusoidal Output from Steering Wheel Motor

3-3

THEORY OF OPERATIONS

Electric Steer Controller “APS”

Travel Request

The Electric Steer Controller determines which direction the operator wishes to steer by comparing the signals from the steering wheel motor. The channels from the steering wheel motor will be out of phase from each other. Depending on which signal is leading or lagging will determine which direction the operator is requesting. The aggressiveness of the steering will be determined through the amplitude and frequency of the signal coming from the steering wheel motor.

Refer to Schematic in Electrical Section Prior to a travel request being accepted, the battery must be plugged into the truck, the emergency power off switch must be closed, the key switch must be turned on and the control system must have passed self-test. The travel request comes from traction sensor B21 within the control handle. The 5V supply for the traction sensor comes from the Logics Unit at connector XA5_1/26. The ground will be supplied through the Logics Unit connector XA5_1/25. The wiper or varying voltage will be an input to the Logics Unit at XA5_1/2. In the neutral position, the voltage at the wiper of the sensor will be nominally 2.5V. As the control handle is moved in the tractor forward direction, the voltage on the traction sensor should gradually increase to nominal value of 4.5V. As the control handle is moved in the forks first direction, the voltage on the sensor should gradually decrease to a nominal value of 0.5V.

After the request for steering has been accepted, the Electric Steer Controller will begin to pulse the three separate inputs (U, V, W) of the AC steer motor. Depending on the frequency and duty cycle, the steer motor controller can vary the speed of the steer motor. (See Figure 3.5) The outputs (U, V, W) from the steer motor controller are pulsed with both a positive and negative voltage. Figure 3.3 shows the varying duty cycle along with the positive and negative values. The actual current passing through the motor will be more sinusoidal than pulsed do to the characteristics of an inductor

The Logics Unit will gather the information from the wiper of the traction sensor many times per seconds. As the voltage from the wiper of the traction sensor increases or decreases in voltage above the nominal neutral value of 2.5V, the Logics Unit will distribute this information as a message over the CAN Bus. All controllers attached to the bus decode the message. When the Traction Motor Controller receives a message from the Logics Unit for a travel request, it will first check the operator presence input at connector XA5_1/30 for 0V. If 0V is present at this input and there are no internal errors with the Traction Motor Controller. It will accept the request.

NOTE The characteristics of the steering can be adjusted using the laptop or service mode. Refer to Section 5 of this manual for additional information.

Before engaging the drive motor the Logics Unit will need to release the electric brake. Once the brake is released the Traction Motor Controller will begin to pulse the traction motor. through the three phases (U, V & W). Since the forklift truck gets its power from a DC battery the Traction Motor Controller must convert the DC to AC in order to satisfy the AC motor requirements. This is accomplished internal to the Traction Motor Controller via a process known as inverting. By applying three inputs out of phase a voltage drop is created between the three phases. Depending on which phase is leading or lagging will determine which direction the motor will rotate. 3-4

THEORY OF OPERATIONS

Velocity is related to the width and frequency of the pulse being sent to the motor. The longer the on time the longer the current will flow through the motor. The duration of on time will increase or decrease depending on the feedback from the traction speed encoder (B31). If the motor is traveling too fast the on time will decrease and vice versa if the motor is traveling too slow. This feedback allows for the control system to maintain an exact speed regardless of whether the vehicle is empty or loaded. Travel speed is indicated to the operator through the Display Unit. Refer to the operator display section of this manual for a full description of information provided by the operators display. This process will continue until the operator releases the handle or an alarm occurs forcing the Traction Motor Controller to cease operation and apply the brakes. If there are no alarms then the Traction Motor Controller will reverse the phasing and slow or “plug” the motion of the motor. The brake is applied once the Traction Motor Controller senses no movement from the traction speed encoder.

NOTE The Diagnozer allows for adjusting the vehicle’s top travel speeds. The encoder plugs into the Traction Motor Controller at connector XA1_2 on pins 5, 6, 7 and 19. Refer to electrical schematic. Pin 5 is the 12V supply. Pin 19 is the ground. Pin 7 is channel A and Pin 6 is channel B. Figure 3.4 shows the pulse from channel A and B and their phase orientation to each other.

Figure 3.4 Traction encoder pulses (Channel A and B)

The Traction Motor Controller determines speed of the motor by counting the number of pulses from a single channel over a certain time period. The faster the motor turns, the more pulses will be generated for that time period. Determining the direction of the drive motor is accomplished by comparing channel A to channel B. The direction in which the motor is turning will determine which channel is leading and which channel is lagging. If we refer back to Figure 3.4 channel A is leading and channel B is lagging. Channel A is leading because it rises before channel B does. The two channels are 90 degrees out of phase thus allowing for the comparison of the two channels. If the motor were to rotate in the opposite direction then channel B would rise prior to channel A d.

After the request for travel has been accepted, the Traction Motor Controller will begin to pulse the three separate inputs (U, V, W) of the AC drive motor. Depending on the frequency and duty cycle, the Traction Motor Controller can vary the speed of the drive motor. The outputs (U, V, W) from the Traction Motor Controller are pulsed with both a positive and negative voltage. Figure 3.3 shows the varying duty cycle along with the positive and negative values. The actual current passing through the motor will be more sinusoidal than pulsed do to the characteristics of an inductor.

A temperature sensor is located in the drive motor. The sensor for the drive motor enters the Traction Motor Controller on connector XA1_2 at pins 1 and 2. The temperature sensor is nominally 600 ohms at room temperature. Figure 3.3 Width modulation of the AC Drive Motor

The Traction Motor Controller determines the speed and direction of the motor through the pulses sent from the traction speed encoder (B31) mounted within the motor. 3-5

THEORY OF OPERATIONS

Plugging Request

Lift\Lower Request

After the travel request has been accepted and the Traction Motor Controller applies power to the AC drive motor the operator may wish to slow the vehicle motion through a plug. Plugging is accomplished by reversing the position of the control handle. Refer to TRAVEL REQUEST within this section of the manual for pin locations of the handle. If there are no errors associated with the control system and the operator presence switch is still engaged the Traction Motor Controller will accept the request to plug the vehicle. Plugging is accomplished through the Traction Motor Controller by reversing the phase of two of the three motor inputs (U, V, W) Reversing the phase with two of the three inputs will force the motor to turn in the opposite direction. During a plug request the reversing of phase between two inputs will initially retard the motion until the vehicle comes to a rest. If the request continues after the vehicle has come to rest the motor will begin to turn in the opposite direction.

The request for lift or lower originates from the sensor module (R13) within the control handle. Within the sensor module is an internal sensor that will be able to determine movement from the neutral position. The internal sensor status will exit the control handle at X14A/8 and be an input to the Logics Unit at XA5_1/22. The sensor will exit the control handle at connector X14/4, X14A/5 and X14A/6. The 5V supply at for the lift potentiometer comes from the logics unit at connector XA5_1/26. The ground will be supplied through the Logics unit at connector XA5_1/25. The wiper or the varying voltage will be an input to the Logics Unit at XA5_1/27. In the neutral position, the voltage at the wiper of the potentiometer will be approximately 2.5V. As the control handle is moved to the left (Lower Request), the voltage on the lift/lower potentiometer should gradually increase to a nominal value of 4.5V at full lower speed request. As the control handle is moved to the right (Lift Request), the voltage on the lift/lower potentiometer should gradually decrease to a nominal value of 0.5V at full lift request.

NOTE Diagnozer allows for adjusting of the plugging characteristics.

The Logics Unit will gather the information from the wiper of the lift/lower potentiometer many times per second. As the voltage from the wiper of the lift/lower potentiometer increases or decreases in voltage above the neutral value of approximately 2.5V, the Logics Unit will distribute this information as a message over the CAN bus which would include request for lift or lower and the velocity associated with it. All controllers attached to the bus decode the message.

Regenerative Braking Regenerative braking occurs during the plugging cycle. This is sometimes referred to as inverse braking. When the drive motor is turning in the opposite direction of the way the motor is being controlled, the motor is producing AC voltage on each phase through the rectifier diodes turning the voltage to DC positive and negative. As long as the voltage is higher than battery voltage, the charging procedure continues.

Figure 3.5 Regenerative Braking 3-6

THEORY OF OPERATIONS

Lift Activation

Lower Activation

Prior to a lift request being accepted, the battery must be plugged into the truck, the emergency power off switch must be raised, the key switch must be turned on and the control system must have passed self-test. When the pump controller receives a message from the Logics Unit for a lift request, it will first check for internal errors. If there are no internal errors or other limiting factors like lift cut out due to a low battery or an activated lift limit switch or lifting being limited by the optional height selector then the lift request will be accepted. The Valve Controller, will control the solenoids used for the hydraulic functions.

The request and rate of lowering will be transmitted by the Logics Unit over the CAN Bus to the Valve Controller. The Valve Controller will activate the lowering proportional valve (m2) at pin XA4_1/22 and cause the lift/lower spool to be moved to the lower position. The amount of time that the valve is on will determine the amount the valve is open and the amount of fluid allowed exiting the lift cylinders to control the vehicle lowering speed. There are mechanical adjustments of the hydraulic manifold to control the maximum lowering speed called out in this section. There is also an electrical adjustment of the lowering function that is described in the Electric Lowering Speed Adjustment.

After the request for lift has been accepted, the pump controller will begin to pulse the three separate inputs (U, V, W) of the AC lift motor. Depending on the frequency and duty cycle, the pump controller can vary the speed of the lift motor. (See Figure 3.3). The outputs (U, V, W) from the pump controller are pulsed with both a positive and negative voltage. Figure 3.3 shows the varying duty cycle along with the positive and negative values. The actual current passing through the motor will be more sinusoidal than pulsed do to the characteristics of an inductor.

See mast section regarding the lift cylinder operation.

Auxiliary Functions The Logics Unit will gather the information from the handle assembly micro switches. All auxiliary functions (Reach/Retract, Tilt Up/Down, Sideshift Left/Right) use the pump motor to supply fluid to the various cylinders. The vehicle has the capability of programming the auxiliary functions speed. The main hydraulic manifold incorporates flow restrictors to reduce the volume of oil flow to the auxiliary system and also contains the auxiliary function directional solenoids (m3 and m4). The manifold is located under the floor of the operator’s compartment. The vehicle is also equipped with a reach/retract and sideshift select manifold located on the mast, it includes a pilot operated counter balance check valves for the reach cylinders, and the solenoids used to route fluid to the reach/retract and sideshift functions. Listed as Table 3.1 is a chart that will show the various solenoids activated for a particular function.

At the same time the lift motor is pulsed the m2 solenoid will be activated by the Valve Controller (RI01 at pin XA4_1/22 causing the lift lower spool to move to the lift position. As the pump motor rotates hydraulic fluid is delivered to the lifting cylinders through the lift valve. (See Hydraulic Schematic). See mast section regarding the lift cylinder operation. Performance vehicles are equipped with a second pump and motor assembly and an additional controller. When a lift function is requested A2 is starting the lift until 90% of the lift pot change is activated and from 90–100% the A3 is assisting the lift function.

The Logics Unit is used to activate the relays that control solenoids to properly route the hydraulic fluid. When the Logics Unit receives a message from the handle controller for an auxiliary request, it will first check for internal errors. If there are no internal errors or other limiting factors then the request will be accepted.

NOTE Location of the hydraulic manifold used for both lifting and lowering functions is located under the floor panel of the operator’s compartment.

3-7

THEORY OF OPERATIONS

Tilt Request

Reach/Retract and Sideshift Activation

The tilt request comes from the micro switches within the control handle. The tilt up (S16) micro switch will exit the control handle at connector X14B/6 and go to pin XA5_1/41 of the Logics Unit, the tilt down (S17) micro switch will exit the control handle at X14B/7 and go to pin XA5_1/40 of the Logics Unit.

After the request for the reach/retract or sides shift has been accepted, the pump controller will begin to pulse the three separate inputs (U, V, W) of the AC lift motor. Depending on the frequency and duty cycle, the pump controller can vary the speed of the lift motor. The outputs (U, V, W) from the pump controller are pulsed with both a positive and negative voltage. Figure 3.3 shows the varying duty cycle along with the positive and negative values. The actual current passing through the motor will be more sinusoidal than pulsed due to the characteristics of an inductor

Tilt Activation After the request for the tilt has been accepted, the pump controller will begin to pulse the three separate inputs (U, V, W) of the AC lift motor. Depending on the frequency and duty cycle, the pump controller can vary the speed of the lift motor. The outputs (U, V, W) from the pump controller are pulsed with both a positive and negative voltage. Figure 3.3 shows the varying duty cycle along with the positive and negative values. The actual current passing through the motor will be more sinusoidal than pulsed due to the characteristics of an inductor

The directional valve in the main hydraulic manifold is used to determine whether a reach/retract or sideshift left/right will occur. The control for these solenoids at the Logics Unit are at connector XA4_1/24 m3 (Reach, Sideshift Left) and XA4_1/25 m4 (Retract, Sideshift Right).

Reach/Retract Activation

The directional valve in the main hydraulic manifold is used to determine whether a tilt up or tilt down will occur.

In addition to the m3 and m4 valve being activated S5 and S6 must be energized in order to divert the hydraulic fluid from the tilt cylinder. The Logics Unit will activate the relay that controls these solenoids using pin XA5_1/60.

Reach/Retract Request The reach request comes from the micro switch (S14) within the control handle. The reach switch (S14) signal will exit the control handle at connector X14B/4. The retract request comes from the micro switch (S15) within the control handle. The retract switch (S15) signal will exit the control handle at connector X14B/5.

Sideshift Activation In addition to the m3 and m4 valve being activated S9 and S10 must be energized in order to divert the hydraulic fluid from the tilt cylinder. The Logics Unit will activate the relay that controls these solenoids using pin XA5_1/61. Also S7 and S8 must be energized to direct the flow to the sideshift cylinder. The Logics Unit will activate the relay that controls these solenoids using pin XA5_1/62.

Sideshift Request The sideshift request comes from the micro switches within the control handle The sideshift left (S18) micro switch signal will exit the control handle at connector X14B/8 and go to pin XA5_1/36 of the Logics Unit and sideshift right (S19) micro switch signal will exit the control handle at connector X14B/9 and go to pin XA5_1/37 of the Logics Unit.

3-8

THEORY OF OPERATIONS

Lift Pressure Adjustment

Maximum Lowering Speed Adjustment (Mechanical)

! CAUTION

1. Make sure parameters for the lowering speeds are properly set!

Turn the key switch OFF and disconnect the battery connector before working on lift system connections.

2. Choose performance mode IV from the display. 3. Lift forks to top maximum position without load.

Make sure that forks are in down position and there is no pressure in the lift cylinders.

4. Measure the lowering time (in seconds) from top till forks in down position with max. lowering speed. (Let’s call this measurement one.) 5. Loosen the lowering speed valve locknut and back-out the screw two full turns.

1. Install a calibrated pressure gauge (5000 psi [34,470 kPa]) in the lift pressure test port (AS).

6. Repeat point 4 action.

2. Loosen the relief valve locknut and back-out the high-pressure relief-valve screw.

7. Compare the lowering time with the original one, if the new lowering time is longer go to point 8. If the lowering time isn’t longer, repeat actions 5. and 6. until the result is longer than the original time.

8. Now tighten the lowering speed valve screw two full turns, repeat point 4 action. Compare the lowering time with the original one, if the new lowering time is longer Repeat point 8 action. If the new lowering time is equal to original one, you are close to the final result and have to tighten the lock nut.

6. Adjust the pressure relief valve to a pressure 100 to 300 psi (689.4 to 2068 kPa) greater than the values observed in step 5. This can be done by chaining the mast sections together or adding more weight to the forks.

9. Check the lowering system for proper operation. This adjustment has now been carried out to make sure that the electrical and hydraulic functions are in balance with each other and the system is working properly.

7. After the adjustment is complete, tighten the relief valve locknut. 8. Check the pressure again. If the value has changed, repeat this procedure until the correct pressure is obtained. 9. Turn the key switch OFF. Disconnect the battery connector. 10. Remove the pressure gauge from the lift pressure test port and replace the cap screw. 11. Check the lift system for proper operation.

3-9

THEORY OF OPERATIONS

Emergency Lowering 1. Slowly rotate the emergency lowering valve screw clockwise until the forks lower. Once the forks start lowering, don’t attempt to increase the lowering speed by turning the valve screw further. If the screw is rotated too deeply into the valve, it can cause external leakage to occur. Rotating the screw too far inward will cause the screw to pass the sealing O-ring. Slight leakage of hydraulic fluid through the threads will eventually empty the outer housing. 2. After lowering, rotate the emergency valve screw counterclockwise. Do not turn too far counterclockwise because the same leakage problem may occur as in the lowering action.

Electrical Lowering Speed Adjustment Handset operation is required. Refer to Section #5 Settings and Programming. 1. Connect the handset to SICOS-display and navigate to MHYRIO-unit. Enter PARAMETER CHANGE menu and find MAX LOWER parameter. Adjust this parameter as high as possible (above 200) in order not to disturb mechanical adjustment of maximum lowering speed. 2. Take maximum load on the forks; adjust the maximum lowering speed with adjustment bolt A (see picture above). Write down the speed value (1) 3. Adjust MAX LOWER parameter downward 5 steps per attempt until the maximum lowering speed begins to decrease (lowering speed is now limited electrically and is below mechanical adjustment level as done in point 2). 4. Adjust MAX LOWER parameter upward 1–2 steps per attempt to find out the exact parameter value that changes the maximum lowering speed. 5. After finding the exact value increase MAX LOWER value 4 steps upward (e.g., if the exact value is 178, increase MAX LOWER value to 182). Write down the speed value (2). Compare recorded values (1) and (2), they should be the same. 6. IMPORTANT!!! ELECTRICALLY ADJUSTED MAXIMUM LOWER SPEED MUST NOT BE SET BELOW MECHANICALLY ADJUSTED SPEED otherwise forks may start to bounce because there is no pressure compensation.

Parameter name Parameter location

3-10

MAX LOWER MHYRIO//MAIN MENU / PARAMETER CHANGE

OPERATOR DISPLAY Operator Display ...........................................................................................

4-1

4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-3 4-3 4-3

Turn KEY On..................................................................................................

4-4

Under General Settings ................................................................................

4-4

History Folder ...............................................................................................

4-5

Shelf Height (Option) ....................................................................................

4-5

To Change Self Height Option .....................................................................

4-6

Mode of Operation (Performance Modes I, II, III and IV) ............................

4-6

Thermal Monitoring ......................................................................................

4-7

SelfTest ..........................................................................................................

4-7

Operation Hours............................................................................................

4-7

Battery State of Charge ................................................................................

4-7

OPERATOR DISPLAY

Operator Display The Operator Display is the control systems method of communicating to the operator. The display is an LCD (Liquid Crystal Display) and will not be visible in extreme cold environments. In cold extreme environments, the vehicle should be equipped with the appropriate cold storage package. Below is a picture of the operator display along with description of the individual component icons.

Operator Display

4-1

OPERATOR DISPLAY

General Information

7.1 mph 1

Mode 1

1. ESC (Escape) Button • •

1. Battery State-of-Charge

To exit from a menu or to return to the main operation menu.

Battery charge level which is indicated as a percentage of total charge.

To gain access to the “text messaging” screen.

2. Parking Brake The letter “P” illuminates here when the parking brake is engaged.

2. Scroll Left Button •

To scroll left within a specific menu.

3. Clock 12 hour or 24 hour clock.

3. Scroll Up Button •

To scroll up within a specific menu or increase the value of a selected object within a setting.

4. Mode of Operation (Optional) The vehicle has performance modes of operation (I, II, III and IV), selected via the buttons located below the display.

4. Scroll Down Button •

To scroll down within a specific menu or decrease the value of a selected object within a setting.

5. Travel Direction Indication of steering direction of truck when traction request is chosen via the Control Handle.

5. Scroll Right Button •

6. Travel Speed Indicator

To scroll right within a specific menu.

Indication of travel speed during traction. Either MPH or KPH can be selected.

6. Enter Key •

Used to confirm settings or move to different screens. NOTE

No password required unless equipped with a keyless entry option. 4-2

OPERATOR DISPLAY

pm /M E S S A G E C E N T E R OPP Hours: Next Service

Warning Alarm

Truck App. xxxxxx, A Display App. yyyyyy, A

01200 01500

No Direction No Alarms

lbs

Code 60 Code 0

Mode 1

9. Load Weight Display (Option)

7. Text Messaging Text messages such as operator warnings, service hours, alarm codes and status reports will be displayed in the Message Center box. Languages available are English, French, Spanish or Portuguese.

/H E I G H T P R E S E L E C T / U N L O A D E D

180

200

0 180

Current 180 inch Selected 0 inch

Current Height Selected Height

0 180

Teach Height

8. Shelf Selector (Option) •

Indicates shelf level (1 through 30).

•

Level number chosen will be highlighted.

•

When chosen, the icon will indicate which level has been selected.

•

Selected Height indicates that “loaded” height level has been selected.

•

Each program must be programmed prior to use.

•

Requires lift height indicator option.

4-3

•

Estimation of load on forks.

•

Accurate to within +/- 50 kgs (110 lbs).

•

Estimation is used as a reference tool and is not legal for trade.

OPERATOR DISPLAY

Turn KEY On

Under General Settings

For General Information Select

Clock pm

12 hour or 24 hour clock

7.1 mph

Units Metric or Imperial

Mode 1

Language English, Portuguese, French, Spanish pm

Press General Settings Histor y Folder

This takes you to the next screen: Clock Units Language

General Settings History Folder

METRIC ENG

Use the arrow buttons to select the option

MM/DD/YY

General Settings Histor y Folder

Press

4-4

HH:MM

12h

OPERATOR DISPLAY

History Folder

Shelf Height (Option)

Displays the last code or warning encountered by the truck

NOTE

BDI

This option works only above the free lift height.

Pump Hrs Traction Hrs To adjust fork height

Use the arrow key to select option

General Settings Histor y Folder

lbs pm

Alarm

Code Alarm Time BDI Hours Traction Hours Pump Hours

68 Output Unit Fault 12/31/08 02:20PM 06 00380 00200 00120

Mode 1

Press

<NEXT>

The screen (Height Pre-select Unloaded) with various preset heights appears. The operator can select the desired preset height by using the arrow buttons. The operator has to be in that screen and the desired height should be selected for this function to work. The shelf selector works for lifting and lowering the forks. pm

/H E I G H T P R E S E L E C T / U N L O A D E D 180

200

0 180

Current 180 inch Selected 0 inch

Current Height Selected Height Teach Height

4-5

0 180

OPERATOR DISPLAY

To Change the Shelf Height Use the arrow key to select option

Mode of Operation (Performance Modes I, II, III and IV)

. pm

The vehicle has performance modes of operation (I, II, III and IV), selected via the buttons located below the display.

7.1 mph

To select mode of operation

Mode 1

Use the arrow key to select option MODE 1 Press

Press

The screen (Height Pre-Select Unloaded) with various presets appears.

7.1 mph

Mode 1

/H E I G H T P R E S E L E C T / U N L O A D E D 180

200

0 180

Use the arrow keys to select the mode Press

0 Current 180 inch Selected 0 inch

Press The screen Height Pre-select/Setup appears. Using the arrow buttons, select Teach Height Then raise the forks to the desired height. pm

Current Height Selected Height

0 180

Teach Height

Press The height changes on the Height Pre-Select Unloaded screen. The setup can be changed in operator, manager and service mode

4-6

OPERATOR DISPLAY

Thermal Monitoring The truck is equipped with thermal monitoring of the drive pump and speed controls. When a controller or motor reaches a specific temperature, it slows the function down, but does not disable the function. A text message will be displayed in the text message box. Drive the truck slowly to a place where it will be out of the way and not pose a danger to others. If a second thermal limit is reached, it will disable the truck. A text message will be displayed in the text message box. The reason for overheating must be found before the truck is driven again.

SelfTest SelfTest occurs whenever the key switch is turned ON. SelfTest checks all electrical components and circuits. If a problem is detected, a fault code is displayed. SelfTest lasts for a few seconds and when “Battery State-of-Charge” appears the truck is ready for operation. During SelfTest, you will hear the contactor’s clicking.

Operation Hours To allow the Operator Display to show the hour meter, switch off the key, wait 5 seconds and switch on the key. The hour meter reading will be shown for a short time. Hour meter is displayed momentarily when Key Switch is turned on.

Battery State-of-Charge Battery State-of-Charge shows the energy which remains in the battery, based on voltage readings. The value displayed is the percentage of useable energy. Fluctuations will occur during normal operation. When there is only 20% energy left, a battery warning symbol is shown in the display. After this it is possible to drive approximately 1/2 hour before an alarm is shown and lift cut-out occurs.

4-7

5-1 5-1 5-1 5-1

5-2 5-2 5-2 5-2 5-2 5-2

Display Parameters Pre-Height Selection ................................................................................... How to Activate the “Pre-select Shelf Height Setting” Function ............... Mode Change ............................................................................................. How to Change the “Mode Change” Function .......................................... Height Display *Service Mode Only*........................................................... How to Activate the “Height Display” Function ......................................... Weight Display *Service Mode Only* .......................................................... How to Activate the “Weight Display” Function ........................................ LCD Contrast .............................................................................................. How to Change “LCD Contrast” ............................................................... LCD Heater................................................................................................. How to Activate the “LCD Heater Control” Function................................. Keyless Entry “Pin Code” *Service Mode Only* .......................................... How to Activate the “Keyless Entry” Function .......................................... Truck Parameters *Service Mode Only*...................................................... How to Access “Truck Parameters ........................................................... BDI Curve............................................................................................. BDI Timer ............................................................................................. BDI Reset ............................................................................................. Low Batt ............................................................................................... Maintenance Warning........................................................................... Stand-by-Timer..................................................................................... Travel Alarm ......................................................................................... Max Speed Fwd ................................................................................... Max Speed Bwd ................................................................................... Release Braking ................................................................................... Inverse Braking..................................................................................... Steer Sensitivity.................................................................................... Forward Steering .................................................................................. Lower Stop / Batt Lock ......................................................................... Cutback Linear .....................................................................................

5-3 5-3 5-4 5-4 5-5 5-5 5-6 5-6 5-7 5-7 5-8 5-8 5-9 5-9 5-10 5-10 5-11 5-11 5-11 5-11 5-11 5-11 5-11 5-11 5-12 5-12 5-12 5-12 5-12 5-12 5-12

Cutback 1 Speed .................................................................................. Cutback 2 Height / Cutback 2 Speed ................................................... Cutback 3 Height / Cutback 3 Speed ................................................... PreSensor Low ..................................................................................... PreSensor Low ..................................................................................... Real Load Weight ................................................................................. Max Lift................................................................................................. FreeLift ................................................................................................. LiftLimit ................................................................................................. Reach 2 ................................................................................................ Retract 2............................................................................................... Reach2 / Retr2 ..................................................................................... 2nd Pump ............................................................................................. E Cushion............................................................................................. Wheel Centering...................................................................................

5-12 5-12 5-12 5-13 5-13 5-13 5-13 5-13 5-13 5-14 5-14 5-14 5-14 5-14 5-14

Diagnostics Diagnostics * Service Mode Only* .............................................................. How to Access “Onboard Diagnostics”..................................................... Digital Inputs ........................................................................................ Analog Inputs ....................................................................................... Outputs................................................................................................. Temperatures........................................................................................ Motor Controls......................................................................................

5-15 5-15 5-15 5-16 5-16 5-17 5-17

5-18 5-18 5-18 5-18 5-19 5-19 5-19 5-19

Height Detection (Option) Height Detection Overview ......................................................................... Height Detection Installation ....................................................................... Pre_Selected Shelf Height Option .............................................................. To Change the Shelf Height .....................................................................

5-20 5-21 5-22 5-22

OPERATOR DISPLAY INFORMATION & PROGRAMMING

Password Protected Modes

Service Mode

1. Management Mode

Service Mode is reserved for authorized dealers and Service Technicians. All options and performance parameters can be accessed through this mode. See the next section for detailed explanations and instructions on parameters and settings. The following parameters can be accessed and set in Service Mode (See flow chart for details):

2. Service Mode

Management Mode Management Mode is a password protected mode that can be used by management to set certain functions or set performance modes. The following parameters can be accessed and set in Management Mode (See flow chart for details):

1. General Settings (Clock, units and Language)\ 2. History Folder (Error code details, up to 16) 3. Password Manage (Change password)

1. General Settings (Clock, units and Language)

4. Parameters (Display and Truck)

2. History Folder (Error code details, up to 16)

5. Diagnostics (System monitor)

3. Password Manage (Change password)

6. Service (Set maintenance intervals, clear history folder, restore parameters and performance modes, restore password

4. Parameters (Display: Allow Pre-height set-up; Allow Mode Change; LCD Contrast; LCD Heater)

How to enter “Management Mode”

How to enter “Service Mode”

1. While holding down the “Enter” button, switch the key on (In the case of keyless entry, press the start button while holding down the “Enter” button).

1. While holding down the “Esc” button, switch the key on (In the case of keyless entry, press the start button while holding down the “Enter” button). 2. The password screen appears and prompts the user for a password. *Default password is 4 4 4 4 4 4

2. The password screen appears and prompts the user for a password. *Default password is 1 1 1 1 1 1

3. Once the correct password is entered, the main truck screen appears and the user can access the above parameters.

4. If any changes are made, the user must “Escape” back to the main menu and the truck must be switched off for the new settings to be saved.

5-1

OPERATOR DISPLAY INFORMATION & PROGRAMMING

Display Enabled Functions

Parameters

1. General Settings

*All Modes*

Display Parameters

2. History Folder

*All Modes*

Display enabled options and performance features of the truck permit the user/operator to review and reconfigure a variety of settings relating to the operation and function of the truck. The display enabled options may be set to the preference of each operator.

3. Password Manage *Service and Management Modes Only* 4. Parameters

*Service and Management Modes Only*

5. Diagnostics

*Service Mode Only*

Configuration Settings

6. Service

*Service Mode Only*

Operational features are password protected, intended for use in setting performance parameters within those features purchased with the truck and any specific application requirement.

General Settings Available in every mode, this function accesses the Clock, Units, and Language settings. - Clock

MM/DD/YY

HH:MM

- Units Height Weight Speed Temp

Metric Meter Kg Km/h Cº

Imperial Inches Lbs mph Fº

- Languages

English, Spanish, French, Portuguese

Since an incorrect setting selection could adversely affect truck performance, and increase the risk to the operator, ONLY an authorized dealer or technician are allowed to change these settings. Possible bodily harm to the operator, damage to property or the truck could occur. Password access must be protected at all times, and used by only trained and authorized personnel.

12/24

History Folder Allows the user to access the fault codes history. Information such as Code, Alarm, Time/Date, BDI and Hours will be displayed. Up to 16 codes can be stored in memory, 0 to 15. - Alarm Code Alarm Time BDI Hours Traction Pump

00 # Description mm/dd/yy hh:mm State of charge 00000 00000 00000

Password Manage Allows the user to set the passwords for accessing the two modes, Management and Service. In Management Mode, only the Management Password can be changed. In Service Mode, both the Management and Service Modes passwords can be changed. Use the left/right buttons to move between spaces and the up/down buttons to change the numbers. 5-2

OPERATOR DISPLAY INFORMATION & PROGRAMMING

Display Parameters

5. “Display Settings” menu will be displayed. pm

Pre-height Settings This function allows the user to activate the preset lift heights option. Different heights can be pre-programmed to set the shelf heights thus enabling the mast to stop at any height above Free-lift. The second pre-set height can then be attained by releasing the handle and lifting again. There are thirty “30” slots available for this function. Please see the “Pre-selected Shelf Height Option” section for programming instructions. This function requires an optional height encoder. For the kit part number, please refer to the parts manual.

Allow P r e-height Setting Allow Mode Change L CD Contrast L CD Heater Cont r o l Pre-height Selector Height Display Weight Display Pin Code

ON ON 15 OFF ON ON ON ON

6. There are two settings that pertain to this option: a. “Allow Pre-height Setting”: This function must be set to “On” to enable the programming of the Pre-select Shelf Height. If this function is set to “Off”, the system will not be able to learn the height settings when being programmed. Using the Left or Right button, set this function to “On” while highlighted. Default setting is “On”.

How to activate the “Pre-Select Shelf Height Setting” function 1. Enter service mode by following the Service Mode Entry instructions. 2. With the exclamation mark highlighted, press “Enter” to access the Service Menu.

Allow P r e-height Setting Allow Mode Change L CD Contrast L CD Heater Cont r o l Pre-height Selector Height Display Weight Display Pin Code

7.1 mph

ON ON 15 OFF ON ON ON ON

b. “Pre-Height Selector”: This function allows the user to turn on/off the Pre-height Select option. To activate the function, use the Left Arrow or Right Arrow button to set this function to “On” while highlighted.

Mode 1 3. In the Service Menu, scroll to “Parameters” and press enter.

pm Allow P r e-height Setting Allow Mode Change L CD Contrast L CD Heater Cont r o l Pre-height Selector Height Display Weight Display Pin Code

General Settings H i s t o r y Fo l de r P as s wo r d Manage P arameters Diagn ostics Ser vice

4. Two choices are given “Display” and “Truck”. Choose “Display” and press enter.

ON ON 15 OFF ON ON ON ON

7. Press Enter. 8. Press escape until the main truck screen is displayed.

9. Turn truck off.

Display Truck

5-3

OPERATOR DISPLAY INFORMATION & PROGRAMMING

Mode Change

5. “Display Settings” menu will be displayed.

This function allows the user to change between modes. There are four “4” performance modes that the manager/operator can choose from. Modes can be set to match the performance of the truck to the experience of the operator. The setting of the truck can only be changed by the manager or authorized service technician.

6. Scroll down to “Allow Mode Change”. pm

Allow P r e-height Setting Allow Mode Change L CD Contrast L CD Heater Cont r o l Pre-height Selector Height Display Weight Display Pin Code

How to activate the “Mode Change” function

ON ON 15 OFF ON ON ON ON

1. Enter service mode by following the Service Mode Entry instructions.

7. While highlighted, use the Left Arrow or Right Arrow button to change from “Off” to “On”.

2. With the exclamation mark highlighted, press “Enter” to access the Service Menu.

8. Press Enter. 9. Press escape until the main truck screen is displayed.

10. Turn truck off.

7.1 mph Mode 1 3. In the Service Menu, scroll to “Parameters” and press enter. pm General Settings H i s t o r y Fo l de r P as s wo r d Manage P arameters Diagn ostics Ser vice

4. Two choices are given “Display” and “Truck”. Choose “Display” and press enter. pm

Display Truck

5-4

OPERATOR DISPLAY INFORMATION & PROGRAMMING

Height Display *Service Mode Only*

5. “Display Settings” menu will be displayed. 6. Scroll down to “Height Display”.

This function displays the height of the mast above Free-lift, in inches or millimeters. This function requires an optional height encoder. For the kit part number, please refer to the parts manual.

Allow P r e-height Setting Allow Mode Change L CD Contrast L CD Heater Cont r o l Pre-height Selector Height Display Weight Display Pin Code

How to activate the “Height Display” function

ON ON 15 OFF ON ON ON ON

1. Enter service mode by following the Service Mode Entry instructions. 7. While highlighted, use the Left Arrow or Right Arrow button to change from “Off” to “On”.

2. With the exclamation mark highlighted, press “Enter” to access the Service Menu.

8. Press Enter. pm

9. Press escape until the main truck screen is displayed. 10. Turn truck off.

7.1 mph Mode 1 3. In the Service Menu, scroll to “Parameters” and press enter. pm General Settings H i s t o r y Fo l de r P as s wo r d Manage P arameters Diagn ostics Ser vice

4. Two choices are given “Display” and “Truck”. Choose “Display” and press enter. pm

Display Truck

5-5

OPERATOR DISPLAY INFORMATION & PROGRAMMING

Weight Display *Service Mode Only*

5. “Display Settings” menu will be displayed. 6. Scroll down to “Weight Display”.

This function displays the weight of the load with a range of +/- 100 lbs (+/- 50 Kg). All trucks are equipped with a pressure sensor that is used by the logics unit to calculate the weight. The weights displayed are for reference only and can be affected by a variety of conditions.

Allow P r e-height Setting Allow Mode Change L CD Contrast L CD Heater Cont r o l Pre-height Selector Height Display Weight Display Pin Code

ON ON 15 OFF ON ON ON ON

How to activate the “Weight Display” function 1. Enter service mode by following the Service Mode Entry instructions.

7. While highlighted, use the Left Arrow or Right Arrow button to change from “Off” to “On”.

2. With the exclamation mark highlighted, press “Enter” to access the Service Menu.

8. Press Enter. 9. Press escape until the main truck screen is displayed.

10. Turn truck off.

7.1 mph Mode 1 3. In the Service Menu, scroll to “Parameters” and press enter. pm General Settings H i s t o r y Fo l de r P as s wo r d Manage P arameters Diagn ostics Ser vice

4. Two choices are given “Display” and “Truck”. Choose “Display” and press enter. pm

Display Truck

5-6

OPERATOR DISPLAY INFORMATION & PROGRAMMING

LCD Contrast

5. “Display Settings” menu will be displayed

This function adjusts the contrast of the display. The higher the value, the darker the display.

6. Scroll down to “LCD Contrast” pm

How to change “LCD Contrast”

Allow P r e-height Setting Allow Mode Change L CD Contrast L CD Heater Cont r o l Pre-height Selector Height Display Weight Display Pin Code

1. Enter service mode by following the Service Mode Entry instructions. 2. With the exclamation mark highlighted, press “Enter” to access the Service Menu. pm

ON ON 15 OFF ON ON ON ON

7. While highlighted, use the Left Arrow or Right Arrow button to change the value from 0 to 15. 0: lighter 15: Darker.

7.1 mph

8. Press Enter. 9. Press escape until the main truck screen is displayed.

Mode 1

10. Turn truck off.

3. In the Service Menu, scroll to “Parameters” and press enter. pm General Settings H i s t o r y Fo l de r P as s wo r d Manage P arameters Diagn ostics Ser vice

4. Two choices are given “Display” and “Truck”. Choose “Display” and press enter. pm

Display Truck

5-7

OPERATOR DISPLAY INFORMATION & PROGRAMMING

LCD Heater

5. “Display Settings” menu will be displayed.

This function is to be used with the cooler/freezer kit. When activated, the internal thermostat will detect temperatures below 32 Fº (0 Cº) and turn on the internal heaters to keep the display within operating range. (Display operating range: -40 Fº to +158 Fº (-40 Cº to +70 Cº))

6. Scroll down to “LCD Heater Control”. pm

Allow P r e-height Setting Allow Mode Change L CD Contrast L CD Heater Cont r o l Pre-height Selector Height Display Weight Display Pin Code

How to activate the “LCD Heater Control” function 1. Enter service mode by following the Service Mode Entry instructions.

ON ON 15 OFF ON ON ON ON

7. While highlighted, use the Left Arrow or Right Arrow button to change from “Off” to “On”.

2. With the exclamation mark highlighted, press “Enter” to access the Service Menu.

8. Press Enter. 9. Press escape until the main truck screen is displayed.

10. Turn truck off.

7.1 mph Mode 1 3. In the Service Menu, scroll to “Parameters” and press enter. pm General Settings H i s t o r y Fo l de r P as s wo r d Manage P arameters Diagn ostics Ser vice

4. Two choices are given “Display” and “Truck”. Choose “Display” and press enter. pm

Display Truck

5-8

OPERATOR DISPLAY INFORMATION & PROGRAMMING

Keyless Entry “Pin Code” *Service Mode Only*

5. “Display Settings” menu will be displayed. 6. Scroll down to “Pin Code” and using the Left Arrow or Right Arrow button, change the setting from “Off” to “On”.

This function allows the user to start and operate the truck using a preset PIN code without the use of a key. This option must be used with the start switch provided with the Keyless Entry kit. For part numbers, please refer to the parts manual.

Allow P r e-height Setting Allow Mode Change L CD Contrast L CD Heater Cont r o l Pre-height Selector Height Display Weight Display Pin Code

How to activate the “Keyless Entry” function 1. Enter service mode by following the Service Mode Entry instructions. 2. With the exclamation mark highlighted, press “Enter” to access the Service Menu.

ON ON 15 OFF ON ON ON ON

7. Press Enter. 8. Press escape until the main truck screen is displayed.

9. Turn the truck off then back on. Display should show “Pin Code” screen.

7.1 mph

10. Press the start switch and enter 1 1 1 1 1 1 to activate the truck.

Mode 1 3. In the Service Menu, scroll to “Parameters” and press enter. pm General Settings H i s t o r y Fo l de r P as s wo r d Manage P arameters Diagn ostics Ser vice

4. Two choices are given “Display” and “Truck”. Choose “Display” and press enter. pm

Display Truck

5-9

OPERATOR DISPLAY INFORMATION & PROGRAMMING

Truck Parameters *Service Mode Only*

3. In the Service Menu, scroll to “Parameters” and press enter.

Truck parameters allow the user to change/set the different performance parameters of the truck. Multiple changes can be made during a single access of the parameters. Once any changes are made, the truck parameter section must be exited and the truck switched off in order for the changes to be saved in the Logic’s memory.

pm General Settings H i s t o r y Fo l de r P as s wo r d Manage P arameters Diagn ostics Ser vice

How to access “Truck Parameters” This section will discuss how to make changes and what the different Parameters are.

4. Two choices are given “Display” and “Truck”. Choose “Truck” and press enter.

1. Enter service mode by following the Service Mode Entry instructions. 2. With the exclamation mark highlighted, press “Enter” to access the Service Menu. pm

7.1 mph Mode 1

5-10

Display Truck

OPERATOR DISPLAY INFORMATION & PROGRAMMING

5. Once in the Truck Parameters menu, use the Up and Down buttons to scroll between parameters and the Left/Right button to change the values. pm

BDI Curve BDI Timer BDI Reset Low Batt Maintenance Warning Stand-By Timer Travel Alarm

5 300 s 37.50 V 20 % 20 h 30 s 2

Maintenance (0 – 50 Hrs) Maintenance warning Warning: will be shown when this many hours from scheduled maintenance. Maintenance Intervals can be set in the Service parameter in the main Service Menu. Stand By Timer:

(0/60 S) When set, if the truck is in idle for 60 seconds, the contactor (K12) will de-energize to reduce power consumption. A setting of “0” disables this function.

Travel Alarm:

0 = disabled; 1 = Fwd; 2 = Bwd; 3 = Fwd and Bwd; 4 = Lift; 5 = Lower; 6 = All Hydraulic Functions; 7 = All.

<NEXT>

BDI Curve:

(0 – 9) Battery Discharge Curve select. Lower curve will drop battery level slower. Newer batteries will have a lower setting, 4 is typical, while older batteries will have a higher number, 6 is typical. Adjustment is dependent on the condition of the battery.

BDI Timer:

(0 – 500 Seconds) BDI level change timer. When battery voltage has dropped below the voltage level defined by the BDI curve setting for an accrued time longer than this setting, the BDI level will be changed.

BDI Reset:

(30 – 45 V) If battery voltage is higher than this at power-on, the BDI will be reset to 10. Typical value is around 37.25 Volts. This value can be higher for newer batteries.

Low Batt:

(0 – 20%) Low battery level indicator. This setting determines when the Low battery alarm/Lift lock out will occur. It is the percentage of an 80% discharged battery (to protect the battery for excessive drain. An indication of 0% equals a 80% discharged battery.

5-11

NOTE Fwd and Bwd settings will reverse operation when forward steering is “On”.

OPERATOR DISPLAY INFORMATION & PROGRAMMING

<PREV> Max Speed Fwd Max Speed Rev Release Braking Inverse Braking Steer Sensitivity Fwd steering Lower Stop/Batt Lock -<NEXT>

<PREV> Cutback Linear Cutback1 Speed Cutback2 Height Cutback2 Speed Cutback3 Height Cutback3 Speed

5.0 mph 3.0 mph OFF OFF OFF OFF

OFF 4.5 mph 150 inch 4.0 mph 200 inch 3.0 mph

<NEXT>

Max Speed Fwd:

(0 – 7.5 mph / 0 – 12 km/h) Forward maximum speed.

Max Speed Bwd:

(0 – 7.5 mph / 0 – 12 km/h) Reverse maximum speed.

Release Braking:

(0 – 15) Sets the level of regenerative braking when the handle is released during forward or reverse operation. 0 is min and 15 is max.

Inverse Braking:

(0 – 15) Sets the level of regenerative braking when the handle is pulled in the opposite direction during forward or reverse ope ation. 0 is min and 15 is max.

Steer Sensitivity:

(0 – 15) Sets the response sensitivity between the steering stepper motor and the controller. The higher the value, the more sensitive the response, which reduces the number of turns from the steer wheel to complete a full steer gear cycle.

FWD Steering

(On/Off) When this option is turned on, steering direction is inverted.

Lower Stop/ Batt Lock:

(0 – 2) 0 = Off; 1 is reserved for future use. 2 = Battery Lock. Battery lock requires an optional sensor and additional wiring to interface with the Logics unit.

Cutback Linear:

(On/Off) Turns on speed reduction with increased mast height. See below for settings. This function requires an optional height encoder. For the kit part number, please refer to the parts manual.

Cutback 1 Speed:

(0 – 7.5 mph / 0 – 12 km/h) Sets maximum speed regardless of height. Cutback Linear must be on for this setting to be active.

Cutback 2 Height/ Cutback 2 Speed:

(890 – 4250 / 2225 mm – 10625 mm) height (0 – 7.5 mph / 0 – 12 km/h) Ses maximum speed at set cut back.

Cutback 3 Height/ Cutback 3 Speed:

(890 – 4250 / 2225 mm – 10625 mm) height (0 – 7.5 mph / 0 – 12 km/h) Ses maximum speed at set cut back.

5-12

OPERATOR DISPLAY INFORMATION & PROGRAMMING

<PREV> PresSensor Low PresSensor High Real load Weight Max Lift Free Lift Lift Limit <NEXT>

Free Lift:

(520 – 2000 / 1300 mm – 5000 mm) This function is to set the Freelift height (890 is typical). Height calculation will be started from this height. This function requires the mast mounted proximity sensor.

Lift Limit:

(0, 890 – 4250 / 2225 mm – 10625 mm) This setting is used to limit the maximum height the mast can travel. This can be bypassed by using the horn button and lifting once the limit has been reached. 0 = Disabled. This function can only be used at heights of or above 890. This function requires an optional height encoder. For the kit part number, please refer to the parts manual.

1,07 V 1,51 V 4000 lbs 318 inch 104 inch 300 inch

PreSensor Low:

(0 – 5 V) Pressure Sensor adjustment in Freelift. This setting is used for adjustments and calibration and SHOULD NOT be adjusted without prior consultation with the Factory.

PreSensor High:

(0 – 5 V) Pressure Sensor adjustment above Freelift. This setting is used for adjustments and calibration and SHOULD NOT be adjusted without prior consultation with the Factory.

Real Load Weight:

(0 – 4500 lbs) This setting is for calibrating the real load on the forks minus the weight of the carriage with “0” being no load on the forks. It is recommended the heaviest rated weight below freelift be used when setting this feature.

Max Lift:

(890 – 4250 / 2225 mm – 10625 mm) This function sets the maximum height of the mast. When a height is set and reached, the hydraulic system shuts down to prevent a high pressure spike. This function requires an optional height encoder. For the kit part number, please refer to the parts manual.

5-13

OPERATOR DISPLAY INFORMATION & PROGRAMMING

<PREV> Reach2 Retract2 Reach2/Retr.2 Hydr. Mode 2nd Pump E Cushion Wheel Centering

1199 rpm 1199 rpm ON ON OFF ON OFF

Reach 2:

(500 – 2000 rpm) Sets the 2nd reach speed.

Retract 2:

(500 – 2000 rpm) Sets the 2nd retract speed.

Reach2/ Retr.2

(On/Off) Turns on 2nd speed for both features for single button operation per direction.

Hydr. Mode:

(On/Off) Shuts off hydraulic functions for servicing.

2nd Pump:

(On/Off) This feature turns on the 2nd pump controller in High Performance trucks and must be on for the hydraulic system to function correctly.

E Cushion:

(On/Off) Turn on the electric cushion feature. This feature will slow the mast down electrically by reducing the speed of the pump motors between Freelift and Secondary Lift transitions.

Wheel Centering:

(On/Off) Auto wheel centering. This setting turns on the auto centering function. Every time the truck is switched on the drive/steer wheel will self test in both directions and center.

5-14

OPERATOR DISPLAY INFORMATION & PROGRAMMING

Diagnostics

Digital Inputs

The functions below will get highlighted when activated. These represent the digital inputs of the Logics Unit.

Diagnostics *Service Mode Only* This reach truck is equipped with onboard diagnostic capabilities. Found in Service Mode, it allows the technician to monitor the operation of different functions and check input/output signals. It also has a dedicated screen for monitoring motor controls.

Digital Inputs Analog Inputs Outputs Temperatures Motor Controls

The different parameters are listed below.

How to access “Onboard Diagnostics” pm

1. Enter service mode by following the Service Mode Entry instructions.

OPPedal 1NO OPPedal 1NO OPPedal2 Cutback 1 Horn Truck En/Dis Lstop/BLock

2. With the exclamation mark highlighted, press “Enter” to access the Service Menu.

Reach Retract SShift Left SShift Right Tilt Fwd Tilt Bwd Free Lift Sens

EMBrakeFS Reach FB Tilt FB SShift FB Steer Ref0 Steer Ref90

7.1 mph Mode 1 3. In the Service Menu, scroll to “Diagnostics” and press enter. pm

- OPPedal 1 NO - Reach

- EMBrake FS

- OPPedal 1 NC - Retract

- Reach FB (Feed back)

- OPPedal 2 NO - SShift Left

- Tilt FB (Feed back)

- Cutback 1

- SShift Right

- SShift FB (Feed back)

- Horn

- Tilt Fwd

- Steer Ref 0

- Truck En/Dis

- Tilt Bwd

- Steer Ref 90

- Lstop/Block

- Free Lift Sens

General Settings H i s t o r y Fo l de r P as s wo r d Manage Parameters Diagn ostics Ser vice

4. Multiple choices are given (See below for the list of choices and their explanation). Choose the desired function by pressing the “Up” and “Down” buttons. Once the desired function is highlighted, press enter.

5-15

OPERATOR DISPLAY INFORMATION & PROGRAMMING

Analog Inputs

Outputs

Monitors voltage of the different analog inputs of the Logics Unit.

Monitors the output signals that correspond to the appropriate input. pm

Digital Inputs Analog Inputs Outputs Temperatures Motor Controls

pm pm

Battery Voltage Fwd/Rev Lift/Lower Lift Enable Pressure Sensor

OFF 90 % OFF OFF OFF 50 % ON

Horn Main Contactor Reach/Retract Sideshift Tilt/Sideshift Magnetic Brake Travel Alarm <NEXT>

36,67 V 24 . 3 V 24 . 3 V OFF 1.58 V

- Horn

Off/On

- Main Contactor

90% (Of operating voltage across the coil)

- Lift/Lower (2.43 V at Neutral)

- Reach/Retract

Off/On

- Lift Enable (0 V at Neutral, 5 V during operation)

- SideShift

Off/On

- Pressure Sensor (Voltage will fluctuate during operation)

-Tilt/Sideshift

Off/On

- Magnetic Brake

50% (Of operating voltage across the coil)

- Travel Alarm

Off/On

- Lift/Lower

0 mA (At solenoid m1 and m2)

- Direction Sel.

0 mA (At solenoid m3 and m4)

- Battery Voltage (Detected at Pin XA5-1/19) - Fwd/Rev (2.43 V at neutral)

5-16

OPERATOR DISPLAY INFORMATION & PROGRAMMING

Temperatures

Monitors motor and controller temperatures.

Motor Conrols

Monitors command and feedback status of the motors. pm

Digital Inputs Analog Inputs Outputs Temperatures Motor Controls

Traction Motor Traction Controller Pump1 Motor Pump1 Controller Pump2 Motor Pump2 Controller Steer Motor Steer Controller

32 F 84 F 32 F 32 F 400 F 400 F 53 F 32 F

- Traction Motor - Traction Controller

(F/C)

- Pump 1 Motor

(F/C)

- Pump 1 Controller

(F/C)

- Pump 2 Motor

(F/C)

- Pump 2 Controller

(F/C)

Traction Set Traction Actual Traction Current

<NEXT>

- Traction Set (Command) - Traction Actual - Traction Current

rpm rpm Amps pm

<PREV> Pump1 Set Pump1 Actual Pump1 Current Pump2 Set Pump2 Actual Pump2 Current

- Steer Motor (F/C) - Steer Controller

2800 rpm 2754 rpm 47 A

(F/C)

1210 rpm 1000 rpm 359 A 3150 rpm 2968 rpm 305 A

<NEXT>

- Pump 1 Set (Command) - Pump 1 Actual - Pump 1 Current - Pump 2 Set (Command) - Pump 2 Actual - Pump 2 Current

rpm rpm Amps rpm rpm Amps pm

<PREV> Pump1 Set Pump1 Actual Pump1 Current Pump2 Set Pump2 Actual Pump2 Current

1210 rpm 1000 rpm 359 A 3150 rpm 2968 rpm 305 A

<NEXT>

- Steer Speed (Actual) - Steer Angle - Steer Current

5-17

rpm deg Amps

OPERATOR DISPLAY INFORMATION & PROGRAMMING

Service

Set Mainenance Interval

Allows the technician to set the service hour Intervals.

Service *Service Mode Only*

Allows the setting up of various Service based options. This parameter allows the technician to set up service intervals, restore parameters, performance modes and passwords.

Set Maintenance Inter val Clear H istor y Folder Reset P r e-Height Sel Restor e Truc k P aram. Restor e P erf. Modes Restor e P ass wor ds

How to access “Service” pm

1. Enter service mode by following the Service Mode Entry instructions.

Restor e P ass wor ds (Enter) Conf ir m (Esc) Cancel

7.1 mph

- Active Hours

hours

- Default Period

hours

- Next Service

hours

- Confirm Service To

hours

Mode 1 2. With the exclamation mark highlighted, press “Enter” to access the Service Menu.

Clear History Folder

pm General Settings H i s t o r y Fo l de r P as s wo r d Manage P arameters Diagn ostics Ser vice

Clears the codes that are stored in the Logic’s memory. Up to 16 codes can be stored in memory. pm

Set Maintenance Inter val Clear H istor y Folder Reset P r e-Height Sel Restor e Truc k P aram. Restor e P erf. Modes Restor e P ass wor ds

3. In the Service Menu, scroll to “Service” and press enter.

4. Multiple choices are given (See list of choices and their explanation). Choose the desired function by pressing the “Up” and “Down” buttons. Once the desired function is highlighted, press enter.

Clear Histor y Folder (Enter) Conf ir m (Esc) Cancel

- Clear History Folder

5-18

OPERATOR DISPLAY INFORMATION & PROGRAMMING

Reset Pre-Height Select

Restore Perf. Modes

Clears any values entered for the height select feature.

Restores the settings for the four (4) Performance modes to factory default.

pm pm

Set Maintenance Inter val Clear H istor y Folder Reset P r e-Height Sel Restor e Truc k P aram. Restor e P erf. Modes Restor e P ass wor ds

pm pm

Clear P r e-Height Selector (Enter) Conf ir m (Esc) Cancel

Restor e P erf. Modes (Enter) Conf ir m (Esc) Cancel

- Clear Pre-height Selector - Restore Perf. Modes

Restore Truck Param.

Restores performance parameters set in Truck Parameters to factory default.

Restore Passwords

Restores all passwords to factory default.

pm pm

Set Maintenance Inter val Clear H istor y Folder Reset P r e-Height Sel Restor e Truc k P aram. Restor e P erf. Modes Restor e P ass wor ds

pm pm

Restor e Truc k P aram. (Enter) Conf ir m (Esc) Cancel

- Restore Truck Param.

Restor e P ass wor ds (Enter) Conf ir m (Esc) Cancel

- Restore passwords

5-19

OPERATOR DISPLAY INFORMATION & PROGRAMMING

Height Detection (Option) Height Detection Overview The vehicle is capable of having an option installed that will enable it to calculate the vehicle fork height once the vehicle is out of the free lift stage. The vehicle is also capable of having programmed shelf height selections that will automatically position the height of the forks to either store or retrieve a load. It is able to accomplish this using the Logics Unit, a switch (S43), an encoder (B41) and cable, and associated brackets. The switch (S43) is mounted near the top of the mast assembly; it is a proximity style switch that is activated by a bracket that is mounted to the vehicle’s telescopic mast. As the mast is elevated above the free lift stage, the bracket will move up and away from the free lift reference switch S43. Once the switch S43 has been transitioned, the controller is able to establish a height reference point. As the telescopic mast is raised or lowered the cable attached to the encoder assembly will cause the encoder wheel to rotate and the encoder pulse count will be converted to a height value.

Bracket RL472017 Sensor RL485304

Bracket RL472021

5-20

OPERATOR DISPLAY INFORMATION & PROGRAMMING

Clearance % 5mm (3/16)

M10 x 20 DIN 912, torque 45 Nm Bracket 97H05-04300

Height Detection Installation •

Install bracket RL472017 to the Mast, with M10x20 DIN 912 bolts, torque is 45 Nm.

•

Install bracket RL472021to the Mast, with M10x20 DIN 912 bolts, torque is 45 Nm.

•

Install Free Lift Sensor RL199213 to the Bracket RL472017.

•

Adjust clearance between Sensor and Bracket. Clearance should be 5 mm.

•

Connect XS43 and X46 together.

•

Install encoder to the bracket RL472023.

•

Install bracket and encoder to the mast.

•

Install spring to the other end of the cable with wire lock.

•

Install M6 x 60 DIN 444—bolt to the spring.

•

Install M6 x 60 DIN 444—bolt to the cable end with wire lock.

•

Install cable around the encoder wheel.

•

Install cable to the mast. Spring to the top.

•

Secure M6 x 60 DIN 444—bolts with M6 DIN 985 nuts.

Bolt Type M8 x 20, DIN 912 M6 x 60, DIN 444 Nut M6, DIN 985

Torque (Nm) 25 10

Quantity (pcs) 2 2 2

Install spring and cable to this hook Use existing bolts to install bracket on the mast

Once the associated hardware has been installed, several setting changes are required to properly install the option. These can be accessed using the handset and console keypad. 5-21

OPERATOR DISPLAY INFORMATION & PROGRAMMING

Pre-selected Shelf Height Option

To change the Shelf Height Use the arrow key to select option

NOTE This option works only above the free lift height. pm

This setup can be changed in operator, manager and service mode. Use the arrow key to select option

7.1 mph

. pm

Mode 1

7.1 mph

Press

Mode 1

Press

180

200

0 180

200

0 180

180

Current 180 inch Selected 0 inch

The Screen (Height Pre-Select Unloaded) with various preset heights appears.

Press

Current 180 inch Selected 0 inch

The Screen (Height Pre-Select Unloaded) with various preset heights appears.

Current Height Selected Height

0 180

Teach Height

The operator can select the desired preset height by using up/down and left/right arrow buttons. The operator has to be in this screen to choose the desired height for this selected function to work. Shelf Height Selector works for lifting and lowering the forks.

The screen Height Pre-Select/Setup appears. Use the arrow keys to Select Teach Height. Then raise the forks to the desired height Press

5-22

OPERATOR DISPLAY INFORMATION & PROGRAMMING

The height changes on Height Pre-Select Unloaded screen.

180

200

0 180

Current 180 inch Selected 0 inch

Current Height Selected Height

0 180

Teach Height

5-23

OPERATOR DISPLAY INFORMATION & PROGRAMMING

Cold Storage Option 6

Tie cold storage wire harness to existing wire harness with 10 cable ties.

1 3

Disconnect battery

Un-install panels

19 Connect battery

18 Install panels

• Class II—Change

gearbox oil to SAE 75W/90 • Recommendation on class I—Hydraulic oil ISO VG 32 • Recommendation on class II—Hydraulic oil ISO VG 15

Un-install pedal

16 Install pedal, torque 25 NM 4

Open doors or uninstall sideplates

17 Install sideplates

Un-install floor plate

16 Install floor plate M3x35 DIN 7985 bolts and M3 DIN 985 nuts, torque 1 Nm

12 11 Un-install micro switches.

Install Resistor 120k Ω to plate with 2 x M3x6 DIN 7985, torque 1 Nm

Install 120k Ω Resistor with two screws

13 Install Micro Switches and Resistor plate with 2 screws and 2 nuts

8 Install Thermostat Bracket

5-24

Install Thermostat Unit with two screws and two nuts.

10 Connect wires

MAST Where to Find Serial Number on Mast ........................................................

6-1

Hydraulic Manifold with Cover.....................................................................

6-1

Hydraulic Manifold with Cover Removed....................................................

6-1

Contents ........................................................................................................

6-2

Periodic Maintenance ...................................................................................

6-2

Inspection......................................................................................................

6-2

500 Hour Inspection .....................................................................................

6-2

Troubleshooting ............................................................................................

6-3

Mast Removal................................................................................................

6-4

6-4 6-4 6-5 6-5 6-6 6-6 6-6

6-7 6-7 6-8 6-8 6-8

Free Lift Cylinder Service Free Lift Cylinder Disassembly ................................................................... 6-9 Cleaning and Inspection ............................................................................. 6-9 Free Lift Cylinder Reassembly .................................................................... 6-10 Piston Rod and Piston ............................................................................. 6-10 Retainer / Retainer Assembly .................................................................. 6-10 Mast Uprights Upright Desciption ...................................................................................... Outer Upright Assembly ........................................................................... Intermediate Upright Assembly ................................................................ Inner Upright Assembly............................................................................

6-11 6-11 6-11 6-11

6-12 6-12 6-12 6-13

Fatigue Cracking ...................................................................................... Stress-Corrosion Cracking ....................................................................... Corrosion Fatigue .................................................................................... Ultimate Strength Failure ............................................................................ Tight Joints ................................................................................................. Chain Length Adjustment............................................................................

6-13 6-13 6-13 6-13 6-13 6-14

6-18 6-19 6-23 6-23 6-23 6-23

6-25 6-25 6-27 6-27 6-28

Lift Bracket Assembly Shimming.................................................................................................... Pantograph Carriage Roller ........................................................................ Checks and Adjustments ............................................................................ Roller Clearance Inspection........................................................................ Service..................................................................................................... Checking Lower Roller Clearance with Upright 6" from Fully Retracted Position ..................................................... When Using a Pry Bar ................................................................................ “C” Clamp Method....................................................................................... Checking Upper Roller Clearance with Upright Extended Approx. 1/2 Full Extension ............................................. Checking Upper Roller Clearance with Upright Extended Approx. to Full Extension ............................................... Checking Lower Roller clearance with Upright Extended Approx. Within 6” of Full Extension.................................

6-30 6-30 6-30 6-35 6-35 6-35 6-35 6-36 6-37 6-39 6-40

6-43 6-43 6-43 6-44 6-45 6-47 6-47

6-47 6-48 6-48 6-48 6-49 6-49 6-49 6-50 6-50 6-50

6-50 6-50 6-51 6-51 6-53 6-53 6-53 6-53 6-54 6-54

Sideshift Cylinder Overhaul Cylinder Removal—Lift Bracket .................................................................. Remove Forks.......................................................................................... Preparation Cleaning and Inspection .......................................................... Disassembly ............................................................................................... Retainer Assembly ...................................................................................

6-55 6-55 6-55 6-55 6-55

Disassembly ............................................................................................... 6-60 Mounting Selector Valve ............................................................................. 6-60 Connecting Hydraulic Plumbing .................................................................. 6-61 Sideshifter Solenoid Control Valve Removal...................................................................................................... Installation .................................................................................................. Mount Selector Valve ............................................................................... Install Hoses ............................................................................................ Connect Coils ..........................................................................................

6-62 6-63 6-63 6-63 6-63

6-67 6-68 6-69 6-71 6-71

MAST

Where to Find Serial Number on Mast

Mast Configuration

Hydraulic Manifold with Cover

Mast Serial Number

Hydraulic Manifold with Cover Removed

6-1

MAST

Contents

500 Hour Inspection

This section of the manual provides the periodic maintenance requirements, troubleshooting and service procedures for the mast.

After each 500 hours of forklift truck operation, and in addition to the Daily and 100 Hour Inspections:

The masts provide excellent visibility for the forklift truck driver. The mast carriage and upright channels are all roller-mounted which provides smooth operation and long service life.

2. Inspect and lubricate the full length of the chains with SAE 40 wt. oil or Bowman Heavy Load Red Grease.

1. Clean and lubricate lift bracket assembly.

In any communication about the mast, refer to the mast serial number stamped in the nameplate of the mast. The mast nameplate is located on the left-hand lower outer rail.

! CAUTION The chains must be coated with a film of lubricant at all times.

Period Maintenance

3. Lubricate the full length of each mast upright rail.

For proper operation and an extended service lift, the Mast should be inspected and serviced regularly as part of your normal forklift truck maintenance schedule according to the following outlines and ANSI/ITSDF B56.1 procedures. The recommended intervals are for masts operating under normal conditions. If operation is in severe conditions or corrosive atmospheres, inspect the mast more frequently,

4. Measure load roller clearances in the carriage/lift bracket and Mast uprights. Pry between the upright and load roller so that the opposite load roller is tight against the upright. Total side-toside clearance should be 0.020 in. (.5 mm) max. across the tightest point throughout the travel of the upright. If shimming is required. 5. Check chains for wear and stretch. 6. Check the backrest capscrews for tightness. Tighten capscrews to 145 ft.-lbs. (195 Nm).

! WARNING Never work on a raised mast with a load without supports, or while anyone is near the forklift truck control handles per ANSI/ITSDF B56.1.

Inspection Perform the following at the beginning of each work shift: 1. Check cylinder rods and retainer for obvious damage, nicks, marring, scratches that might damage the cylinder packings. 2. Check lift chains for damage. 3. Check the chain anchor pins. Be sure the cotter pins (6) are in place and not damaged. 4. Examine the hydraulic plumbing and connections. Tighten loose connections. 5. Check harness hold-down clamps, brackets, and connectors for security of mounting and damage. 6. Inspect the lift chains. They must be coated with a film of lubricant at all times. 6-2

MAST

Troubleshooting The following table lists hydraulic or mechanical problems that may be encountered on your Mast, the probable causes, and the recommended corrective action that should be taken to restore the Mast to normal operating condition. PROBLEM

PROBABLE CAUSE

SOLUTION

a) Plugged inlet hose b) Insufficient oil.

a) Unplug hose or replace. b) Check the truck hydraulic system for correct oil level in tank, defective pump or pump drive, leaks in the lines or disconnect control valve linkage. Repair or replace as necessary. c) Repair or replace as necessary.

Cylinders don’t lift load or won’t move Empty

c) Bent or jammed plunger. Loaded

a) Plugged piston check valve. b) Truck relief valve setting low.

a) Unplug check valve or replace. b) Raise truck relief setting to specified level c) Reduce load to specified capacity. d) Remove mechanical bind by replacing/freeing plunger and rollers.

c) Over capacity. d) Mechanical bind due to bent plunger or bad rollers

! WARNING Extreme care should be used when working on a unit when the carriage (with or without a load) is in the raised position.

Cylinders drift

Spongy or jerky action

a) External leak in pressure line. b)Truck valve defective-cycle to full lift height to verify. c) External leaks at retainer. d) Piston check valve leaking. a) Sticky or defective truck relief valve.

a) Tighten or replace as necessary.

b) Repair or replace truck valve. c) Replace all cylinder seals. d) Replace check valve. a) Remove and check the truck relief valve. If contaminated oil caused the malfunction, drain and flush the system, change the filter and refill with fresh oil. b) Bent or damaged cylinder plunger. b) Disassemble, check and repair cylinder assembly. c) Load rollers not properly adjusted or defective. c) Adjust or repair as necessary. d) Mast channels improperly lubricated. d) Lubricate mast. e) Low Battery charge. e) Charge battery. f) Low pump volume. f) Install accumulator. g) Low oil level. g) Fill oil reservoir. h) Insufficient hydraulic tank capacity or baffles h) Install larger tank baffles

! WARNING Extreme care should be used when working on a unit when the carriage (with or without a load) is in the raised position. 6-3

MAST

Mast Removal It is recommended that the lift bracket assembly be removed before attempting to remove the uprights.

Cylinders Main Lift Cylinder Description The main lift cylinders (see Figure 6.1) are single stage displacement type cylinders consisting of a shell and a telescopic plunger/piston assembly. During extension hydraulic pressure is acting against the plunger outer diameter due to the internal porting through the piston. The piston seals do not affect cylinder extension. The vehicles hydraulic controls hold the cylinders in place once extension has stopped.

Retainer

Retainer Seals Back-Up O-Ring

The shell is internally threaded at the top end to hold the retainer. The retainer seals provide a high pressure hydraulic seal against the plunger. The retainer also limits the upward stroke of the plunger. A piston is attached to the bottom end of the plunger. The piston seal provides a high-pressure hydraulic seal against the shell that engages the cushion valve when the cylinder is fully lowered.

Shell

A hydraulic fuse/cushion valve is located in the left hand cylinder’s inlet port. In case of a hose failure between the lowering control valve and the cylinders, the fuse limits the lowering speed of the cylinder. The valve also cushions the piston when the cylinder nears the fully lowered position.

Rod

Spacer

Piston Seal Wear Ring Retainer

MA2974.eps

Figure 6.1

6-4

MAST

Free Lift Cylinder Description The free lift cylinder (see Figure 6.2) is a single stage piston type cylinder consisting of a shell and plunger/piston assembly. During extension hydraulic pressure is acting against the fill piston area. The truck’s hydraulic controls hold the cylinder in place once extension has stopped.

Retainer

Retainer Seals

Back-Up

A piston is attached to the bottom end of the plunger. The piston seal provides a high-pressure seal against the shell. A check valve located in the bottom of the piston allows residual oil between the shell and plunger to escape when the cylinder is extending.

O-Ring

A hydraulic fuse/cushion valve is located in the cylinder inlet port. In case of hose failure between the lowering control valve and the cylinder, the fuse limits the lowering speed of the cylinder.

Rod Shell

Piston Back-Up Set Screw

Piston Seal W/O-Ring Wear Ring

Retainer

Plug

MA2975.eps

Figure 6.2

6-5

MAST

Cylinder Operation

Cylinder Lowering

Cylinder Raising

1. Actuating the truck hoist control valve to lower the mast causes the main lift cylinder plungers then free lift cylinder plunger to lower, forcing

1. As mentioned in theory section the pump motor controller will vary the volume on the fluid that is sent to the lift cylinders. The fluid that is entering the cylinders will flow unrestricted through the lowering control cartridge.

NOTE

2. Hydraulic fluid flows to the cylinder inlet ports. Due to the larger bore diameter of the free lift cylinder compared to both main lift cylinders, the free lift cylinders raise first.

The restriction setting of each hydraulic fuse is lower (allows more flow) than the setting of the lowering control valve. The hydraulic fuses restrict flow only during failure of a lowering control valve or hose.

3. Hydraulic fluid flows through the free lift cylinder hydraulic fuse/cushion valve to the bottom of the piston. Lifting force is created against the bottom of the piston causing the plunger to raise. Hydraulic fluid in the areas between the plunger and the shell is allowed to escape through the check valve in the piston as the plunger raises to the end of its stroke.

hydraulic fluid out through the hydraulic fuse/cushion valves. 2. Hydraulic fluid flows to the lowering control valve where it is restricted at a controlled speed determined by the load being handled. 3. As the main lift cylinder pistons lower over the spear in the bottom of the shell, a high pressure area is developed between the piston and the shell which engages the cushion valve to restrict flow. This allows the plunger/piston just prior to bottoming, providing a smooth transition to free lift cylinder lowering.

4. Hydraulic fluid flows through the hydraulic fuse/cushion valve to the bottom of the pistons as the free lift cylinder has fully extended, lifting force is created against the bottom of the main lift cylinder pistons causing their plungers to raise. Hydraulic fluid in the area between the plunger and the shell is allowed to escape through the check valve in the piston as the plunger raises. 5. When hydraulic fluid flow from the truck hoist control valve is discontinued, the cylinders are held in position by the closed center spool of the truck valve.

6-6

MAST

Main Lift Cylinder Service Main Lift Cylinder Disassembly 1. Wash the exterior surface of the cylinder thoroughly before disassembling. •

A soft fiber brush should be used to remove debris and foreign objects from grooves and threaded areas, etc.

•

A Stoddard type cleaning solvent should be used to wash the cylinder.

Retainer

2. Place retainer end of cylinder in a vise equipped with soft jaws. Do not over tighten.

Retainer Seals

3. Using a spanner wrench or a bronze (brass) drift, remove the retainer assembly from the cylinder barrel. •

Remove back-up ring and O-ring from cylinder retainer.

•

Remove rod wiper and seal from cylinder retainer.

Back-Up O-Ring

4. Pull piston rod from barrel assembly. •

Shell

Remove spacer and split piston from piston rod.

5. Remove snap ring, retaining washer, plunger, ball and spring from base end of piston rod.

Rod

Cleaning and Inspection

Spacer

1. Discard old seals, O-rings, back-up rings, wiper and lock washer. 2. Wash remaining parts in a stoddard type cleaning solvent and dry with a clean shop rag.

Piston Seal

3. Inspection threaded parts for damage.

Wear Ring Retainer

4. Examine the piston rod, inner surfaces of the retainer assembly and cylinder barrel for scoring, nicks or scratches. A crocus cloth may be used to clean up light scratches, etc. Be careful not to remove the chrome plating when polishing surfaces.

MA2974.eps

Figure 6.3

6-7

MAST

Main Lift Cylinder Reassembly

NOTE Placing a plastic parts bag over the retainer threads when installing the O-ring and back-up ring will help protect parts against damage, cutting, etc.

Piston Rod and Piston 1. Lubricate all parts with clean hydraulic fluid. 2. Lubricate and install the spring, plunger, washer, snap ring and ball into base end of the piston rod. Refer to Figure 6.3.

5. Carefully start the retainer assembly over the piston rod and screw it into the barrel finger tight. Do not cut or nick sealing lips upon installation.

3. Lubricate and install spacer onto the piston rod. Refer to Figure 6.3.

6. Using a spanner, tighten the retainer against the shell assembly.

4. Now, lubricate and place split piston onto the piston rod. Start piston rod into cylinder barrel and gently push rod inward until it bottoms out. Be careful no to nick or scratch the chrome surfaces.

Retainer / Retainer Assembly 1. Lubricate new seals, wiper ring and retainer assembly with clean hydraulic fluid. 2. Install the inner seal into the retainer groove. Be certain the sealing lip faces inward. Use a seal installation tool for best results. Be careful not to nick or scratch the chrome surfaces. 3. Install a new wiper ring into the retainer. 4. Lubricate and install a new O-ring and back-up ring into the outer groove on the retainer. Install lock washer on outside of retainer.

6-8

MAST

Free Lift Cylinder Service Free Lift Cylinder Disassembly 1. Wash the exterior surface of the cylinder thoroughly before disassembly •

•

A soft fiber brush should be used to remove debris and foreign objects from grooves and threaded areas, etc.

Retainer

A stoddard type cleaning solvent should be used to wash the cylinder. Retainer Seals

2. Place retainer end of cylinder in a vise equipped with soft jaws. Do not over tighten vise. 3. Using a spanner wrench or a bronze (brass) drift, remove retainer assembly from cylinder barrel.

Back-Up O-Ring

4. Remove and discard lock washer, back-up ring and O-ring located inside cylinder retainer. 5. Remove and discard both O-rings and back-up ring located on the outside of the cylinder retainer. 6. Pull piston rod from barrel assembly. 7. Remove wear ring (ring bearing) from piston rod. Refer to Figure 6.4.

Rod Shell

Cleaning and Inspection 1. Discard old seals, O-rings, back-up rings, wiper and lock washer

Piston Back-Up

2. Wash remaining parts in a Stoddard type cleaning solvent and dry with a clean shop rag.

Set Screw

Piston Seal W/O-Ring

3. Inspect threaded parts for damage.

Wear Ring

4. Examine the piston rod, inner surfaces of the retainer assembly and cylinder barrel for scoring, nicks or scratches. A crocus cloth may be used to clean up light scratches, etc. Be careful that you do not remove the chrome plating when polishing surfaces.

Retainer

Plug

MA2975.eps

Figure 6.4

6-9

MAST

Free Lift Cylinder Reassembly

NOTE Placing a plastic parts bag over the retainer threads when installing the O-rings and back-up rings will help protect parts against damage, cutting, etc.

Piston Rod and Piston 1. Lubricate all parts with clean hydraulic fluid. 2. Lubricate and install wear ring onto the piston rod. Refer to Figure 6.4. 3. Now, start piston rod into cylinder barrel and gently push rod inward until it bottoms out. Be careful that you do not nick or scratch chrome surface.

4. Next, lubricate and install a new back-up ring and O-ring into the outer groove at the base end of the retainer. 5. Install a new wiper into the retainer.

Retainer / Retainer Assembly 1. Lubricate new seals, O-rings, back-up rings, wiper ring and retainer assembly with clean hydraulic fluid. 2. Install back-up ring and the inner seal into the retainer groove. Be certain the sealing lip faces inward. Use a seal installation tool. Be careful that you do not cut or nick the sealing lip upon installation. 3. Lubricate and install (large) O-ring into the outer groove nearest to end of retainer.

6. Now, carefully place the retainer assembly over the piston rod and after applying lube to threads, screw it into the barrel finger tight. Do not cut or nick sealing lip(s) upon installation. 7. Using a spanner wrench, tighten retainer against barrel assembly. 8. Next, using drift as shown in opposite illustration, deform lock washer into groves provided in both the retainer and barrel to securely lock them together.

6-10

MAST

Mast Uprights Upright Description Pantograph Rollers

Pantograph Rollers

Outer Upright Assembly The outer upright assembly is mounted to the truck. A pair of shim adjustable load rollers are attached to stub shafts located near the top of the upright. A pair of adjustable hoist chain anchors are located in the top crossmember. The secondary cylinders rest on an integral lower crossmember.

Intermediate Upright Assembly The intermediate upright assembly telescopes within the outer upright assembly. A pair of shim adjustable load rollers are attached to stub shafts located at the top and bottom of the upright. A pair of chain sheaves are located near the top of the upright to provide a rolling surface for the main lift chains.

Inner Upright Assembly The inner upright assembly telescopes within the intermediate upright assembly. A pair of shim adjustable load rollers are attached to stub shafts located at the bottom of the upright. The free lift chain anchors are attached to the center crossmember. The free lift cylinder rests on a cradle which is integral with the lower crossmember.

Intermediate Upright Rollers

Inner Upright Rollers Outer Upright Rollers

MA2191.eps

Figure 6.5

6-11

Intermediate Upright Rollers

MAST

Upright Chain Inspection Each 50–250 hours of operation (more frequently in severe or extreme environments), chains should be inspected and lubricated. Inspection should involve the following:

integrity between outside plates and pins has been altered, it cannot be restored. Any wear pattern on the pin heads or the sides of the link plates indicates misalignment in the system. This condition damages the chain and increases frictional loading, and should be corrected. See Figure 6.6.

Elongation When a length of 12.00 inches (305 mm) of a new chain has elongated to a length of 12.360 inches (315 mm), it should be discarded and replaced. It is important to measure the chain in the section that moves over the sheaves because it receives the most frequent articulation. Measuring the chain near its clevis terminals could give an erroneous reading as it would not have flexed as frequently, if indeed at all, as nearer the middle of the assembly. See Figure 6.6. Chains should be replaced when wear exceeds 3% of the pitch or when 12 inches (305 mm) of chain is stretched 3.8 inch (10 mm).

Edge Wear Check the chain for wear on the link plate edges caused by running back and forth over the sheave. The maximum reduction of the material should not exceed 5%. This can be compared to a normal link plate height by measuring a portion of chain that does not run over the sheave. Distorted or battered plates on the leaf chain can cause tight joints and prevent flexing. See Figure 6.6. Worn contours and worn surfaces on the outside links or pin heads should not exceed 5% of new height.

Turning or Protruding Pins Highly loaded chain operated with inadequate lubrication can generate abnormal friction forces between pin and link plates. In extreme instances, the torque could surpass the press fit force between the pins and the outside plates, resulting in pin rotation. When chain is allowed to operate in this condition, a pin, or series of pins, can begin to twist out of the chain resulting in failure. The pin head rivets should be examined to determine if the “VEE” flats are still in correct alignment. Chains with rotated/displaced heads or abnormal protrusion should be replaced immediately. Do not attempt to repair the chain by welding or driving the pin(s) back into the chain. Once the press fit 6-12

Figure 6.6

MAST

Cracked Plates The chains should be periodically inspected very carefully, front and back as well as side to side, for any evidence of cracked plates. If any one crack is discovered, the chain(s) should be replaced. It is important, however, to determine the causes of the crack before installing new chain so the condition does not repeat itself.

If a plated chain is required, consult the factory. Plated chains are assembled from modified, individually plated components which may reduce the chain rating.

MA1002.eps

Fatigue Cracking Fatigue cracks are a result of repeated cyclic loading beyond the chains endurance limit. The magnitude of the load and frequency of its occurrence are factors which determine when fatigue failure will occur. The loading can be continuous or intermittent (impulse load). Fatigue cracks almost always start at the link plate pin hole (point of highest stress) and are perpendicular to the chain pitch line. They are often microscopic in their early stage. Unlike a pure tensile failure, there is no noticeable yielding (stretch ) of the material.

Stress-Corrosion Cracking The outside link plates which are heavily press fitted to the pins, are particularly susceptible to stress corrosion cracking. Like cracks, these initiate at the point of highest stress (pin hole) but tend to extend in an archlike pattern between the holes on the plate. More than one crack can often appear on a link plate. In addition to rusting, this condition can be caused by exposure to an acidic or caustic medium or atmosphere.

Figure 6.7 Arc-like cracks in plate are a sign of stress corrosion.

Corrosion Fatigue Corrosion fatigue cracks are very similar (in many cases identical) to normal fatigue cracks in appearance. They generally begin at the pin hole and move perpendicular (900) to the chain pitch line. Corrosion fatigue is not the same as stress corrosion. Corrosion fatigue is the combined action of an aggressive environment and a cyclic stress (not a static stress alone, as in stress corrosion).

Ultimate Strength Failure This type of failure is caused by overloads far in excess of the design load. See Figure 6.8.

Stress corrosion is an environmentally assisted failure. Two conditions must be present: a corrosive agent and static stress. In the chain, static stress is present at the pin hole due to the press fit pin. No cycle motion is required, and the plates can crack during idle periods. The reaction of many chemical agents (such as battery acid fumes) with hardened steel can liberate hydrogen which attacks and weakens the steel grain structure. For this same reason, never attempt to electroplate a leaf chain or its components. The plating process liberates hydrogen and hydrogen embrittlement cracks will appear. These are similar in appearance to stress corrosion cracks.

MA1003.eps

Figure 6.8

Tight Joints All joints in leaf chain should flex freely. Tight joints resist flexure and increase internal friction, thus increasing chain tension required to fit a given load. Increased tension accelerated wear and fatigue problems. See Figure 6.13, Page 6-20.

6-13

MAST

Periodic Inspection

Chain Length Adjustment

Triple-Stage Upright (TSU) Chain Length Adjustments

! WARNING An upright or carriage can move unexpectedly: •

Do not walk or stand under raised forks.

•

Keep clear of load and carriage when making any check or adjustment.

•

Keep your arms and fingers away from moving parts of the upright.

•

Block the carriage or upright when working with the components in a raised position.

•

Triple-Stage uprights use two chain set; one set for carriage lift and one set for rail lift. Adjustment anchors for the lift cylinder stage are located at the back of the outer rail. Adjustment anchors for the primary lift stage are behind the primary cylinder. Carriage chain anchors are not intended for adjustment. For TSU inner rail lift chains, chain length must be adjusted if the difference between the bottom of the inner rail and the outer rail is greater 10 mm (0.40 in.) For the TSU primary cylinder lift chain, the chain length must be adjusted if:

Do not reach through open areas of the upright.

•

The fork-to-ground clearance is less than 5 mm (0.20 in.) or more than 25 mm (1.0 in.) when the upright is vertical.

Failure to follow these warning could result in serious injury.

•

The center of the bottom carriage roller comes within 20 mm (0.80 in.) of the bottom edge of the inner rail.

IMPORTANT

•

The carriage safety stop hit the inner rail stop at full extension height.

•

• • • •

Never attempt to move or align the rails by hand. Use a prybar.

Threaded chain anchors must be left free to pivot in mounting hole.

To adjust the cylinder lift chains on a TSU use the following illustration and procedures:

Anchor pin heads must be to the inside of the upright.

1. Set the upright in the vertical position. 2. Break the jam nuts loose on the chain anchors.

Torque jam nuts to adjustment nuts to 100–200 Nm (74–148 Ft-Lbs).

3. Adjust the chain anchor adjustment nuts until the bottom of the inner rail is within 2.5 mm (0.10 in.) of the bottom of the outer rail.

Make sure chain anchors are secured so that no twist is evident in the chains.

IMPORTANT The carriage stop must not be allowed to contact the upright stop under any circumstances during normal operations.

6-14

MAST

To adjust the primary cylinder lift chains on a TSU use the following illustration and procedures:

IMPORTANT •

Threaded chain anchors must be left free to pivot in mounting hole.

•

Anchor pin heads must be to the inside of the upright.

•

Torque jam nuts to adjustment nuts to 100–200 Nm (74–148 Ft-Lbs).

•

Make sure chain anchors are secured so that no twist is evident in the chains.

1. Fork-to-ground clearance: a. Set the upright to vertical position. b. Break the jam nuts loose on the chain anchors. c. Turn the chain adjustment nuts until clearance between forks and ground is 10-20 mm (0.40–0.80 in.). 2. Carriage roller position: a. Raise carriage about 1M (3.2 ft.) and smear a bead of grease on the bottom 75 mm (3 in.) of the inner rail in the area of the roller pattern. b. Tilt upright fully back and completely lower. c. Measure the distance from where the center of the bottom carriage roller stopped to the bottom edge of the inner rail. Distance should not be less than 20 mm (0.80 in.) or chain length adjustment is required. 3. Carriage Stop-to-Upright:

To inner rail

a. Lift upright to its full height and check for clearance on the carriage safety stop. b. If carriage stop hits the upright stop, adjust the chain anchor adjustment nuts out until there is at least 3 mm (0.12 in.) clearance between the stops.

MA1004.eps

Adjust chain length here

Figure 6.9

If all three chain length requirements listed previously cannot be met, the tire diameter may be out of the design range allowance. Also, excessive tire wear will decrease carriage stop clearance.

IMPORTANT The carriage stop must not be allowed to contact the upright stop under any circumstances during normal operations.

To Carriage

Adjust Chain Length Here Figure 6.10 6-15

MAST

Chain Lubrication

General Guidelines

Like all bearing surfaces, the precision manufactured, harden-steel, joint-wearing surfaces of a leaf chain require a film of oil between all mating parts to prevent accelerated wear. Maintaining a lubrication film on all chains surfaces will:

Chain Movement—Make sure that the chain operating path is clear and that the chain articulates freely through its full range of operation.

•

Minimize joint wear.

•

Improve corrosion resistance.

•

Reduce the possibility of pin turning.

•

Minimize tight joints.

•

Lower chain tension by reducing internal friction in the chain system.

Laboratory wear test indicate that #40 oil has the ability to prevent wear better than #10 oil. Generally, the heaviest (highest viscosity) oil that will penetrate the joint is best. Whatever method is used, the oil must penetrate the chain joint to prevent wear. Applying oil to external surfaces will prevent rust, but oil must flow into the live bearing surfaces for maximum wear life. To prepare the chain for oil. The leaf chain plates should be brushed with a stiff brush or wire brush to clear the space between the plates so that oil may penetrate the live bearing areas.

Protection—Where necessary, as a protection from atmosphere or sliding wear, the chain may be covered with a layer of grease. It should be noted, however, that the grease will have to be removed at a later date for chain inspection and relubrication. Chain Mountings—Double check to be sure all chain fastening devises are secures and all adjustments have been made to assure uniform loading of multiple chain applications. Check chain anchors and pins for wear, breakage and misalignment. Damaged anchors and pins should be replaced. Sheaves—Sheaves with badly worn flanges and outside diameter should be replaced. This wear may be due to chain misalignment or frozen bearings.

Oil may be applied with a narrow paint brush or directly poured on. Chain should be well flooded to be sure the oil penetrates the joint. In locations difficult to reach, it may be necessary to use a good quality oil under pressure such as an aerosol can or pump pressure spray.

6-16

MAST

Chain Removal and Replacement

! WARNING The procedures for removing and replacing chain set involve hoisting and blocking components. •

Do not walk or stand under raised forks.

•

Keep your arms and fingers away from moving parts of the upright.

2. Remove the chain anchor pins from the back of the primary cylinder. Pull the chains through the chain sheave and lay them over the carriage load backrest.

•

Do not reach through open areas of the upright.

3. Remove the chain anchor pins from the back of the carriage.

Failure to follow these warnings can result in serious injury.

Lift Chains (Standard & TSU)

4. Use these steps in reverse order to replace the primary cylinder/carriage chain. Perform the chain length adjustment and chain tension check before returning the truck to service.

To remove and replace the lift cylinder and/or carriage chain set on standard and triple-stage uprights (TSU):

Other Chain Service Notes

1. Attach a hoist strap on the carriage of the standard upright or inner of the TSU.

•

Use lengths of factory assembled chain. Do not build lengths from individual components.

2. Lift the carriage or inner rail slightly to create slack in the chains. Block the carriage or inner rail up for safety.

•

Do not attempt to rework damaged chains by replacing only the components obviously faulty. The entire chain may be compromised and should be discarded.

•

Never electroplate assembled leaf chain or its components. Plating will result in failure from hydrogen embrittlement. Plated chains are assembled from modified, individually plated components.

•

Welding should not be performed on any chain or components. Welding splatter should never be allowed to come in contact with chain or components.

•

Leaf chains are manufactured exclusively from heat treated steels and therefore must be annealed. If heating a chain with a cutting torch is absolutely necessary for removal, the chain should not be used.

•

Always replace chains in sets. Failure to do so may damage new chain.

3. Remove the chain anchor pins on the outer rail and pull the chains off of the sheaves on the inner or intermediate rails. 4. Remove the chain anchor pins from the carriage on the standard upright or the inner rail on the TSU. On the TSU, the inner rails must be lowered to the floor to access the chain anchor pins. NOTE If a hose adapter is used, the chain sheaves must be loosened and removed to prevent the hoses from stretching when the inner rails of the TSU are lowered to access the chain anchor pins.

5. Use the steps in reverse order to replace the lift chain set.

6-17

MAST

Periodic Inspection Upright & Lift Bracket Removal & Replace Roller Shim Adjustments It is recommended that the lift bracket carriage assembly be removed before attempting to remove the uprights.

Lift Bracket Removal Preparation 1. Truck should be parked on a level surface. Extend the lift bracket fully. Lower the lift bracket onto hardwood (oak) blocks. Refer to Figure 6-11. 2. Place a support (2 X 4 or 4 X 4) between the front and rear members of the lift bracket to prevent the lift bracket from retracting once the hydraulic supply is disconnected. 3. Activate the lowering control long enough for the primary cylinder to collapse and slacken the chains. Release the control. 4. Turn the key to the “OFF” position and remove the key. 5. Disconnect the battery. NOTE If the upright is to be removed, a 5-ton chain hoist equipped with safety hooks is required.

Support Block

MA1028.eps

Hardwood (Oak) Blocking

Figure 6.11 6-18

MAST

Removal & Replace Roller Shim

NOTE

6. Remove two bolt from cable retainers.

Lift chains may be disconnected at the primary lift cylinder crosshead (see next page) or from the carriage as shown.

7. Remove front and rear retainers. 8. Disconnect electrical plug. 9. Remove both harness clamp bolts. 10. Disconnect hydraulic hoses from tube connections using two wrenches. One wrench to hold the tube connection(s) while loosening the hose connection(s). There will be some hydraulic fluid leakage upon disconnecting fittings. 11. Remove cotter pins. 12. Remove chain anchor pins securing the lift chains to the carriage chain anchors.

Figure 6.12

6-19

MAST

NOTE

Carriage chains may be disconnected at the primary cylinder. Remove cotter pins securing lift chains to the chain anchors. Remove lift chains one at a time from the chain anchors.

Once a lift chain has been disconnected, lay it over the Lift Bracket. Then, using wire, tie the chain end to the load backrest. This will keep the chains out of the way and from falling to the ground.

Figure 6.13 6-20

MAST

13. Using a 5-ton chain hoist, attach hoist to the inner and intermediate rail assemblies, See Figure 6.14 below. Be sure hoist is equipped with safety hook(s).

14. Raise both inner and intermediate rails until the inner rails clear the upper carriage rollers.

5 Ton Chain Hoist

Safety Hook Lifting Straps or Chains

Raise both inner and intermediate rails until the inner rail channels are clear of the carriage rollers.

Inner Rail

Carriage Roller

Support Block MA2183.eps

Hardwood (Oak) Blocking

MA2195.eps

Figure 6.14 6-21

MAST

15. Move truck away from lift bracket just far enough to allow the intermediate and inner rails to clear the lift bracket. 16. Completely lower the intermediate and inner rail assemblies. 17. Disconnect hoist and move truck away from lift bracket.

NOTE If the upright rail lift cylinders are to be removed, refer to the following pages. The free lift (center) cylinder may be removed without removing the upright.

Figure 6.15 6-22

MAST

Upright & Lift Bracket Removal Upright Removal It is recommended that the lift bracket carriage assembly be removed before attempting to remove the upright.

Preparation 1. Turn key switch off. Remove key from switch. 2. Disconnect disconnect.

truck

battery

the

battery

8. Place lifting strap beneath the upper tie bars of the outer, intermediate and inner rail assemblies. Connect strap ends to the chain hoist. Be certain the hoist is equipped with safety hooks. See Figure 6.17. 9. Raise lift to remove slack in the strap. Strap should be taut enough to support the upright after it is disconnected from the truck. 10. Remove all fasteners securing the upright to the truck.

3. Remove battery from truck.

! WARNING Do not stand on or near the Mast while it is suspended by an overhead hoist.

NOTE The lift bracket must be removed before attempting to remove the upright.

! WARNING

Disconnect Battery 4. Remove any overhead guards and/or screen guards.

Do not stand the Mast up vertically unless it is chained to a support.

5. Elevate and support each side of truck with suitable 3" hardwood (oak) blocking. 6. Disconnect all hydraulic supply lines to the upright. Cap all open lines and fittings. 7. Disconnect all electrical connections to the mast and tie wires out of the way.

MA1037.eps

Figure 6.16

Figure 6.17 6-23

MAST

11. Use hardwood (oak) blocks to support the bottom end of the upright and to keep it level when laid horizontally on the floor. Avoid resting the mast on hydraulic fittings.

12. Lower the upright onto the blocks with the truck side down. This will allow the rail assemblies to be pulled out of the outer rail assembly to access rail rollers and secondary cylinders.

Outrigger(s)

Inner Rail Assembly

Top

Bottom MA1038.eps

Intermediate Rail Assembly

Truck Side Outer Rail Assembly Figure 6.18

6-24

Hardwood (Oak) Blocking

MAST

Upright Disassembly 1. Pull the inner and intermediate rail assemblies part way out of the outer rail assembly to provide access for secondary cylinder removal. The rail cylinders must be removed to adjust or replace the lower rail rollers. 2. Loosen and remove the hydraulic fittings at the base of the left and right secondary cylinders. Discard old O-rings. Install new O-ring(s) at time of installation. 3. Remove the snap ring at the base of each cylinder.

Rail Cylinders Rollers and Shims Pulling the rail assemblies part way out of the bottom of the outer rail assembly will allow access to remove and/or replace rollers and shims. The rail cylinders must be removed to accomplish this.

Figure 6.19

Cylinder Base

Snap Ring

MA1040.eps

Figure 6.20 Outrigger(s)

Inner Rail Assembly

Top

Bottom MA1038.eps

Intermediate Rail Assembly

Truck Side Outer Rail Assembly Figure 6.21 6-25

Hardwood (Oak) Blocking

MAST

Upright Disassembly (continued)

! WARNING

4. Remove the external snap ring from the top of each cylinder piston rod.

Rail cylinders are heavy and care must be taken to avoid personal injury.

5. Remove the washer from each cylinder rod. 6. Support the cylinders, and move the rails outward far enough to allow removal of the cylinders. NOTE

NOTE

Each cylinder is equipped with a weldment near the top end of each barrel assembly. This weldment fits over an alignment pin that is part of the chain anchor mount of the outer upright.

Record the number of shims removed for each side. The same number of shim should be reinstalled on each side to prevent “racking” of the upright assemblies.

Figure 6.22

6-26

MAST

Cable, Hose and Chain Sheaves

! WARNING

•

Remove snap rings (6) and sheaves (5).

•

Remove screws (4) securing mounting plates to crosshead (16) and remove assembly from block.

•

Remove pins (15) and crosshead (16) from primary cylinder piston rod.

•

Loosen and remove nuts (1), capscrews (3), and spacers (2).

•

Disassemble assembly. Replace and worn and/or damaged components.

The free lift cylinder is heavy and care must be taken to avoid personal injury.

Installation is the reverse of removal.

Free Lift Cylinder •

15 5

Remove cotter pins (7), jam nuts (11), full nuts (10) and concentrical washer.

6 13

•

Remove chain anchors (8) and lift chains (13).

•

Remove snap ring (14). Lift cylinder off alignment pin (12) and out of upright.

7 9

Installation is reverse of removal.

10 11 12

Free Lift Cylinder

NOTE The free lift cylinder may be removed with upright attached to truck.

13 14 MA1041.eps

Figure 6.23

Outrigger(s)

Inner Rail Assembly

Top

Bottom MA1038.eps

Intermediate Rail Assembly

Truck Side Outer Rail Assembly

Figure 6.24 6-27

Hardwood (Oak) Blocking

MAST

Upright Disassembly (continued) Roller

Mounting Plate

Nut

2 Spacer

4 Allen Head Screw

3 Capscrew

MA1042.eps

Block

10 Roll Pin Secures Block to Cylinder Rod

5 Sheave

6 Snap Ring

Figure 6.25

Cable and Chain Sheaves •

Loosen and remove retainer bolt from stub shaft.

•

Remove washer, sheaves and spacer.

•

Replace worn and/or damaged components. Installation is the reverse of removal.

Removal

Figure 6.26 Figure 6.27 6-28

MAST

Shimming

Upright Disassembly (continued)

Figure 6.28

Figure 6.29

Shimming Load Roller Adjustment Shims

Carriage

Scissors

Lift Fork Carriage Allen Head Screw

MA2190.eps

Figure 6.30 6-29

MAST

Lift Bracket Assembly Shimming Pantograph Carriage Rollers

Outrigger(s)

Inner Rail Assembly

Top

Bottom MA1038.eps

Intermediate Rail Assembly

Truck Side Outer Rail Assembly

Hardwood (Oak) Blocking

Figure 6.31

The clearance between the upright inner rails and the lift bracket carriage rollers must be checked and adjusted.

Checks and Adjustments NOTE Roller clearance and adjustment may accomplished with the upright mounted to the truck or removed and laying on the floor as shown above.

Shimming 2. Set outside spanning tool to match the adjusted inside spanning tool. 3. Lock the outside spanning tool in the adjusted position.

1. Span inner rail with inside spanner tool. •

Find the smallest distance between rails.

•

After finding the smallest distance, place a roller shim between the spanner tool and the inner rail. Lock the tool in position.

Figure 6.33

Figure 6.32 6-30

MAST

Shimming 4. Span the upper carriage rollers at their outer most camber point. Add or remove shims at the roller shaft to match tool size. 5. Center carriage rollers by counting the shims and using equal numbers of shims on both sides. If there is an odd number of shims, place the odd shim on the right hand side.

7. Span center carriage rollers at their outer most camber point. Add or remove shims to match tool size. 8. Center carriage rollers by using equal amounts of shims on both sides. If an odd number is used, place the odd shim on the right hand side.

Figure 6.34

Figure 6.36

IMPORTANT When upright is fully extended, the upper carriage rollers extend beyond the inner rail assembly. To allow the rollers to retract smoothly back into the rail, one shim should be removed from each side. 6. Install upper carriage rollers and securely tighten the Allen head retaining capscrews. Load Roller Adjustment Shims

9. Place a carpenters square at the outer most camber point of the center and lower rollers. Hold the square tight against rollers and take the following measurements. •

Measure the distance between the top of the square and the straight edge at point (A).

•

Take a measurement at point (B). These measurements should be the same. If they are not, add or remove shims from the lower rollers shaft(s) until the distance measured at each point is equal.

Carriage

Scissors

Allen Head Screw

MA1052.eps

Figure 6.35

6-31

MAST

Shimming

11. Check and adjust rollers on the opposite side of carriage. Place square at the outer most camber of the center and lower rollers. Take measurements as before. This side will be square within 1/32:, if not , return to step 9 and repeat procedure. Make sure rollers are center as previously described.

Figure 6.37

10. Span lower rollers. Add or remove shims to (the roller that has not be squared) match the size of the outside spanning tool.

Figure 6.38

6-32

Figure 6.39

MAST

Shimming 12. The top rollers are checked last. Remember that the top carriage rollers extend out of the inner rails when the mast uprights are at full extension. To make reentry of these rollers into the inner rails easier, additional clearance is required for the top rollers. (Refer to steps 4,5 and 6). •

13. Check opposite roller in use the same procedure, adjusting if necessary.

Place the square directly through the center of the rollers as shown in the illustration to the right.

•

The rollers are shimmed properly when a 1/32" shim can be fit between the outer most camber point of top roller and the square. The clearance should not exceed 1/32".

•

If adjustments are necessary, remove the Allen head capscrew and the roller. Add or remove shims to correct the adjustment.

•

Install Allen head capscrew and check adjustment.

NOTE Upper Rollers are retained only with the Allen head capscrews. Center and lower rollers are always captive within the rails.

Carriage

1/32" Shim

Scissors

Carriage 1/32" Shim

MA1058.eps

Figure 6.41

Scissors

MA1057.eps

Figure 6.40

6-33

MAST

Shimming Upright Rails to Rollers The following procedure explains how to: •

1st—Measure rail-to-roller clearance.

•

2nd—Adjust rail-to-roller clearance.

IMPORTANT With age and wear, clearances between the upright rails and the rollers can increase and cause excessive looseness between rails and rollers. Upright rollers become worn, rail surfaces wear, and stress relieving due to handling heavy loads over a period of time may cause slight dimensional changes between upright rails. The illustration shows clearance between rails and rollers. A roller clearance inspection should be performed if, during normal operational checks of the upright, noticeable looseness or binding between rails sets, or if scoring is evident on the rails. Proper roller clearance should be maintained because the mast is designed to nest the rails snugly while providing smooth operation. Intermediate Rail

Inner Rail

Roller Figure 6.43

Outer Rail MA1060.eps

Point of roller Contact Figure 6.42 6-34

MAST

Shimming

Checking Lower Roller Clearance with upright 6" from fully retracted position Evaluation of shim requirements generally dictates the a specific roller is acceptable until 0.040" clearance is exceeded, meaning adjustment requires one standard 1/32" shims to reduce rail-to-roller clearance to proper tolerances.

! CAUTION Watch for overhead extending upright.

clearance

when

ROLLERS SHOULD BE INSTALLED “LINE-TOLINE” 0.020" MINIMUM CLEARANCE

! WARNING

Refer to adjustment reference chart when using feeler gauges.

Use extreme care when working on the upright to avoid placing hands or fingers into potential pinch points. Unexpected movement of the upright can cause serious injury.

Step

Feeler Gauge

Gauge will Pass / Not Pass

Shimmed Correctly

Shim QTY

1 2 3

0.020" 0.050" 0.050" 0.080" 0.080" 0.120"

PASS NOT PASS PASS NOT PASS PASS NOT PASS

Check with a No, ADD Check with a No, ADD Check with a No, ADD

0 1 2

Roller Clearance Inspection Service Before checking the roller clearances, place the intermediate rail approximately 6 inches out of the outer rail and the inner approximately 6 inches out of the intermediate rail as illustrated on the previous page. If the upright is mounted and the rails are being elevated hydraulically, the inner rail will automatically assume it’s correct position. Note the procedure for checking the clearance is basically the same whether the upright is mounted or has been removed from the truck. There are two methods presented, one using a pry bar to position the rails and rollers and the other using a “C” clamp. If the upright is mounted to the truck,, the use of an approved safety platform or step ladder is recommended when making inspections and checking clearances at the upper levels. If the upright has been removed and placed on the flat floor, proper blocking of hardwood (Oak) or steel supports must be used to keep the upright horizontal with the floor. This is especially important when fully extending the intermediate and inner rails.

When Using a Pry Bar Shimming •

Insert the pry bar between the outer and intermediate upright rail on the right side ( as shown in Figure 6.42. Pry with moderate pressure moving the intermediate and inner rails to the left top end of the upright.

•

Using a 0.020" feeler gauge, see if you can insert a shim between the roller and rail. There needs to be some clearance but it is not to exceeds 0.040". If the clearance between the roller and the rail is two or more shims, record the number of shims that will fit in the space between the roller and rail. Refer to chart above.

•

Pry the intermediate rail away from the inner rail. Check the clearance between the intermediate rail roller and the inner rail.

•

Record the number of shims needed to fit in the space between the roller and the rail for the outer and intermediate rail.

6-35

MAST

Shimming “C” Clamp Method •

Install “C” clamp at the location shown in Figure 7.42. It may be necessary to use a block on the inside of the channel as shown.

•

Tighten the “C” clamp to displace the roller clearance on that side of the upright. Now, check roller clearance on the opposite side of the upright.

•

Using a 0.020" feeler gauge, try to insert it between the roller and the rail at the point of contact as shown in Figure 6.42.

•

If a 0.020" will pass between the roller and the rail, and 0.040" will not fit between the rail and roller, it does not require adjustment. If clearance exceeds 0.040", refer to the chart on 6-35.

•

Record the number of shims needed to fill the space between the roller and the rail.

IMPORTANT There needs to be at least 0.020" of clearance but no more than 0.050".

Checking Lower Roller Clearance with upright 6" from fully retracted position Now check the lower rollers in the same manner as for the upper rollers. Record the number of shim needed for the outer and inner rails opposite the rollers checked.

Figure 6.44

6-36

MAST

Shimming Intermediate Rail

Checking Upper Roller Clearance with upright extended approx. 1/2 of full extension

Inner Rail

Roller

Now check the roller clearance in the same manner as before. Record the number of shim needed for the outer and inner rails opposite the rollers checked.

Pry Here

Check Clearance Here

Outer Rail MA1060.eps

ROLLERS SHOULD BE INSTALLED “LINE-TO-LINE” 0.020" MINIMUM CLEARANCE

Feeler Gauge (0.020)

Point of roller Contact

Refer to adjustment reference chart when using feeler gauges.

Check Clearance Here Inner Rail

Step

Feeler Gauge

Gauge will Pass / Not Pass

Shimmed Correctly

Shim QTY

1 2 3

0.020" 0.050" 0.050" 0.080" 0.080" 0.120"

PASS NOT PASS PASS NOT PASS PASS NOT PASS

Check with a No, ADD Check with a No, ADD Check with a No, ADD

0 1 2

Pry Here

Intermediate Rail

Check Clearance Here

Pry Here Use "C" clamp to force rollers to one side. Torque on "C" clamp should not exceed 20 ft.lbs.

Outer Rail

MA1063.eps

Figure 6.45

6-37

MAST

Shimming

Intermediate Rail

Checking Lower Roller Clearance with upright extended approx. 1/2 of full extension

Inner Rail

Roller

Now check the roller clearance in the same manner as before. Record the number of shim needed for the outer and inner rails opposite the rollers checked.

Pry Here

Check Clearance Here

Outer Rail MA1060.eps

ROLLERS SHOULD BE INSTALLED “LINE-TO-LINE” 0.020" MINIMUM CLEARANCE

Feeler Gauge (0.020)

Point of roller Contact

Refer to adjustment reference chart when using feeler gauges.

Inner Rail

Step

Feeler Gauge

Gauge will Pass / Not Pass

Shimmed Correctly

Shim QTY

Intermediate Rail

1 2 3

0.020" 0.050" 0.050" 0.080" 0.080" 0.120"

PASS NOT PASS PASS NOT PASS PASS NOT PASS

Check with a No, ADD Check with a No, ADD Check with a No, ADD

0 1 2

Pry Here

Check Clearance Here

Use "C" clamp to force rollers to one side. Torque on "C" clamp should not exceed 20 ft.lbs.

Pry Here

Check Clearance Here Outer Rail MA1064.eps

Figure 6.46

6-38

MAST

Shimming Intermediate Rail

Checking Upper Roller Clearance with upright extended approx. to full extension

Inner Rail

Roller Pry Here

Now check the roller clearance in the same manner as before. Record the number of shim needed for the outer and inner rails opposite the rollers checked.

Check Clearance Here

Outer Rail MA1060.eps

ROLLERS SHOULD BE INSTALLED “LINE-TO-LINE” 0.020" MINIMUM CLEARANCE

Feeler Gauge (0.020)

Point of roller Contact

Refer to adjustment reference chart when using feeler gauges.

Inner Rail

Check Clearance Here Pry Here

Intermediate Rail

Check Clearance Here Pry Here Use "C" clamp to force rollers to one side. Torque on "C" clamp should not exceed 20 ft.lbs. MA1065.eps

Outer Rail

Figure 6.47

6-39

Step

Feeler Gauge

Gauge will Pass / Not Pass

Shimmed Correctly

Shim QTY

1 2 3

0.020" 0.050" 0.050" 0.080" 0.080" 0.120"

PASS NOT PASS PASS NOT PASS PASS NOT PASS

Check with a No, ADD Check with a No, ADD Check with a No, ADD

0 1 2

MAST

Shimming Intermediate Rail

Checking Lower Roller Clearance with upright extended approx. within 6" of full extension

Inner Rail

Roller

Now check the roller clearance in the same manner as before. Record the number of shim needed for the outer and inner rails opposite the rollers checked.

Pry Here

Check Clearance Here

ROLLERS SHOULD BE INSTALLED “LINE-TO-LINE” 0.020" MINIMUM CLEARANCE Outer Rail MA1060.eps

Feeler Gauge (0.020)

Point of roller Contact

Refer to adjustment reference chart when using feeler gauges.

Inner Rail

Pry Here

Check Clearance Here

Intermediate Rail

Pry Here Use "C" clamp to force rollers to one side. Torque on "C" clamp should not exceed 20 ft.lbs.

Check Clearance Here Outer Rail MA1066.eps

Figure 6.48

6-40

Step

Feeler Gauge

Gauge will Pass / Not Pass

Shimmed Correctly

Shim QTY

1 2 3

0.020" 0.050" 0.050" 0.080" 0.080" 0.120"

PASS NOT PASS PASS NOT PASS PASS NOT PASS

Check with a No, ADD Check with a No, ADD Check with a No, ADD

0 1 2

MAST

Shimming Determining the Number of Shims Needed To Make Roller Adjustments •

Refer to step 3. Look at the three numbers that were recorded at each roller on the rails. The smallest of these is the total number of shims that need to be added. “0” means DO NOT add shims.

•

If any of the rollers require adjustment, refer to adjustment procedures on next page.

•

If the upright roller clearance was checked with the upright mounted to the truck, and roller adjustment is required, remove the upright from the truck as described at the beginning of this section.

•

Do not attempt to adjust roller with the upright mounted to the truck. Step 1

# of Shims

Dimension per Shim (in)

one two three

1/32"

Example of Gauge Readings

Step 2

Dimension (decimal - in) 0.031 0.062 0.093

Step 3

1 1

Inner Rail

0.020 - 0.040" 0.040 - 0.060"

Inner Rail

0 2 2

0 2 3

0.080 - 0.100"

1 3

Intermediate Rail

1 1

Intermediate Rail

3 2 3

0 2 2 0 2 3

Intermediate Rail

Outer Rail

Outer Rail Rail extended to within 6 - 10" of fully retracted.

Outer Rail Rail extended to within one half of full extension.

Figure 6.49 6-41

MA1067.eps

Rail extended to within 6 - 10" of full extension.

MAST

Shim Adjustment

Lift Bracket & Fork Carriage Assembly

With the upright laying horizontal on blocking.

The Lift Bracket Assembly may be serviced while installed in the upright with two exceptions: the carriage rollers and the inner and outer arm bushings must be serviced with the lift bracket removed from the upright.

•

Expose the rollers by pulling the rails part way out of the bottom as shown.

•

Pull rollers (one set at a time) from their stubshaft. Count the number of shim(s) currently used on each shaft. Add shims as indicated in the roller clearance check.

•

If the check indicates that an even number of shims are needed (2 etc..), split the number between the right and left sides. If the check indicates an odd number of shims (3, etc..), place the odd shim on the right hand side shaft. Always keep the odd number of shims on to one side.

•

The target for adjustment is to have the same number of shims on each roller set (right and left per rail assembly). An odd or extra shim must be placed on the same side as the one before.

•

Reposition each roller on it’s shaft using a rubber or plastic mallet. Gently tap the roller to seat it evenly and snugly on the shaft.

Preparation • Move truck to service area. • Park truck on a flat level surface. • Extend and lower lift bracket. • Turn key switch OFF. 1. Remove Load Back Rest Extension. Remove bolts from load backrest Extension and lift the extension free of the fork carriage. 2. Elevate and Block Lift Bracket. • Turn key switch ON and elevate lift bracket approximately 3 to 4 feet. • Place an oak block (hardwood) between lift bracket carriage and ground. Lower lift bracket until carriage rests on 4X4 blocking as shown. • Tilt forks forward. • Turn key OFF and remove key. • Disconnect truck battery.

Figure 6.51

MA2189.eps

Figure 6.50

Figure 6.52 6-42

MAST

Fork Removal

Lift Bracket Service

Refer to Figure 6.53

Fork Carriage Removal

Remove fork by releasing the locking pin on the top fork hanger and sliding the fork to the center of the carriage fork bar. Lift the fork up and disengage the fork hanger from the carriage bar.

Models Equipped with Sideshift Only 1. Remove hose hold down cap.

! WARNING Forks are heavy. Care must be taken to avoid personal injury.

2. Disconnect electrical plug (1) from the main harness connector. 3. Disconnect both hydraulic connections at the connector fitting (2). Cap the open ports and connections.

Upright

Pantograph

MA2192.eps

Block

Figure 6.54

MA2201.eps

Figure 6.53

MA2207.eps

Figure 6.55 6-43

MAST

Lift Bracket Service

To Remove Arm Roller “B” (or “C”):

Models Equipped with Tilt Only 1. Remove both cable and hose covers (4), See below.

Slowly move Arm “A” (up as required) while rotating Arm “B” (as shown) to move arm roller upward and out of the carriage channel.Â

2. Disconnect hydraulic connection (a) from tilt cylinders. All Models 3. Install lifting straps as shown to chain hoist equipped with safety hook.

Be extremely careful that you do not “pinch” your hands or fingers.

4. Remove retainer bolts and pins (C) securing scissor arms to the fork carriage. 5. Slowly elevate carriage until free of arms. Continue to elevate until lower scissor rollers are free to one side.

B Arms C C

A 4

MA2193.eps

MA1016.eps

Lift Straps & Safety Hook

Figure 6.57

2 1

MA2218.eps

Figure 6.56 6-44

MAST

Servicing Lift Bracket Arm Rollers Thrust Pads (Scissor Arm Roller “B” & “C”) When pad is worn near “flush” with carriage roller, new pads should be installed 1. Disconnect reach arm cylinders. See Figure 6.55. Remove retainer bolts and pins (item “B”) securing reach cylinder to lift bracket arms. 2. Lift reach arms (A) upward while pivoting arm (B) in direction shown in Figure 6.57. This allows access to arm roller and thrust pad without removing scissor assembly from carriage. 3. Inspect the thrust pads for further service as shown in Figure 6.58. Pads that are damaged or worn to their wear limit should be removed and new pads installed. 4. Remove Allen screw and pad. Install new pad. Be certain same number of shims are installed on the shaft if they were removed.

6-45

Figure 6.58

MAST

Pivot Bearing Grease Fitting Grease Fitting Inner Arm Pivot Bearings

Outer Arm

MA1019.eps

Snap Ring Cup Cone Shield

Grease Fitting Cylinder Bearing Cone Lock Nut Nut (*) Cup

Shims Grease Fitting O-Ring

Roller Wear Pad

Housing Snap Ring

Allen Screw

Shims

Roller Wear Pad Allen Screw

Figure 6.59

Important: Prepack bearing cup and cone assemblies prior to installation.

5. Disassemble the outer arm assembly.

NOTE

6. Replace seals with new ones. 7. Wash bearings (cups and cones) in a Stoddard type solvent. Inspect parts for further serviceability. Replace any part that is nicked or having rough spots in the cones or cups. Cones and cups must be replaced together. Do not install a new cone in an old cup.

If the Inner Arm Pivot Bearings need to be replaced, the lift bracket carriage must be removed from the upright. 9. Reassemble to the reverse of disassembly. Lubricate parts with clean chassis grease prior to assembly.

8. Check grease fitting for damage and to make certain none are missing.

6-46

MAST

Tilt Cylinder Overhaul Figure 6.60

Cylinder Removal Remove forks. Refer to Figure 6.60 Remove fork by releasing the locking pin on the top fork hanger and sliding the fork to the center of the carriage fork bar. Lift the fork up and disengage the fork hanger from the carriage bar.

! WARNING Forks are heavy. Care must be taken to avoid personal injury. MA2201.eps

ITA LIFT BRACKETS ITA Lift Bracket with Sideshifter Carriage Pin Carrier Assembly

Dowel Pin

Lock Washer Shim Capscrew Hose Clamp Capscrew

Snap Ring Shim Upper Wear Pad

Tilt Cylinder

Bushing

Carriage Weldment Cap

Tilt Pivot Bushing

Fitting Seal

Fitting

Tilt Pin

Seal Wiper SS Rod Retainer

Tilt Pin Bushing

Capscrew

Snap Ring

Valve Assembly Carriage Claw

Fitting

Lower Wear Pad

Grease Fitting

Coil

Capscrew MA2202.eps

Guard Lockwasher Capscrew

Carriage Bar Assembly

Figure 6.61 6-47

MAST

ITA Lift Bracket without Sideshifter Carriage Frame Assembly

Dowel Pin

Capscrew Shim Lockwasher Hose Clamp Snap Ring

Capscrew

Shim

Carrier Assembly

Cap Shaft Bushing

Clip Ring

MA2219.eps

Figure 6.62

Cylinder Removal Remove the fork carriage by removing the lower claws and lifting the carriage bars off the carriage frame. Refer to Figures 6.61 and 6.62.

7. Disconnect the hydraulic hoses from the tilt cylinder. 8. Remove the capscrews holding the tilt cylinder pivot caps in place.

1. Extend the tilt cylinder completely.

9. Remove the tilt cylinder.

2. Secure the carriage frame using an overhead hoist and a lifting strap.

Preparation and Cleaning

3. Remove snap rings from the tilt pin. See Figures 6.61 and 6.62.

The exterior surface of a cylinder should be thoroughly washed before disassembly.

4. Using the hoist, take the slack out of the strap.

A soft fiber brush should be used to remove debris and foreign objects from grooves and threaded areas, etc.

5. Using a brass drift, drive shaft out. See Figures 6.61 and 6.62. 6. Using the hoist, rotate the carriage section up to gain access to the tilt cylinder from below the carriage weldment.

A Stoddard type cleaning solvent should be used to wash the cylinder. Any part unfit for further service should be replaced with a new part.

6-48

MAST

Disassembly

Retainer Assembly 1. Remove wiper ring.

(Refer to Illustration Below) Wash exterior of the tilt cylinder in a Stoddard type cleaning solvent before disassembly. Use a brush to remove grease and grime from the cylinder tube, anchor and rod ends. 1. Place cylinder in a vise equipped with soft jaws. Do not overtighten—distortion of the shell will result.

2. Remove rod seal from inner groove. Be careful that you do not nick or scratch surface of retainer assembly. 3. Remove outer O-ring and backup ring from the retainer assembly. 4. Discard seals, wiper and backup rings.

2. Push piston rod all the way into cylinder.

Piston Rod and Piston 1. Separate the inner shell from the rod assembly.

3. Using a narrow blade screwdriver, remove the capscrew securing the pull wire / retaining ring.

2. Remove the back rings and O-rings from the inner shell and discard.

4. Remove the pull wire by rotating the upper section of the shell clockwise while gently prying the pull wire out of it’s groove.

3. Remove the piston retaining ring.

5. Remove the upper section of the shell while pushing the piston rod through the upper shell section.

5. Remove the piston. 6. Discard O-ring, sealing ring and energizer. Always install new seals.

6. Remove the piston / rod assembly.

Capscrew Inner Shell Seal Piston w/O-Ring

4. Remove piston seal with O-ring from piston and discard.

Retaining Ring Back-Up O-Ring

Rod

Base Retaining Ring O-ring Piston

Rod Seal Wiper Fitting

Outer Shell Pivot Shaft MA2209.eps

Figure 6.63

6-49

MAST

5. Lubricate and install a new O-ring in the groove next to the backup ring. Note the position of the backup and O-ring per Figure 6.63. 6. Push retainer as far as it will go into the housing. 7. Insert the new pull wire in the pull wire pushing on the wire with your fingers. Rotate the top section of the outer shell counter clock wise while pushing the pull wire into the groove. 8. Once the pull wire is installed, insert and tighten the capscrew to secure the pull wire.

5. Inspect surfaces of the piston and piston rod to be sure they are clean, smooth and free of damage.

Reassembly 1. Using only new seals and O-rings, lubricate all parts with clean hydraulic fluid. 2. Lubricate and install the energizer O-ring into the groove in the piston. Refer to Figure 6.62. 3. Lubricate and install the piston seal over the energizer. Be careful not to nick or cut the seals. 4. Install new O-rings and back-up rings onto the inner shell.

Reach Cylinder Overhaul Cylinder Removal Remove Forks Refer to Figure 6.64. Remove fork by releasing the locking pin on the top fork hanger and sliding the fork to the center of the carriage fork bar. Lift the fork up and disengage the fork hanger from the carriage bar.

5. Lubricate the seals of the inner shell and insert the inner shell into the outer shell. 6. Lubricate the piston and piston rod with clean hydraulic fluid.

! WARNING Support forks as forkbar is removed so they cannot fall.

7. Start piston into cylinder tube while gently pushing and rotating piston rod. Be careful not to damage seal. 8. Shove the piston rod all the way into the cylinder tube until it bottoms. Retainer Assembly 1. Lubricate new seals, wiper ring and retainer assembly with clean hydraulic fluid. 2. Install the inner seal, with the sealing lip facing inward, into the retainer groove. Be careful not to nick the sealing lip upon installation. 3. Install a new wiper into retainer. MA2201.eps

4. Lubricate and install a new backup ring into the outer groove on the retainer. Figure 6.64 6-50

MAST

Remove the Fork Carriage Refer to Figure 6.65. 1. Extend the reach cylinder completely. 2. Using an overhead crane, secure the scissor arms (C) to keep the scissor arms from falling once the reach cylinder has been disconnected. 3. Disconnect the hydraulic connectors and plug all open lines. 4. Remove retainer bolt and pin (B) securing cylinder shaft ends in position. It may be necessary to use a brass drift to gently tap the pins loose. 5. Remove the reach cylinder and place on a clean work bench.

Figure 6.66

Preparation, Cleaning and Inspection 1. The exterior surface of a cylinder should be thoroughly washed before disassembly. 2. A soft fiber brush should be used to remove debris and foreign objects from grooves and threaded areas, etc. 3. A Stoddard type cleaning solvent should be used to wash the cylinder. 4. Threaded area of piston rod should be examined for damage, stripping or marring after removal of rod end and jam nut. The bushing in rod end should be inspected for further serviceability. 5. All foreign objects should be removed from between threads on the piston rod, in the nut and rod end. 6. Any part unfit for further service should be replaced with new part.

Figure 6.65

6-51

MAST

MA2788.eps

2 1301 1302

1303

1304 1305 1306

1307 1308 1309 1310 1311

9 10

11 3 Left Hand Reach Cylinder

REACH CYL-1 ITEM # DESCRIPTION ITEM # 13 1 CYLINDER ASSEMBLY 2 JAM NUT RETAINER 1301 3 PISTON 1302 4 HEAD GLAND 1303 1304 5 CYLINDER ROD 6 CLEVIS 1305 7 JAM NUT 1306 8 LOCKNUT 1307 1308 9 SPRING PIN 10 DOWEL PIN 1309 11 DOWEL PIN 1310 12 LUBE FITTING 1311

Figure 6.67 6-52

DESCRIPTION O-RING BACKUP RING O-RING BACKUP RING SQUARE RING PISTON SEAL O-RING BACKUP RING SQUARE WRAP-IN RING Z-SEAL ROD WIPER SEAL

Right Hand Reach Cylinder

MAST

Disassembly

Piston Rod and Piston

(Refer to Figure 6.67) Wash exterior of the reach cylinder in a Stoddard type cleaning solvent before disassembly. Use a brush to remove grease and grime from the cylinder tube, anchor and rod ends. Remove rod end and jam nut.

1. Using a 3/4" wrench, hold the rod using the “flats” provided just below threaded area of piston rod. Now install a 2-2/8 in. socket onto the piston rod nut.

1. Place cylinder in a vise equipped with soft jaws. Do not overtighten—distort shell. 2. Push piston rod all the way into cylinder. 3. Using snap ring pliers, remove the snap ring from the cylinder retainer. 4. Remove O-ring. 5. Using a bronze drift, gently tap retainer assembly into cylinder housing clear of the shear ring. 6. Using a screwdriver, carefully lift end of shear ring from it’s groove. Be careful not to nick or scratch the piston rod. 7. With a pair of pliers, carefully pull shear ring from cylinder tube. Again, be careful not to nick or scratch the piston rod. 8. Pull outward on piston rod until rod and retainer are free of cylinder housing. Remove retainer.

Retainer Assembly 1. Remove wiper. 2. Remove seal from inner groove. Be careful that you do not nick or scratch surface of retainer assembly. 3. Remove outer O-ring and backup ring from the retainer assembly. 4. Discard seals, wiper and backup rings.

2. Remove nut from piston rod while holding the piston rod. 3. Pull piston free of piston rod. 4. Remove sealing ring and the energizer from piston. Use care not to nick or scratch piston surfaces. 5. Discard O-ring, sealing ring and energizer. Always install new seals.

Cleaning and Inspection 1. Discard old seals, wiper and shear ring. 2. Wash all parts in a Stoddard type cleaning solvent and dry with a clean lint free shop rag. 3. Inspect cylinder mounting bushing for damage. If the bushings show signs of wear and/or damage, they may be pressed out and new bushing installed. A Sleeve to fit over spherical inner bushing will be needed. Do not press out by prying on the inner bushing. 4. Inspect threaded parts for damage. Examine cylinder barrel for scoring, nicks or scratches. The cylinder barrel may be sanded with crocus cloth to remove minor scratches, etc. Be careful not to remove the chrome plating when polishing the surface. Replace all damaged or unserviceable parts. 5. Inspect surfaces of the piston and piston rod to be sure they are clean, smooth and free of damage.

6-53

MAST

Reassembly 1. Lubricate all parts with clean hydraulic fluid. 2. Lubricate and install the energizer ring into the groove in the piston. Refer to Figure 6.67. 3. Lubricate and install the piston seal over the energizer. Be careful not to nick or cut the seals. 4. Place a plastic parts bag over the threaded area of the piston rod (to protect seal). Slide a new O-ring over the bag and into the groove in the piston rod. 5. Remove bag and install piston onto rod. Carefully slide the piston over and up against the rod shoulder. 6. Install nut onto piston rod finger tight against the piston.

Figure 6.68

7. Install the 3/4" wrench back into the “Flats” provided in the piston rod.

7. Push retainer as far as it will go into the housing.

8. Using a torque wrench and 1-1/8 in. socket, torque nut to 115–132 ft. lbs. (156–179 Nm).

8. Insert the open end of a new shear ring into the cylinder housing while pushing on the ring with your fingers. Push ring inward as far as you can.

9. Now, lubricate the piston and piston rod with clean hydraulic fluid. 10. Start piston into cylinder tube while gently pushing and rotating piston rod until piston and seal have passed the shear ring groove in the cylinder tube. Be careful not to damage seal. 11. Push the piston rod all the way into the cylinder tube until it bottoms.

9. Using a bronze punch, gently tap ring the rest of the way into the tube and groove. Be sure the shear ring is fully seated in it’s groove. 10. Pull the piston rod out as far as it will come. This will position the retainer so that the retainer ring groove and into the housing on top of the retainer. 11. Lubricate a new backup ring and place it over the O-ring just installed. 12. Install the washer over the retainer and next to the backup ring previously installed.

Retainer Assembly 1. Lubricate new seals, wiper ring and retainer assembly with clean hydraulic fluid. 2. Install the inner seal, with the sealing lip facing inward, into the retainer groove. Be careful not to nick the sealing lip upon installation. 3. Install a new wiper into retainer. 4. Lubricate and install a new backup ring into the outer groove on the retainer. 5. Lubricate and install a new O-ring in the groove next to the backup ring. Note the position of the backup and O-ring per above diagram. 6. Place a plastic parts bag over the threaded end of the rod (to protect seals) and carefully slide the retainer over the rod and into the cylinder housing.

13. Install a new split retainer into it’s groove in the retainer assembly. Be sure it is completely seated in it’s groove. 14. Install jam nut and rod end to the same location it was when removed from the piston rod. 15. Cap cylinder ports until the cylinder is installed on the truck. 16. Check fluid level of truck once cylinder have been installed. 17. Purge air from hydraulic system by cycling cylinders several times to force air from the lines into the sump tank.

6-54

MAST

Sideshift Cylinder Overhaul

Preparation Cleaning and Inspection

Cylinder Removal—Lift Bracket

1. The exterior surface of a cylinder should be thoroughly washed before disassembly.

Remove Forks 1. Refer to Figure 6.69. Remove fork by releasing the locking pin on the top fork hanger and sliding the fork to the center of the carriage fork bar. Lift the fork up and disengage the fork hanger from the carriage bar. 2. Loosen fittings at the bottom of the sideshifter cylinder, catching any oil that may escape. 3. Using a pry bar, push the sideshifter rods into the cylinder body catching any oil be leaks from the cylinder. 4. Remove the capscrews securing the carriage claws to the back of the lower carriage bar. 5. Rotate the front of the carrier frame up and remove the carriage bars. 6. Remove all wear pads and discard.

! WARNING Support forks as forkbar is removed so they cannot fall.

Disassembly (Refer to Figure 6.70) Wash exterior of the sideshift cylinder in a Stoddard type cleaning solvent before disassembly. Use a brush to remove grease and grime from the cylinder tube, anchor and rod ends. 5. Using a spanner wrench in the holes located in the top of the retainer, rotate the retainer assembly counter clockwise to loosen the retainer. 6. Remove retainer and rod. 7. Remove rod from retainer.

Retainer Assembly 1. Remove the piston rod seal and wiper. Be careful that you do not nick or scratch surface of retainer assembly. 2. Remove outer O-ring from the retainer assembly. 3. Discard seals, wiper and backup rings.

MA2201.eps

Figure 6.69

6-55

MAST

LIFT BRACKET SERVICE

Figure 6.70

6-56

MAST

Reach and Sideshift Selector Valve

Cleaning and Inspection 1. Discard old seals and wiper. 2. Wash all rods and retainers in a Stoddard type cleaning solvent and dry with a clean lint free shop rag.

Preparation 1. Move the truck to a service area. •

Move truck to a flat level surface.

•

Extend lift bracket.

•

Fully lower lift bracket.

Reassembly

•

1. Lubricate new seals, wiper ring and retainer assembly with clean hydraulic fluid.

Tilt (if so equipped) forks forward until the fork tips touch the ground.

2. Turn key switch off.

3. Inspect surfaces of the rod to be sure they are clean, smooth and free of damage.

2. Install the inner seal, with the sealing lip facing inward, into the retainer groove. Be careful not to nick the sealing lip upon installation.

•

Remove key.

•

Disconnect truck battery.

3. Install a new wiper into retainer. 4. Lubricate and install a new O-ring in the groove. 5. Push retainer as far as it will go into the housing. 6. Using a spanner wrench, tighten the retainer. 7. Start rod into cylinder tube while gently pushing and rotating the rod. Be careful not to damage seal. 8. Push the rod all the way into the cylinder shell until it bottoms out. 9. Purger air from hydraulic system by cycling cylinders several times to force air from the lines into the sump tank. a. Reinstall new wear pads and lubricate wear pads. b. Reinstall front carrier on cylinder body. c. Reinstall carriage claws and capscrews to back face of the lower bar.

Figure 6.71 6-57

MAST Figure 6.72

! CAUTION The solenoid valve stem is very fragile. Be very careful when handling the valve that you do not dent or bend the stem. Over torquing the coil nut or the valve at installation will cause damage to the valve.

Figure 6.73

6-58

MAST

Mast Hydraulic Schematic FREE LIFT CYLINDER

MAIN LIFT CYLINDERS

MAIN LIFT HOSE SIDESHIFT CYLINDER (OPTIONAL)

C5 C2

V1 C1

V2 V2

C6 S8

C4 C1 V2

TILT CYLINDER REACH CYLINDERS

Mast Hydraulic Schematic Figure 6.74

6-59

SIDESHIFT CYLINDER

MAST

Reach and Tilt Selector Valve

1. Loosen guard mounting bolts and remove the guard. 2. Unplug connect (#1) from coil (S6) and unplug connectors (#2) from coil (S5). 3. Remove fasteners (#4) from clamp (#3). 4. Tag hoses and disconnect hydraulic connections (#5) and (#8) from valve (A). Cap both hose ends.

! CAUTION Residual pressure will be present when disconnecting hydraulic lines. Use caution when disconnecting fittings. 5. Tag tubes and disconnect fittings (#11) and (#12) from bottom side of valve (A). Cap both hose ends. 6. Remove both mounting fasteners from lift bracket frame (B) and valve (A). 7. Remove valve from lift bracket. Place components on a clean work bench.

Disassembly •

Remove nuts, coils and solenoid valves (S5) and (S6) from the valve body. NOTE The valve body and valves are not serviceable. If the unit is not functioning properly, it must be replaced.

Figure 6.75

! WARNING Be sure the lift bracket is blocked.

! WARNING Hydraulic lines may have trapped pressure. “Crack” the fittings to bleed pressure before disconnecting.

Mounting Selector Valve 1. Position the valve to the lift bracket frame aligning holes in frame with those in the valve. Refer to illustration on previous page. 2. Install mounting fasteners finger tight. Do not tighten fasteners until after the hydraulic hoses are installed.

! WARNING When trapped pressure is bled, the lift bracket may settle. Beware. 6-60

MAST

Connecting Hydraulic Plumbing 3. Remove cap, hose tag and install connection (#11) to the valve finger tight. 4. Remove cap, hose tag and install (#12) connection finger tight. 5. Install connections (#5) and (#8). Install connections (#6, 7, 8, 9 and 10) to the reach cylinders finger tight. 6. Securely tighten each hydraulic connection to the valve body and the reach cylinder.

IMPORTANT Be sure the hoses are routed correctly before attempting to connect them to the valve.

Installing clamps, connect wire, tighten nuts and bolts 7. Be sure the valve guard is located properly and securely tighten both solenoid valve mounting bolts. 8. Install wire clamps (#3) and bolts (#4). 9. Connect coil plugs to their respective receptacles.

IMPORTANT All electrical plugs and their receptacles are matched labeled for easy connection. Check to be sure each plug and receptacle match before attempting to make connections. 10. Install and tighten clamp bolts (#4).

! CAUTION The system must be purged of air before putting truck back into service or damage to the hydraulic system may occur.

6-61

MAST

2. Turn key switch off.

Sideshifter Solenoid Control Valve Removal

•

Remove key.

•

Disconnect truck battery.

3. If equipped, control circuit capacitors must be discharged to avoid possibly being shocked when working on the solenoid valve.

1. Move the truck to a service area. •

Move truck to a flat level surface.

•

Extend lift bracket.

•

Fully lower lift bracket.

•

Tilt (if so equipped) forks forward until the fork tips touch the ground.

a. Remove guard lockwashers and capscrews.

Figure 6.76 6-62

MAST

•

Unplug Connectors from (S7) coil.

•

Label each hose with it’s location.

•

Disconnect hydraulic connections (V1, V2, C6, C5, C2, and C4) from the sideshifter selector valve.

•

Cap each hose when disconnected.

Installation Mount Selector Valve •

Line up mounting holes in selector valve with those in the mounting bracket. Install mounting bolts finger tight.

Install Hoses

! WARNING

•

Hydraulic lines may have trapped pressure. “Crack” the fittings to bleed pressure before disconnecting.

Wipe hose ends and connectors clean. Remove hose caps just prior to installation. Be certain all connections are tight.

Connect Coils NOTE There will be some fluid leakage when hydraulic fittings are disconnected. Place a rag beneath the fitting to be removed. •

Remove mounting bolts securing the selector valve to the lift bracket.

•

Remove valve and place on a clean work bench.

•

The valve assembly is not serviceable, if unit is not functioning properly, it must be replaced.

•

Inspect hoses and connectors for further serviceability.

•

Replace defective parts.

•

Plug connectors to (S7) and (S8) coils.

•

Tighten all mounting fasteners.

•

Install guard.

Figure 6.78

MA2207.eps

Figure 6.77 6-63

MAST

Servicing a Double Reach Lift Bracket The Double Reach Lift Bracket is serviced the same as the Single Reach Lift Bracket with one exception. The Double Lift Bracket has two scissor assemblies.

Figure 6.79 6-64

MAST

Double Reach Without Sideshifter Hose routing.

Figure 6.80

Figure 6.81

6-65

MAST

Installing Reach Cylinders Use this procedure when installing or replacing reach cylinders. Remove glass or wire screen to access reach cylinders. 1. Fully retract cylinders. 2. Break fitting on piston side. 3. Adjust until both pistons are bottomed out. 4. Tighten connector/fittings. 5. Turn 2 to 2.5 full turns in. 6. Adjust same amount to both sides. 7. Make final adjustment per drawing.

Figure 6.82

6-66

MAST

Reach and Tilt Selector Valve Service

NOTE

Disassembly 1. Remove nuts, coils, and solenoid valves (S5) and (S6) from the valve body. 2. Remove both counter balance valves from the valve body.

It is not necessary to separate the the valve bodies unless there is leakage between the two bodies. If there is leakage between the two bodies, then remove the four 1/4-20 screws and separate the bodies. Replace the valve bodies with new ones.

Typical Counterbalance Valve

MA2580.eps

Typical Solenoid Valves

Figure 6.83

6-67

MAST

Reach and Tilt Selector Valve Service

! CAUTION

Cleaning 1. Wash all parts except the coils in a Stoddard type cleaning solution. Wipe the coils with a clean cloth.

Cleanliness is of extreme importance. Before disconnecting hydraulic components, clean exterior of plumbing and solenoid valve to prevent dirt and other foreign material from entering hydraulic system.

2. Wipe all parts with a clean lint free cloth. Allow components to air dry before reassembly.

O-Ring(s)

Typical Cartridge Kit

Back-Up Ring(s)

Solenoid Valve

Typical Illustration

Figure 6.84

6-68

MAST

Reach and Tilt Selector Valve Service

Leads

Reassembly—Solenoid Valves 1. Lubricate all parts in clean hydraulic fluid prior to installation. 2. If the O-rings are damaged, replace the valve. 3. Install the solenoid valves back into their respective ports on the valve body. Be certain the solenoid valve is torqued correctly to the body. Torque between 8–10 ft-lbs (11–14 Nm). 4. Install the coil over the solenoid valve. 5. Install the coil retainer nut and torque to 25 ft-lbs (33.9 Nm) maximum. This allows the coil to be correctly positioned during installation to the truck.

6-69

Nut Torque to 5 lb.ft. (6.8 Nm) Max.

Coil MA1073.eps

Figure 6.85

Valve Body

MAST

Reach and Tilt Selector Valve Service O-RINGS

BACK-UP RINGS

Counterbalance Valve (NON-ADJUSTABLE) If the valve has been tampered with, it must be replaced.

BODY

MA2581.eps

Figure 6.86

! CAUTION Cleanliness is of extreme importance. Before disconnecting hydraulic components, clean exterior of plumbing and solenoid valve to prevent dirt and other foreign material from entering hydraulic system.

6-70

MAST

Reach and Tilt Selector Valve Service

Valve Body

Reassembly—Counterbalance Valves 1. Lubricate all parts in clean hydraulic fluid prior to installation. Use only new seals. 2. If the O-rings are damaged, replace the valve. 3. Install the counterbalance valves back into their respective ports on the valve body. Torque to 35 ftlbs. (47 Nm) maximum.

MA2582.eps

Check Valve

Installation

Solenoid Stem Valve

IMPORTANT Inspect hoses, hydraulic connections and their seals for damage.

Solenoid Coil

Wipe hose ends and connections clean, prior to installing them to the solenoid valve. Remove hose caps prior to installation.

Figure 6.87

6-71

MAST

Sideshift Selector Valve Service O-Ring(s)

Typical Cartridge Kit

Back-Up Ring(s)

Solenoid Valve

Typical Illustration

Figure 6.88

Disassembly

Cleaning

1. Remove nut and coil from each solenoid valve. 2. Remove both solenoid valves from the valve body.

1. Wash all parts except the coils in a Stoddard type cleaning solution. Wipe the coils with a clean cloth. 2. Wipe all parts dry with a clean lint free cloth. Allow components to air dry before reassembly. 3. If the O-rings are damaged, replace the valve.

6-72

MAST

Sideshift Selector Valve Service

Leads

Reassembly 1. Lubricate all parts in clean hydraulic fluid prior to installation. 2. Install the solenoid valves back into their respective ports on the valve body. Be certain the solenoid valve is torqued correctly to the body. Torque 8–10 ft-lbs. (11–14Nm). 3. Install the cover over the solenoid valve. 4. Install the coil retainer nut and torque to 25 ft-lbs. (33.9 Nm) maximum. This allows the coil to be correctly positioned during installation to the truck.

6-73

Nut Torque to 5 lb.ft. (6.8 Nm) Max.

Coil MA1073.eps

Figure 6.89

Valve Body

MAST

Mast Triline Hose/Cable Routing Pantograph Tri-Line Hose/Cable

Mast Tri-Line Hose/Cable

Pantograph Cable end

Mast Cable end

MA2583.eps

Figure 6.90

SEAL-PROTECTOR PLUG

SEAL

SEAL-INTERMEDIATE

SEAL

WIRE 1 WIRE 2 WIRE 3

POSITION 1

SOCKET (Not Shown) POSITION 1

POSITION 1

WIRE COLOR: WIRE #1-BLACK W/BROWN STRIPE WIRE #2-GREY W/YELLOW STRIPE WIRE #3-GREY W/GREEN STRIPE WIRE #4-GREY WIRE #5-GREEN

CAP

POSITION 1

WIRE 5 WIRE 4

WIRE #1 (POWER) WIRE #2 (REACH) WIRE #3 (SS) WIRE #4 (TILT) WIRE #5 (TILT IND.)

WIRE #1 WIRE #2 WIRE #3 WIRE #4 SPADE FEMALE (LENGTH TO BE SAME AS WIRE 1-4)

MA2584.eps

Pantograph End

Mast End

WIRE #5

Figure 6.91

6-74

MAST

Field Replacement of Mast Triline Harness 1. Remove mast guard (plexiglass) in order to access the backside of the mast from the chassis.

11. Disconnect mainlift triline hose at the “U” tubes attached to the bottom of the inner rail and lay hose along side of chassis with pull wire still in it. Cap “U” tubes and plug the hose. Unbolt “U” tube bracket assembly from inner rail.

2. Extend scissor mechanism (pantograph) forward and block it, to prohibit movement while servicing.

12. Disconnect freelift triline hose from the “U” tubes. Cap “U” tubes and plug the hose. Unbolt “U” tube bracket assembly from inner rail.

3. Disconnect mast harness from chassis at front left side of chassis.

13. Pull old harness and pull wire through the “U” tube bracket assembly near the mainlift triline hose with pull wire still in it.

4. Remove the six pin plug from the harness. 5. Attach pull wire to the end of the harness where the plug was removed. This will be used to pull the new harness back through the triline hose and will ensure that it is properly routed. 6. Disconnect triline hose from the termination bulkhead fittings on the left rear of the mast outer channel. Cap the fittings and plug the hose. Caps on bulkhead fittings should be positive engagement SAE type to prohibit inadvertent auxiliary flow while raising mast. 7. Raise the mast, so that the intermediate rail is approximately 6" above the outer rail. Block the intermediate rail with equal length 4x4 pine blocks at this position to prohibit unintended lowering of the mast. 8. Remove mainlift hose sheave at top of intermediate rail and feed slack hose toward the rear (chassis side) of the mast. Be sure hose is fed rearward below the upper crossmembers of the outer rail. 9. Raise mast, while continuing to feed slacked hose rearward. Keep hose taut while raising mast to avoid damaging it. Keep hands out of mast. Continue raising mast until bottom of inner rail is visible and accessible above the cowl of chassis. 10. Block intermediate rail at this position using equal length 4x4 pine blocks to prohibit unintended lowering of the mast.

14. Remove blocks and lower mast, keeping tension on freelift triline hose to avoid damaging it. Keep hands out of mast. Continue lowering until pantograph is approximately 4 feet off the floor. Block pantograph at this position to prohibit unintended lowering of the mast. 15. Unplug mast harness from pantograph harness. 16. Remove the clips and brackets securing mast harness and end plug. 17. Pull old harness and pull wire through freelift triline hose. Be sure end of pull wire is not pulled through into main-line triline hose. Freelift triline should remain routed through freelift cylinder crosshead. 18. Disconnect pull wire through old harness. 19. Connect pull wire to new harness. Wire en pins should be staggered when taping/attaching pull wire to minimize diameter of bundle. This will greatly facilitate pulling harness through triline. Be sure to add several inches of the wires and not the end pins. Add a small of lubricant to bundle for easier pulling. 20. Pull new harness through freelift triline hose using pull wire. 21. Connect plug to pantograph harness. 22. Reinstall clips and brackets to secure new harness near plug end.

6-75

MAST

23. Raise mast back to height where bottom of inner rail is visible and accessible. Re-block at this location to prohibit unintended lowering. 24. Pull harness through “U” tube and reinstall “U” tube bracket assembly on lower cross member of inner rail. 25. Reattach freelift triline hose to “U” tubes (right side of “U” tube bracket assembly). 26. Pull new harness through mainlift triline hose. 27. Reconnect mainlift triline hose to “U” tubes. 28. Remove blocks and lower mast until inner weldment is approximately 2 feet above outer rail. Be sure to guide triline to avoid damaging it. Keep hands out of mast. 29. Block inner rail at this position to prevent unintended lowering of mast. 30. Lower the mast enough onto the blocks to get minimal slack in mainlift chains. Lower no further. 31. Install mainlift triline hose sheave with triline hose on sheave. Follow mainline chain to ensure proper routing. 32. Reconnect mainlift triline hose to rear termination bracket. 33. Remove pull wire. 34. Install plug. 35. Reconnect plug to chassis harness. 36. Remove blocks and lower mast.

6-76

MAST

Mast “Auxiliary” Hydraulic Flushing Procedure

Step 3

This procedure should be used when contamination is found in the mast auxiliary hydraulic system. The contamination may be dirt or small metallic particles. Due to the restrictor fittings in the tilt cylinders and the close fit in the solenoid and counterbalance valves, most contamination will become trapped in these areas. The two most likely areas of contamination are in the sideshift and tilt cylinders.

•

If the mast is equipped with a sideshifter, loosen and remove the sideshift cylinder head retainers. If the unit does not have a sideshifter, skip to Step 4. Keep the rod installed in the retainer and remove as a complete unit. Examine the rod for contamination and clean if necessary.

•

Disconnect the sideshifter hoses at the fitting near the sideshifter. Flush the hoses by using the truck hydraulics to pump approximately 1 quart of oil through each hose. Check the oil for contamination and repeat the flushing until the oil is clean.

•

Using the truck hydraulics and sideshifter hoses, pump oil into the open end of the sideshift cylinder to flush the cylinder. Use a light to look into the cylinder for contamination. If contamination is present, flush the cylinder again and wipe out the inside with a long brush and clean rag. The straight fittings at the bottom of the cylinder may have to be removed and flushed if extensive contamination is found.

•

Examine the seals and O-rings for damage. The use of a new seal kit is recommended. Reassemble the gland nuts and rods into the sideshift cylinders and torque. Install the straight fittings back into the bottom of the cylinder if they were removed. Do not attach the hoses.

Review safety procedures located in the front of this service manual and wear protective hand and eye protection. A copy of the parts and service manuals, an adequate supply of fresh oil for the truck, blocking or a hoist to support the mast and pantograph, sufficient catch pans, drain hoses and clean rags. Step 1 •

Disconnect the bulkhead fittings at the two auxiliary supply hoses from the truck to the mast on the left side of the chassis.

•

Attach hoses to the truck feed lines and run the hoses into a clean container or through a clean rag into a container. Using the truck’s hydraulic system, pump approximately 1-1/2 quarts of oil through each of the supply lines to flush them.

•

Check the oil for signs of contamination to verify that the truck system is clean. If the oil is clean, reconnect and tighten the truck auxiliary mast feed lines to the mast and proceed to Step 2.

•

Step 4 •

Raise the carriage approximately 3-1/2 feet, extend the pantograph and tilt the carriage full up. Block up the rear frame assembly, block the pantograph from retracting and block the carriage from tilting down. Remove the guard over the valve block.

•

Remove the hoses from both ends of the tilt cylinder. The solenoid valve bolts may be loosened to allow easier access to the fittings. Use the truck hydraulics to pump approximately 1 quart of oil through both the tilt up and tilt down hoses to flush the hoses. If oil shows contamination, repeat the flushing operation until oil is clean.

If the oil is contaminated, repeat the flushing operation. If the oil is still contaminated, the truck’s hydraulic tank will need to be drained and the whole truck system flushed.

Step 2 •

Remove the load backrest from the mast carriage.

•

Raise the carriage about 3 feet and remove the lower carriage claw. Lower the carriage and remove the front carriage.

6-77

MAST

Step 5

Step 8

•

Remove the 4 solenoid coils with the wires attached from the reach/retract and tilt solenoid stems. Note the location of each coil prior to removal.

•

Remove the 4 solenoid stems and note the location of each stem. Examine each stem for contamination, flush in clean oil and slightly tap stem while looking for contamination. If contamination is present, replace the solenoid stems.

•

Flush all 4 valve stem ports by pumping approximately 1 quart of oil through each of the valve body ports by actuating the reach/retract and tilt up/down functions on the truck. Examine the valve body ports while looking for evidence of contamination. Repeat the flushing procedure until no contamination is evident.

•

Reassemble the valve stems and solenoid coils onto the valve body.

•

Remove the solenoid assemblies with electrical wires still connected. (If the unit does not have a sideshifter, there may be plugs in the ports or no coils on the solenoid stems). Remove the solenoid valve stems or plugs. Carefully examine them for contamination and flush if necessary. If the sideshifter has been repeatedly malfunctioning, replace the solenoid stems with new stems. Protect the solenoid coils and flush the valve body by using the truck hydraulics. Pump approximately 2 quarts of oil through the valve body by activating both the tilt up and tilt down functions. Examine the valve body ports for contamination and flush again. If contamination still exists, install a new valve body.

Step 6 •

•

Remove the bolts and caps holding the tilt cylinder and remove the cylinder. Remove the 90° fittings from the cylinder and create a drawing showing how each is positioned. Turn the cylinder, so that the port at the butt end of the cylinder points down and then push in the rod to flush out any oil. Examine both ports of the cylinder for contamination. If contamination is present, the cylinder should be replaced with a new cylinder. Inspect the two fittings for contamination. One fitting is a straight through fitting which can be easily cleaned. The other fitting is a restriction fitting with a very small port. The fitting may have free flow going into the cylinder and restricted floe coming out of the cylinder; however, air should pass through the fitting in both directions. If the fitting appears to be plugged, order and install a replacement fitting.

Step 7 •

Remove the valve cover bracket from the upper mast valve.

•

Remove the reach and retract counter balance valves from the valve body noting the location of each valve. Examine the valves and valve body for contamination. The valves can be flushed in oil and tapped lightly while looking for hidden contamination. If no contamination is found, reinstall the counter balance valves.

Step 9 •

Disconnect both hydraulic hoses from the reach cylinders and check for contamination. Flush the hoses by plumbing approximately 1 quart of oil through the hoses using the reach/retract hydraulic function on the truck.

•

Check the oil for contamination. If no contamination is found, reconnect the hoses.

•

If contamination is present, repeat the flushing until the oil is clean. Order replacement cylinders and install cylinder and reconnect the hoses.

Step 10 •

Install the tilt cylinder and reconnect and tighten the hydraulic lines.

•

Attach and tighten the sideshift hydraulic lines.

•

Remove the blocks, hold the tilt and reach mechanism in place.

•

Test the system for leaks by actuating each hydraulic function. Note that air has been trapped in the system and the tilt and sideshift function may need to be actuated several times to remove the trapped air.

•

Actuate each function at least 10 times to insure all functions are operating properly.

6-78

HYDRAULIC SCHEMATICS Legend ...........................................................................................................

7-1

Standard Performance with Tilt ...................................................................

7-2

Standard Performance with Tilt and Sideshift ............................................

7-3

High Performance with Tilt ...........................................................................

7-4

High Performance with Tilt and Sideshift ...................................................

7-5

HYDRAULIC SCHEMATICS

Legend Identifier

Description

M (Top) M (Bottom) m1 m2 m3 m4 S5 S6 S7 S8 S9 S10

2nd Pump Motor and Pump (High Performance Only) Main Motor and Pump Mast Lower Solenoid Mast Lift Solenoid Auxiliary Oil Direction Solenoid Auxiliary Oil Direction Solenoid Reach Solenoid (Activated) Retract Solenoid Sideshift Left Solenoid Sideshift Right Solenoid Tilt Up (Activated) Tilt Down (Activated)

7-1

Standard Performance with Tilt

HYDRAULIC SCHEMATICS

7-2

Standard Performance with Tilt and Sideshift

HYDRAULIC SCHEMATICS

7-3

High Performance with Tilt

HYDRAULIC SCHEMATICS

7-4

High Performance with Tilt and Sideshift

HYDRAULIC SCHEMATICS

7-5

8-11 8-11 8-11 8-12 8-13 8-13 8-14 8-14 8-14 8-16 8-16 8-17 8-17 8-17 8-18 8-19 8-19 8-20 8-20 8-20 8-20 8-21 8-21 8-22 8-22 8-23 8-23

8-24 8-24 8-24 8-25 8-26 8-27 8-28 8-29 8-30 8-32 8-34 8-35 8-36 8-37 8-38

8-38 8-38 8-38 8-39 8-40 8-50

CONTROLLER

System Configuration and Outline System Configuration The controller has more than one independent controller on the Controller Area Network (CAN) connected and controls the vehicle by letting the controllers communicate mutually.

System Configuration

Battery voltage Pedal Lever Contactor Electromagnetic brake

Display unit

Tire angle Tire angle switch U

V W

Logic unit

APS unit

CAN bus

Traction inverter

Pump inverter

Pulse encoder

U V

2nd Pump inverter (HP only)

Control valve

Output unit

Temperature sensor

Traction motor

Pump motor

2nd Pump motor (HP only)

8-1

211829

CONTROLLER

Outline

Inverter

Logic Unit

The inverter consists of the Digital Signal Processor (DSP) card, Insulated Metal Substrate (IMS) module and their drive boards.

The logic unit consists of the logic card and the power supply card.

The DSP card has the following functions.

The logic card has the following functions.

(1) The DSP card controls the AC induction motors (traction and pump motors).

(1) The logic card controls all the jobs for the truck. •

Calculates the traction motor control command according to the traveling operation and sends the command to the traction inverter.

•

Calculates the pump motor control command and solenoid current according to the hydraulic operation, and sends the command to the pump inverter (in the Contactor Control Type, turns on and off the pump contactor) and the output unit.

•

Controls the AC induction motors according to the motor control command sent from the logic unit.

(2) The DSP card detects the malfunctions and activates the fail-safe function.

Monitors and sends the display data to the display unit.

(2) The logic card detects the malfunctions and activates the fail-safe function.

•

Overheat or fault of the IMS module and drive boards

•

Sensor fault (current sensor, pulse encoder, etc.)

•

Overheat, over-current, over-speed, wire breakage or short circuit of the motors

(3) Others

•

Battery voltage fault

•

Equipped with the CAN interface.

•

Wire breakage or short circuit of the input equipment

•

Software update available (with specific tools).

•

Over-current, wire breakage or short circuit of the output equipment

The IMS module has the following function. (1) The IMS module has plural MOS-FET modules and converts the battery direct current into the alternating current for supplying it to the AC induction motors.

(3) The logic card monitors the malfunctions of each controller and activates the fail-safe function. (4) The logic card stores the fault data detected. (5) The logic card sets the truck parameters and stores the setting data into the internal memory. (6) Others •

Equipped with the CAN interface.

•

Software update available (with specific tools).

•

Equipped with the serial communication for the Service Tool.

The power supply card has the following function. (1) The power supply card reduces the battery voltage and supplies the voltage to each card.

8-2

CONTROLLER

Output Unit (RIO)

APS (Advanced Power Steering) Unit

The output unit has the following functions.

The APS unit has the following functions.

(1) The output unit controls the solenoids (control valves).

(1) The APS unit controls the AC induction motor (steering motor).

•

Controls the solenoids according to the solenoid current command sent from the logic unit.

•

(2) The output unit detects the malfunctions and activates the fail-safe function.

Controls the AC induction motor according to the steering operation and controls the rear wheel.

(2) The APS unit detects the malfunctions and activates the fail-safe function.

•

Wire breakage or short circuit of the solenoids

•

Sensor fault (tire angle sensor, etc.)

•

Motor fault

•

Over-current or leakage current of the solenoids

(3) Others •

Equipped with the CAN interface.

•

Software update available (with specific tools).

Display unit The display unit has the following functions. (1) The display unit displays the data according to the display data sent from the logic unit. (2) The display unit sends the switch input on the display to the logic unit. (3) Others •

Equipped with the CAN interface.

8-3

Equipped with the CAN interface

CONTROLLER

External View Logic Unit

Power card assy 1 3 5 7 9 11 13 15 2 4 6 8 10 12 14 16

Pin location of power card side XA5_1P

Logic card assy

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64

Pin location of logic card side XA5

211830

LOGIC/POWER SUPPLY CONNECTOR XA5_1P

LOGIC CONN 2 XA5_1

Harness View

LOGIC CONN 1 XA5_1

LOGIC CONN 3 XA5_1

Harness View

8-4

CONTROLLER

Inverter (1) Traction and Pump Inverters

A Card assy, DSP

1 3 5 7 9 11 13 15 17 19 2 4 6 8 10 12 14 16 18 20

Pin location of DSP card assy (from view A) Inverter Card Side Traction/Pump XA1_2 Traction XA2_2 Pump XA6_2 Pump

PUMP INVERTER (XA2_2, XA6_2) TRACTION INVERTER (XA1_2)

Harness View

8-5

211831

CONTROLLER

Output Unit

1 3 5 7 9 11 13 15 17 19 2 4 6 8 10 12 14 16 18 20

21 23 25 27 29 31 33 35 37 39 22 24 26 28 30 32 34 36 38 40

Remote Output Controller Connector pin number from view A XA4_1 211833

SOLENOID CONTROL XA4_1

Harness View

8-6

CONTROLLER

Display Unit

11 12 13 14 15 16 17 18 19 20

7 8 9 10 11 12

1 2 3 4 5 6 7 8

1 2 3 4 5 6

9 10

Connector pin number from view A XA7_1

211834

DISPLAY CONNECTOR XA7_1

Harness View

8-7

CONTROLLER

Controller Area Network (CAN) The terminal resistors must be active at two places on the network system. In this system, the internal terminal resistors of the pump inverter and output unit are activated as shown in the figure below.

The controllers are connected in parallel on the CAN bus as shown in the figure below. Each controller (except for the logic unit) has internal terminal resistors and they become active by short-circuiting two terminals (pins) of connector.

Pump inverter

Traction inverter

2nd Pump inverter

APS unit

Display unit

Logic unit

Output unit

CAN_H CAN_L 211835

The data are expressed with electric potential difference in high-and low-level signals as follows. They are transferred to each controller through serial communication protocol.

Logic

dominant

recessive

potential

Kind of bit

VCAN-L

Vdiff

VCAN-H recessive

dominant

recessive time 211176

Main specifications Communication protocol

CAN bus 2.0B passive

Non-Return to Zero method Broadcast communication protocol

Communication line Communication speed Data length

Dual 2-wire type serial communication 500 kbps 0 to 8 bytes

8-8

CONTROLLER

AC Motor System Basics Feature of AC motor The AC motor model trucks covered by this manual use AC motors (three-phase induction motors) as the traction motor and pump motor. AC motors have the following advantages over DC motors:

The frequency and voltage can be controlled in a variety of methods including the “vector control method” employed in the AC motor model trucks. This method provides highly responsive control according to ever changing truck-operating conditions through highspeed calculation on huge amount of data. The vector control calculation is performed by the inverter. (Figure 2)

(1) AC motors are simple in construction. As they have no such friction parts as brushes and commutators, daily maintenance load is significantly reduced. (2) AC motors are compatible with high-speed operation.

(3) An AC motor of a certain size produces higher power than a DC motor of the same size.

Inverter

Speed control of induction motors Speed control of DC motors depends on regulation of the field and armature current amounts, while that of AC motors basically depends on adjustment of the frequency of the alternating current power supply. The speed of an AC motor is determined by the frequency of the power supply AC current and the load on the motor. In addition, the voltage and current to the motor must be controlled properly so that the motor operates in its optimum characteristic range. (Figure 1)

V V W t Low-speed operation (low frequency)

t High-speed operation 209542

Figure 1

Logic unit

Inverter Gate driving pulse

Accelerator

V U

Speed Calculation for order required output

Vector control calculation

MOS-FET modules

Control Handle Truck speed Traction Pedal

Current Speed

211214

Figure 2 8-9

CONTROLLER

Inverter

Switch

The truck battery delivers DC current, so the current must be converted into AC current to drive an AC motor. The device that converts direct current into alternating current is generally called “inverter.” The processes involved in creating AC current from DC current are described below.

Load

VL =

T1 × VB T1 + T2

ON OFF ON

Average voltage VL

(1) Changing DC voltage cyclically If the switch in a circuit like a one shown in Figure 3 is turned on for time T1 and then turned off for time T2 and this on-off operation is repeated many times, the average of the voltage applied to the load is determined by the ratio between T1 and T2. Varying the ratio, therefore, results in varying voltage. The ratio between T1 and T2 is called “duty ratio.” By changing the duty ratio cyclically, it is possible to obtain cyclically changing DC voltage shown in Figure 3.

Small duty ratio

Large duty ratio

ON ON ON

OFF OFF

209544

Figure 3

(2) Converting DC power into AC power Driving a three-phase AC motor using battery delivered power requires creating three phase outputs (U, V, W) of an identical waveform that differ in phase by 120° using a circuit with six switches S1 to S6 that are arranged as shown in Figure 4. The outputs thus created forms a three-phase alternating current. Figure 5 shows on-off condition of each switch (arm) and output voltage variation. Functioning as switches in the inverter of the AC motor trucks are MOS-FET transistors. The MOSFET transistors can switch at very high speeds, thus creating smooth waveforms of alternating current.

S1 S3 S5 U V W S2 S4 S6

209545

Figure 4

S1 ON Switching for U phase S2 ON

S3 ON

Switching for V phase S5 ON

S4 ON

Switching for W phase S6 ON 209546 V lt

b t

Figure 5

8-10

CONTROLLER

Function

Powering (1) Normal traveling

Traction Control Function The line contactor closes in the following conditions when the key switch is turned on. This enables the inverter to control the traction motor.

The controller supplies power to the traction motor according to the acceleration rate (set by SUO #10) and the torque characteristic (set by SUO #11) when the traction lever is shifted. The controller returns power to the battery according to the deceleration rate and the torque characteristic that are set as fixed values when the truck is decelerated by returning the traction lever (regeneration function).

Conditions for closing line contactor All the following must be satisfied. •

The presence pedal is depressed.

•

The hydraulic operation is not performed (the hydraulic lever input does not occur).

•

The traveling operation is not performed (the traction lever is placed to Neutral and the traction pedal is not pressed).

•

Error related to the traveling and hydraulic operations does not occur.

Truck speed is controlled by shifting the traction lever. The speed is also controlled by shifting the traction lever when descending a grade and it is controlled only in the output torque range of the traction motor.

Torque [%] 100

HIGH POWER(3) STANDARD(2) ECONOMY(1) Thermal, BDI [0] or Service indicator* 1 Voltage drop* 2

Speed [km/h]

*1 Thermal, BDI [0] or Service indicator:

15 211836

*2 Voltage drop: Curve of limited torque when battery

Curve of limited torque under a condition of overheating, BDI [0] or maintenance time over.

8-11

voltage drops 25 volts or less.

CONTROLLER

(2) Boost When the truck traveling is blocked by a step, the boost function prevents stalling of the truck. Usually the motor maximum torque is set by SUO #11, but this function allows the truck to bypass a step regardless of the value setting of the motor maximum torque. Shift the traction lever into its maximum position (100%) for 2 seconds. The boost function increases the motor maximum torque for 5 seconds. If the traction lever is returned (less than 100%), the boost function will be canceled immediately.

Torque [%] required to * Torque climb over a step

# 11 HIGH POWER: Full acceleration

100

STANDARD: Full acceleration ECONOMY: Full acceleration

Time [sec]

211837

NOTICE: When the motor overheats or the battery voltage drops (25 volts or less), the boost will not work. If the stall time setting is small, the motor protection function will be applied during prolonged slow speed traveling.

Limitation of maximum travel speed This function limits the maximum travel speed of the truck. (The maximum forward travel speed is set by SUO#8 and the maximum backward travel speed is set by SUO#9.) The limitation that functions at all times and is used to keep the speed within the limits.

8-12

CONTROLLER

Regeneration There are three types of regeneration control: the auto regeneration, lever regeneration and controlled rollback.

Amount of auto regeneration [%] 100

(1) Auto regeneration The auto regeneration starts when the traction lever is shifted into the neutral position or the traction pedal is slightly released during traveling. The amount of regeneration is determined by the auto regeneration characteristic (set by SUO #23). 0

1 2 3 4 5 6 7 8 9 10 Value of #23 211838

(2) Lever regeneration The lever regeneration starts when the traction lever is shifted into the position opposite to the truck traveling direction during traveling.

Amount of lever regeneration [%] 100

The amount of regeneration is determined by the lever regeneration characteristic (set by SUO #22).

1 2 3 4 5 6 7 8 9 10 Value of #22 211839

Controlled Roll Back This function prevents hazardous descending of the truck on a grade. The controlled roll-back is activated when the traction lever is shifted into the neutral position or the traction pedal is slightly released on a grade. The descending speed changes with the steepness of grade and the weight of load. NOTICE: This function is activated only in the output torque range of the traction motor. If the truck can be decelerated until it stops in the output torque range, the electromagnetic brake will also be activated when the truck stops.

8-13

Truck descends slowly when traction lever is shifted into neutral position or traction pedal is slightly released on a grade.

211840

CONTROLLER

Steering (1) Rear wheel The rear wheel is steered by the APS controller when the steering wheel is turned. Because the rear wheel is offset from the center of the truck, it has a maximum rotation of 100° CW and 80° CCW from the straight position. (2) Front wheel The torque distribution for the right and left traction motors is controlled by the logic unit according to the rear wheel angle.

Right traction motor

Torque distribution (%)

Left traction motor

100

•

The torque for the right and left wheels is equal when the steering wheel is in the straight-ahead position.

Rear wheel angle [deg.] 0

100(left)

The torque for the inner wheel is decreased when the steering wheel is turned from the straight-ahead position.

-100

211841

The inner wheel stops when the steering wheel is turned further.

•

100 (right)

The inner wheel rotates in reverse when the steering wheel is turned further from the position where the inner wheel stopped.

Travel speed limited [km/h]

(3) Limitation of travel speed

The travel speed is limited by the rear wheel angle.

100(left)

100 (right)

Rear wheel angle [deg.] 211842

8-14

CONTROLLER

Stall timer Traction Motor Stall Timer (Error codes 16 and 26) error occurs to prevent the traction motor from overheating when the truck traveling is blocked for several seconds by a step though the traction lever is shifted into its maximum position. The time to shut down the truck can be set by SUO #20. The less time provides the highest level of protection allowed.

Free lift (Speed Limit) This function limits the travel speed to 6 km/h when the lift is in the high lift position. The icon

is shown on the display unit.

8-15

CONTROLLER

Hydraulic Control Function Hydraulic Controller The hydraulic control system configuration as described on page 8-1 is a transistor control type. The pump inverter controls the AC induction pump motor.

Pump motor output [%] SUO #4, #5 10

100

The hydraulic control valve is controlled by the output unit.

2 1

The controller drives the AC induction motor when the hydraulic levers are operated. 0

SW Close

Switch operation 211843

Pump motor output characteristics (Tilt and attachment 1 operations) Pump motor output [%]

SUO #7

#34 100

SUO #6

10 9 8

#33 2 1

SWa or SWb Both SWa and Switch operation is closed. SWb are closed.

211844

Pump motor output characteristics (Attachments 2 and 3 operations) Pump motor output [%]

SUO#3

100

9 8

SUO#2

2 1

0 100

Lever operation 211845 [deg.] Pump motor output characteristics (Lift-up operation) 8-16

CONTROLLER

Priority When the hydraulic levers or switches are operated simultaneously, the pump motor speed is decided by the following priority. High

Tilt Lift

Priority

Attachment 1 Low

Attachments 2 and 3

Inhibition of Simultaneous Operation The tilt, attachment 1, and attachments 2 and 3 can not be operated in the simultaneous operation. If the simultaneous operation is performed, the previous operation will continue and the following operation will not be performed. Allowable Simultaneous Operation

See table for Allowable Simultaneous Operation.

- Travel, Lift/Lower, Horn

Attachments 2 and 3

- Travel, Lift/Lower, One Aux Hydraulic Function*, Horn

(1) Selection of attachment 2 or 3 Attachment 2 or 3 is selected by using the attachment 2/3 selector switch. Switch OPEN: Attachment 2 Switch CLOSE: Attachment 3 Attachment 2 or 3 can be selected only when lift or tilt are not operating. (2) 2-step speed In attachment 2 or 3 operation, the speed of attachment 2 or 3 will increase if the switch for the attachment not operated is turned on (if “b” side is turned on with “a” side operated, or if “a” side is turned on with “b” side operated). The speed of attachments 2 and 3 is set by SUO #6 and #7, and SUO #33 and #34.

8-17

- Travel, One Aux Hydraulic Function, Horn - Lift/Lower, One Aux Hydraulic Function, Horn * Aux hydraulic functions include sideshift left/right, tilt forward/backward

CONTROLLER

Steering Control Function The APS controller drives the steering motor when all the conditions for closing the line contactor (described in the traction control function) are satisfied. This enables the power steering operation. The APS controller drives the steering motor to steer the drive wheel according to the input of the steering wheel angle and rear wheel angle.

8-18

CONTROLLER

OPP (Operator Presence Pedal) Function Preventing operator’s absence This function prevents the truck from traveling or lifting without the operator pressing the pedal. For details, see the table below.

Item

When turning on power

Prevention result During normal operation

Presence pedal: OFF

Presence pedal: ON

Traveling

Stop Stop Error codes "E" and "L" flicker. Error codes "E" and "L" flicker. Stop

Lifting

Stop Stop Operable Error codes "E" and "L" flicker. Error codes "E" and "L" flicker.

Line contactor Steering

CLOSED On

Electromagnetic Brake is applied. brake

CLOSED Operable (Steering contactor CLOSED)

Brake is applied.

Prevention result Item

When turning on power Presence pedal: ON Traveling, lifting and steering stop. Error codes "E" and "L" flicker. "TRACTION LEVER SETTING"

During normal operation Presence pedal: from OFF to ON Traveling, lifting and steering stop. Error codes "E" and "L" flicker. "TRACTION LEVER SETTING"

Lift lever: ON

Traveling, lifting and steering stop. Error code "H1" flickers.

Traveling and lifting stop. Error code "H1" flickers.

Tilt switch: ON

Traveling, lifting and steering stop. Error code "H2" flickers.

Traveling and lifting stop. Error code "H2" flickers.

Reach switch: ON

Traveling, lifting and steering stop. Error code "H3" flickers.

Traveling and lifting stop. Error code "H3" flickers.

Sideshifter switch: ON

Traveling, lifting and steering stop. Error code "H4" flickers.

Traveling and lifting stop. Error code "H4" flickers.

Traction lever: ON

8-19

CONTROLLER

Other Functions

Service indicator

BDI (Battery Discharge Indicator)

The maintenance time can be set by SUO #05.

The BDI shows the remaining battery capacity of the current battery voltage with 11 levels from BDI 0 to BDI 10. The BDI level is calculated by the battery voltage and the battery type set by SUO #42. If the previous indication is BDI 4 or less and the following indication is not BDI 7 or more when turning on the key switch, the BDI will show the previous indication.

The service indicator starts flickering 20 hours before the set maintenance time, and remains lit when the truck hour meter indication reaches the set time.

Hour Meter Function (1) Hour meters This function displays four hour meters as shown in the following table. D A T A MON I T OR HOURS DR I V E 0 0 0 0 0 . 0H 211846

Item Vehicle hour meter (HB)

Description Indicates cumulative hours of vehicle operations (when traveling operation, lifting operation or steering motor operation is performed).

Drive hour meter (HD)

Indicates cumulative hours of traveling operation.

Pump hour meter (HP)

Indicates cumulative hours of hydraulic operation.

Steering hour meter (HS)

Indicates cumulative hours of steering motor operation.

8-20

CONTROLLER

Chime Control Function This function sounds the chimes when the initial check is completed after turning on the key switch (when the truck becomes operable), or when error or warning occurs. The following table shows the condition in which the chimes are sounded and the pattern of chimes. Condition When error or warning occurs. When initial check is completed after turning on key switch.

Chimes Sounds twice. Sounds once.

Battery Voltage Monitor This function restricts the traveling and lifting operations to protect the battery when the battery voltage drops. Item Traveling BDI 1ýýýýýýýýýLimits traveling power to "Economy." Limits traveling power. BDI 0 See "Powering" of Traction Control Function. Limits traveling power. Battery voltage drops into See "Powering" of Traction Control range of 25V to 22V. Function. Battery voltage drops less than 22V.

Stops truck (turns off line contactor). Error code: L0

8-21

Lifting Not limited Decreases hydraulic output*1 or inhibits lifting operation during traveling.

Inhibits lifting operation during traveling.

CONTROLLER

Display Function (See Display Section) Normal Operation Display The following is displayed on the display unit during the normal operation. Item

Description

Speed/Load

Indicates the load when the truck is stopped, and the truck speed during traveling. (Load: LBS or KG Speed: KM/H or MPH) If the optional load sensor is not installed, the truck speed will only be indicated.

BDI level

Indicates the remaining battery capacity of the current battery voltage with 11 levels from BDI 0 to BDI 10. The battery icon flickers when BDI level becomes BDI 1 or less.

Electromagnetic brake operation Overheat warning

Lights when the electromagnetic brake is engaged.

Wheel indicator

Indicates the icon according to the steering angle.

Lights when the traction motor, pump motor or inverter overheats.

Turtle

Lights in the following conditions. (1) When the maximum traveling speed is limited by the free lift speed limit function or high lift ý speed limit function. (2) When the maximum traveling speed is limited by the low BDI or the overheating of the motor and controller. (3) When the maximum traveling speed is limited by the service indicator function.

Clock

Indicates the time (hour and minute) in the following two patterns. 12-hour indication 24-hour indication h:mm A*1 or h:mm P*1 h:mm*1 *1: h: Hours mm: Minutes A: a.m. P: p.m.

Date

Indicates the date (year, month and day) in the following three patterns. US: MM/DD/YYYY*2 EU: DD/MM/YYYY*2 JP: YYYY/MM/DD*2 *2: YYYY: Year (4 digits) MM: Month DD: Day

Vehicle hour meter

Indicates cumulative hours of the vehicle operations. (The vehicle hour meter is indicated for only 2 seconds after turning on the key switch.)

8-22

CONTROLLER

Error Display The error code is displayed when a malfunction occurs.

When plural faults occur simultaneously, the errors are displayed successively as shown in the figure below.

F A ULT 6 3 C O N T RO L L E R TRA C- R CTRL

CA L L

SERV I CE

F A ULT 6 5 C O N T RO L L E R PUMP C T R L

CA L L

SERV I CE

211853

Description

Item Error code

Indicates the code assigned to the fault.

Error

Lights (or flickers) while the fault is occurring.

Password Display (1) Function The following function can be used only when the password is entered properly by changing the 6-digit number on the display. •

Data Monitor function

•

Setup Option function

•

Output Check function

•

History Folder function

•

Password Change function

8-23

CONTROLLER

Removal and Installation

(b) Disconnect the battery plug, then discharge electric charges from all inverters and APS unit.

Inspecting Before Replacing Controllers

See “Discharging Electric Charges From Inverters and APS Unit.”

Checking Inverter and DSP Card

Check the inverter and DSP card by using the following procedures.

(d) Check for the insulation resistance by using the following table.

(1) Check the inverters.

Measure the resistance between the connector pin described in the measuring item and the measuring point.

See “Checking Inverter.” (2) Check the DSP card for the insulation resistance by using the following procedures. (a) Turn off the key switch.

Measuring point

Measuring item

Body

GND (DSP Pin No. 19)

GND (DSP Pin No. 20)

GND (DSP Pin No. 19)

Resistance: ∞Ω

GND (DSP Pin No. 20)

Resistance: ∞Ω

CAN_H (DSP Pin No. 3)

Resistance: ∞Ω

Resistance: Several kΩ

Resistance: ∞Ω

CAN_L (DSP Pin No. 4)

Resistance: ∞Ω

Resistance: Several kΩ

Resistance: ∞Ω

+15V_G (DSP Pin No. 16)

Resistance: ∞Ω

Resistance: Several ten kΩ or more

+15V_L (DSP Pin No. 17)

Resistance: ∞Ω

Resistance: Several MΩ or more

+5V_L (DSP Pin No. 18)

Resistance: ∞Ω

Resistance: Several ten kΩ or more

Traction inverter XA1_2 connector

Pump inverter XA2_2 connector

2nd Pump inverter XA6_2 connector

CAN_H

XA1_2/3

XA2_2/3

XA6_2/3

CAN_L

XA1_2/4

XA2_2/4

XA6_2/4

15V_G

XA1_2/16

XA2_2/16

XA6_2/16

+15V_L

XA1_2/17

XA2_2/17

XA6_2/17

+5V_L

XA1_2/18

XA2_2/18

XA6_2/18

GND

XA1_2/19

XA2_2/19

XA6_2/19

GND

XA1_2/20

XA2_2/20

XA6_2/20

The connector number, pin number and wiring number of each inverter are as follows. Item

XA1_2

XA6_2

XA2_2

Harness Connectors

8-24

211901

CONTROLLER

Checking Logic Card

(1) Check the logic card for the wiring connection and the insulation resistance by using the following procedures.

(d) Check for the wiring connection. Check whether the resistance between GND XA5_1/1 and GND XA5_1/13 is 0W.

(a) Turn off the key switch. (b) Disconnect the battery plug, then discharge electric charges from all inverters and APS unit.

(e) Check for the insulation resistance by using the following table. Measure the resistance between the connector pin described in the measuring item and the measuring point.

See “Discharging Electric Charges From Inverters and APS Unit.”

Measuring point

Measuring item

Body

GND XA5_1/1

GND XA5_1/23

GND XA5_1/25

GND XA5_1/43

GND XA5_1/11

Resistance: Several MΩ

GND XA5_1/23

Resistance: ∞Ω

GND XA5_1/25

Resistance: Several MΩ

GND XA5_1/43

Resistance: ∞Ω

CAN_H XA5_1/5

Resistance: ∞Ω

Resistance: Several kΩ

Resistance: ∞Ω

Resistance: Several ten kΩ

CAN_L XA5_1/6

Resistance: ∞Ω

Resistance: Several kΩ

Resistance: ∞Ω

Resistance: Several ten kΩ

Resistance: +15V_L XA5_1/2 Several ten MΩ or more

Resistance: Several ten kΩ or more

+5V_L XA5_1/4

Resistance: Several ten MΩ or more

Resistance: Several ten kΩ or more

+5V XA5_1/24

Resistance: Several ten MΩ or more

Resistance: Several kΩ or more

+5V XA5_1/26

Resistance: Several ten MΩ or more

Resistance: Several kΩ or more

XA5_1

XA5_1 25

22 20

Harness Connectors

8-25

211902

CONTROLLER

Checking Power Supply Card

(d) Check for the wiring connections.

(1) Check the power supply card for the wiring connections and the insulation resistance by using the following procedures.

Check whether the resistance between GND XA5_1P/11 and GND XA5_1P/12 is 0W. Check whether the resistance between GND XA5_1P/15 and GND XA5_1P/16 is 0W.

(a) Turn off the key switch. (b) Disconnect the battery plug, then discharge electric charges from all inverters and APS unit.

(e) Check for the insulation resistance by using the following table. Measure the resistance between the connector pin described in the measuring item and the measuring point.

See “Discharging Electric Charges From Inverters and APS Unit.” (c) Disconnect connector XA5_1P from the power supply card. Measuring item

Measuring point Body

GND XA5_1P/6

GND XA5_1P/11

GND XA5_1P/15

GND XA5_1P/6

Resistance: ∞Ω

GND XA5_1P/11

Resistance: ∞Ω

GND XA5_1P/5

Resistance: ∞Ω

+15V_L XA5_1P/3

Resistance: ∞Ω

Resistance: Several ten kΩ or more

+5V XA5_1P/4

Resistance: ∞Ω

Resistance: Several ten kΩ or more

+15V_G XA5_1P/5

Resistance: ∞Ω

Resistance: Several ten kΩ or more

Resistance Several ten kΩ or more

+15V_L XA5_1P/9

Resistance: ∞Ω

Resistance: Several MΩ or more

+5V XA5_1P/10

Resistance: ∞Ω

Resistance: Several kΩ or more

+V POW XA5_1P/13

Resistance: ∞Ω

Resistance: Several hundred kΩ or more

+V POW XA5_1P/14

Resistance: ∞Ω

Resistance: Several hundred kΩ or more

XA5_1P 15

Harness Connector 211903

8-26

CONTROLLER

Checking Output Unit

Output Unit 1 (Disconnect connector XA4_1)

(1) Check the output unit for the wiring connections and the insulation resistance by using the following procedures.

•

(a) Turn off the key switch.

Check the following wiring connections. The resistance between GND XA4_1/1 and GND XA4_1/2: 0Ω The resistance between GND XA4_1/1 and GND XA4_1/3: 0Ω

(b) Disconnect the battery plug, then discharge electric charges from all inverters and APS unit.

The resistance between GND XA4_1/1 and GND XA4_1/4: 0Ω

See “Discharging Electric Charges From Inverters and APS Unit.”

The resistance between GND XA4_1/1 and GND XA4_1/19: 0Ω

The resistance between +VE XA4_1/5 and +VE XA4_1/6: 0Ω

(d) Check for the wiring connections.

The resistance between +VE XA4_1/5 and +VE XA4_1/7: 0Ω

(e) Check for the insulation resistance. Measure the resistance between the connector pin described in the measuring item and the measuring point.

The resistance between +VE XA4_1/5 and +VE XA4_1/8: 0Ω

•

Check for the insulation resistance by using the following table.

Measuring point

Measuring item

Body

GND XA4_1/1

Resistance: ∞Ω

CAN_H XA4_1/13

Resistance: ∞Ω

Resistance: Several kΩ or more

CAN_L XA4_1/14

Resistance: ∞Ω

Resistance: Several kΩ or more

+VE XA4_1/5

Resistance: ∞Ω

Resistance: Several hundred kΩ or more

VCC XA4_1/2

Resistance: ∞Ω

Resistance: Several ten kΩ or more

XA4_1 19

211904

Harness Connector

8-27

CONTROLLER

Checking Display Unit

(d) Check for the wiring connection.

(1) Check the display unit for the wiring connection and the insulation resistance by using the following procedures.

Check whether the resistance between KEY SWITCH INPUT XA7_J1L/13 and LCD HEATER XA7_J1L/19 is 0W.

(a) Turn off the key switch.

(e) Check for the insulation resistance by using the following table.

(b) Disconnect the battery plug, then discharge electric charges from all inverters and APS unit.

Measure the resistance between the connector pin described in the measuring item and the measuring point.

See “Discharging Electric Charges From Inverters and APS Unit.” (c) Disconnect connectors XA7_J1L/2 XA7_J1L/1 from the display unit.

and

Measuring point

Measuring item

Body

GND XA7_J1L/2

Resistance: ∞Ω

CAN_H XA7_J2L/1

Resistance: ∞Ω

CAN_L XA7_J2L/2

Resistance: ∞Ω

BATTERY XA7_K1/L1

Resistance: ∞Ω

Resistance: Several kΩ or more

KEY XA7_J1L/13

Resistance: ∞Ω

Resistance: Several MΩ or more

XA7_J1L

XA7_J2L

13 14

Harness Connectors

211906

8-28

CONTROLLER

Discharging Electric Charges From Inverters and APS Unit Discharge electric charges stored in the inverters and APS unit by using the following procedure.

Deck cover

(1) Turn off the key switch. (2) Disconnect the battery plug. (3) Remove the deck cover.

211907

(4) Place a 150 Ω/25 Ω resistor between P and N terminals in the traction inverter to discharge electric charges stored in the inverter. (5) After touching the resistor to the P and N terminals for approx. five seconds, measure the voltage between the terminals with a multimeter and confirm a reading of 5 V or less. (6) Perform the same procedure for the pump inverter in order to discharge electric charges from all inverters. (7) Perform the same procedure for the APS unit. To discharge electric charges from the APS unit, place a 150 W/25 W resistor between BATT+ and BATT – terminals in the APS unit. Check whether the resistance between + and – of the battery plug on the truck side is 1 kW or more when connecting the battery plug for the first time after maintenance. (Discharge electric charges completely before measuring. Longer measurement time reduces resistance value.)

8-29

211908

CONTROLLER

Replacing Inverter Removal (1) Raise the front wheels. (2) Perform steps 1 to 7 in “Discharging Electric Charges From Inverters and APS Unit.”

! CAUTION Be sure to discharge electric charges from all inverters and APS unit.

(3) Disconnect all five power cables from P, N, U, V and W terminals (F, N, U, V and W terminals for the pump inverter). (4) Disconnect the connector.

M10

M8 nut (five places)

! CAUTION When disconnecting the connector, hold the connector housing and plug, and unlock the connector.

M8 Connector

Holding the case may cause damage to the inside card, while holding the cable may cause wire breakage.

M10 M10 bolt (four places)

(5) Remove M10 bolts (four places) fixing the inverter, then remove the inverter.

211909

Installation (1) Wipe off the dirt and thermal paste from the inverter mounting surface once, and also remove dirt from the mounting surface and the aluminum base plate of the inverter. (2) Apply thermal paste approx. 1 mm (0.04 in.) thick to the area where the aluminum base plate of the inverter comes into contact with the truck body.

! CAUTION

Connector housing

Cable

Plug 211910

Apply thin and even thermal paste since it works to release generated heat from the inverter to the truck body.

8-30

CONTROLLER

(3) Fix the inverter with M10 bolts. Tightening torque M10 bolt

33.3 ± 6.7 N·m (3.39 ± 0.68 kgf·m) [25 ± 5 lbf·ft]

(4) Connect the power cables to P, N, U, V and W terminals. (F, N, U, V and W terminals for the pump inverter).

! CAUTION Use the correct power cables and terminate marked cable ends to the correct terminals marked on the motor. Cables terminated at the wrong terminals on the motor may cause the motor to rotate in the opposite direction when activated. Tightening torque M8 nut

11.77 ± 1.96 N·m (1.20 ± 0.20 kgf·m) [8.68 ± 1.45 lbf·ft]

(5) Connect the main harness connector to the inverter.

! CAUTION Forcibly pressing the connector may cause damage to the DSP card. Hold the connector housing and press the connector, if not easy to lock.

8-31

CONTROLLER

Replacing DSP (Digital Signal Processor) Card Removal (1) Perform steps 1 to 7 in “Discharging Electric Charges From Inverters and APS unit.”

! CAUTION Be sure to discharge electric charges from all inverters and APS unit before working on the electrical system. (2) Disconnect the connector.

! CAUTION When disconnecting the connector, hold the connector housing and plug, and unlock the connector. Holding the case may cause damage to the inside card, while holding the cable may cause wire breakage. (3) Push and lift up at the four corners of the card cover to remove the cover.

211911

(4) Unlock the connector that is connected to the flat cable. Hold the both ends of the white part of the connector and pull it straight up. (5) Pull the flat cable to disconnect it. If it cannot be disconnected smoothly, raise the lock again to unlock. (6) Pinch the plastic spacers at the four corners of the DSP card with pliers to unlock and remove the card.

! CAUTION 211201

Be careful not to damage mounted parts with the pliers since the card has a number of fragile parts.

8-32

CONTROLLER

Installation (1) Align the four mounting holes of the new DSP card with the plastic spacer positions and press it into place.

! CAUTION Press at the card edges. Make sure that the spacer lock works completely and the card cannot be removed. (2) Confirm that the flat cable connector is unlocked by raising the connector lock. (3) Insert the flat cable into the connector. Press down the connector lock.

! CAUTION Do not forcibly bend the flat cable. Insert its conductive surface in the direction shown in the illustration. Also, confirm that the cable is not tilted. (4) Install the cover while pushing the flat cable toward the card side slightly.

211202

! CAUTION Do not push the flat cable by the inside of the inverter cover. Do not forcibly bend the flat cable. Make sure that the cable will not be pinched underneath the cover. Confirm that the cover is completely locked. (5) Connect the main harness connector to the inverter.

! CAUTION

211613

Forcibly pressing the connector may cause damage to the DSP card. Hold the connector housing and press the connector, if not easy to lock.

8-33

CONTROLLER

Replacing Logic Unit Removal

Deck cover

(1) Turn off the key switch. (2) Disconnect the battery plug. (3) Remove the deck cover.

211907

(4) Disconnect the connectors from the logic card and power supply card. Connector housing

! CAUTION When disconnecting the connector, hold the connector housing and plug, and unlock the connector. Cable

Holding the case may cause damage to the inside card, while holding the cable may cause wire breakage.

Plug 211451

(5) Remove M10 bolts (two places) and remove the logic unit.

Installation Follow the removal sequence in reverse.

8-34

CONTROLLER

Replacing Logic Card NOTICE: When replacing the logic card, it is recommended to replace the logic unit as an assembly.

Cover

When the cover is removed from the logic unit case, its tapped holes may be damaged. Replace the cover if the tapped holes of the cover are damaged.

Removal (1) Perform steps 1 to 5 in Replacing Logic Unit. (2) Remove M3 flat head screws (four places) from the bottom of the logic unit to remove the cover.

M3 flat head screw (four places) 211913

(3) Remove M3 screws (seven places) fixing the logic card to the logic unit case to remove the logic card. (4) Remove the grommet from the logic card.

Logic card

Installation

Heat sink

M3 screw (seven places)

Follow the removal sequence in reverse.

! CAUTION When installing the logic card onto the logic unit case, carefully tighten the logic card and heat sink fixing screws to the specified torque to avoid excessive stresses. Repair the heat sink first.

Apply Loctite No.242 when installing.

211914

! CAUTION When installing the heat sink of the logic card to the case, apply Loctite No. 242 (manufactured by Henkel Loctite) to the screw thread. Tightening torque M3 screw

0.98 ± 0.20 N·m (0.10 ± 0.02 kgf·m) [0.72 ± 0.15 lbf·ft]

M3 flat head screw

0.30 ± 0.10 N·m (0.03 ± 0.01 kgf·m) [0.22 ± 0.074 lbf·ft]

211423

8-35

CONTROLLER

Replacing Power Supply Card NOTICE: When replacing the power supply card, it is recommended to replace the logic unit as an assembly.

Cover

When the cover is removed from the logic unit case, its tapped holes may be damaged. Replace the cover if the tapped holes of the cover are damaged.

Removal (1) Perform steps 1 to 5 in Replacing Logic Unit. M3 flat head screw (four places)

(2) Remove M3 flat head screws (four places) from the bottom of the logic unit to remove the cover. (3) Remove M3 screws (seven places) fixing the power supply card to the logic unit case to remove the power supply card. (4) Remove the grommet from the power supply card.

211913

Heat sink

Power supply card M3 screw (seven places)

Installation Follow the removal sequence in reverse.

! CAUTION When installing the power supply card onto the logic unit case, carefully tighten the power supply card and heat sink fixing screws to the specified torque to avoid excessive stresses. Fix the heat sink first.

Apply Loctite No.242 when installing. 211915

! CAUTION When installing the heat sink of the power supply card to the case, apply Loctite No. 242 (manufactured by Henkel Loctite) to the screw thread. Tightening torque M3 screw

0.98 ± 0.20 N·m (0.10 ± 0.02 kgf·m) [0.72 ± 0.15 lbf·ft]

M3 flat head screw

0.30 ± 0.10 N·m (0.03 ± 0.01 kgf·m) [0.22 ± 0.074 lbf·ft]

211425

8-36

CONTROLLER

Replacing Output Unit Removal

Deck cover

(1) Turn off the key switch. (2) Disconnect the battery plug. (3) Remove the deck cover. (4) Disconnect the output unit connector.

211907

(5) Remove M6 bolts (four places) to remove the output unit.

Installation Follow the removal sequence in reverse. Tightening torque M6 bolt

6.90 ± 1.38 N·m (0.70 ± 0.14 kgf·m) [5.09 ± 1.02 lbf·ft]

8-37

CONTROLLER

Replacing APS (Advanced Power Steering) Unit

Basic

Removal

Always follow basic troubleshooting steps.

Basic Items

(1) Turn off the key switch. (2) Disconnect the battery plug. (3) Remove the top cover from the truck. (4) Locate the APS controller and disconnect APS connectors CNB and CNA.

! CAUTION When disconnecting the connectors, hold the connector housing and plug, and unlock the connector.

•

Talk to the operator.

•

Confirm his description of the problem with an operational check.

•

Visually inspect cables, connectors, contactor tips, etc.

•

Perform basic battery cables to frame resistance test. (at least 20 k ohm)

•

Check battery condition.

Always check each option and write down the reading.

Holding the case may cause damage to the inside card, while holding the cable may cause wire breakage.

Testing Tools (b)

(5) Disconnect the U, V and W cable connections from the APS unit.

(a)

(6) Disconnect the B+ and B- connections from the APS unit.

(c)

(7) Remove the four M8 nuts securing the APS unit onto the deck.

Installation 208282

Follow the removal sequence in reverse. (a) Multimeter

Tightening torque M8 Nuts

13.5 ± 1.3 N·m (1.37 ± 0.13 kgf·m) [10 ± 1 lbf·ft]

(b) Clamp Amp Meter (c) IC clip NOTE The illustrations show digital multimeters. In these multimeters, the positive (+) terminal is applied with positive charge, and the negative (–) terminal with negative charge. It should be noted that the terminals must be connected inversely when using an analog meter.

! WARNING Disconnect the battery plug before inspecting or adjusting the controller.

8-38

CONTROLLER

Pin by Pin Voltage Measurement Tubular BDI

Normal BDI

BDI# 0 1 2 3 4 5 6 7 8 9 10

36V – 34.4 34.5 – 34.8 34.9 – 35.2 35.3 – 35.6 35.7 – 36.0 36.1 – 36.4 36.5 – 36.7 36.8 – 37.0 37.1 – 37.3 37.4 – 37.6 37.7 –

BDI# 0 1 2 3 4 5 6 7 8 9 10

36V – 35.2 35.3 – 35.5 35.6 – 35.8 35.9 – 36.1 36.2 – 36.4 36.5 – 36.7 36.8 – 37.0 37.1 – 37.2 37.3 – 37.4 37.5 – 37.6 37.7 –

8-39

Reserve BDI

BDI# 0 1 2 3 4 5 6 7 8 9 10

36V – – – – – – – – – – –

CONTROLLER

Pin by Pin Measurement Chart Component

LABEL / PIN

NAME

LOCATION

CONDITION

READING

EXAMPLE

NOTES

1F1

KEYSWITCH FUSE

FUSE BLOCK

KEY ON/OFF

B+ V

36 VDC

REFERENCE BATTERY NEG.

3F1

AUX DEVICES

FUSE BLOCK

KEY ON/OFF

B+ V

36 VDC

REFERENCE BATTERY NEG.

1F2

KEYSWITCH FUSE

FUSE BLOCK

KEY ON/OFF

NEGATIVE

0.01

SET METER TO CONTINUITY

3F2

AUX DEVICES

FUSE BLOCK

KEY ON/OFF

NEGATIVE

0.01

SET METER TO CONTINUITY

7F1

STEER CONTROL

FUSE BLOCK

KEY ON

B+ V

36 VDC

K12 CLOSED

9F1

CONTROLLER CIRCUIT

FUSE BLOCK

KEY ON

B+ V

36 VDC

K11 CLOSED

10F1

CONTROLLER CIRCUIT

FUSE BLOCK

KEY ON

B+ V

36 VDC

K11 CLOSED

11F1

CONTROLLER CIRCUIT

FUSE BLOCK

KEY ON

B+ V

36 VDC

K11 CLOSED

12F1

AUX DEVICES

FUSE BLOCK

KEY ON

B+ V

36 VDC

K11 CLOSED

12F2

AUX DEVICES

FUSE BLOCK

KEY ON

NEGATIVE

0.01

SET METER TO CONTINUITY

X12/1

E-STOP

KEY ON/OFF

B+ V

36 VDC

REFERENCE BATTERY NEG.

X12/2

KEYSWITCH

KEY ON

B+ V

36 VDC

REFERENCE BATTERY NEG.

X12/4

KEYSWITCH

KEY ON

B+ V

36 VDC

REFERENCE BATTERY NEG.

K11/A1

COIL

LINE CONTACTOR

KEY ON

24V

24 V +/- 10%

RESISTOR VALUE 24 OHMS

K11/A2

COIL

LINE CONTACTOR

KEY ON/OFF

NEGATIVE

0.01

SET METER TO CONTINUITY

K12/A1

COIL

LINE CONTACTOR

KEY ON

B+ V

36 VDC

FUSE 11F1

K12/A2

COIL

LINE CONTACTOR

KEY ON

NEGATIVE

0.01

SET METER TO CONTINUITY

XA5_1/30

OPP INPUT

LOGICS UNIT

KEY ON

12V

11.98 VDC

12V

11.98VDC

FUSE BLOCK

E-STOP S1 KEYSWITCH S2

K11 CONTACTOR

K12 CONTACTOR

X13/2

OPP INPUT

OPP

S12 NORM OPEN

XA5_1/39

OPP INPUT

LOGICS UNIT

KEY ON

0.01

OPP

NEGATIVE REFERENCE XA5_1/9 OR X13/1

X13/3

OPP INPUT

OPP

S11 NORM CLOSED

XA5_1/38

OPP INPUT

LOGICS UNIT

KEY ON

12V

11.98VDC

OPP

S11 NORM OPEN

12 V

11.98 VDC

LOGICS UNIT

KEY ON

NEGATIVE

0.01

SET METER TO CONTINUITY

NEGATIVE REFERENCE XA5_1/9 OR X13/1

X13/4

OPP INPUT

XA5_1/59

BRAKE CONTROL

XA5_1/64

BRAKE FAILSAFE

XY31/2

BRAKE

KEY ON

NEGATIVE

0.01

SET METER TO CONTINUITY

XY31/1

BRAKE

KEY ON

B+ V

36 VDC

REFERENCE BATTERY NEG.

BRAKE

8-40

CONTROLLER

Pin by Pin Measurement Chart (continued) Component

LABEL / PIN XA5_1/26 X14A/1

CONTROL HANDLE (TRAVEL)

XA5_1/20 X14A/2 XA5_1/25 X14A/3

NAME THROTTLE SENSOR SUPPLY

THROTTLE SIGNAL THROTTLE SIGNAL

THROTTLE SENSOR NEGATIVE

LOCATION

CONDITION

READING

EXAMPLE

LOGICS UNIT

KEY ON

4.79 VDC

CONTROL HANDLE

KEY ON

4.79VDC

KEY ON

2.5 V AT REST

2.48 VDC

FORWARD 2.5V TO 0.5 REVERSE 2.5V TO 4.5

LOGICS UNIT

KEY ON

0V (NEGATIVE)

0.01

SET METER TO CONTINUITY

CONTROL HANDLE

KEY ON

0V (NEGATIVE)

0.01

SET METER TO CONTINUITY

LOGICS UNIT CONTROL HANDLE

NOTES NEGATIVE REFERENCE XA5_1/ 25 OR X14A/3

X14A/4

LIFT/LOWER SENSOR SUPPLY

CONTROL HANDLE

KEY ON

4.79 VDC

NEGATIVE REFERENCE XA5_1/ 25 OR X14A/6

XA5_1/27

LIFT/LOWER SIGNAL

LOGICS UNIT

KEY ON

2.5 V AT REST

2.48 VDC

LIFT 2.5V TO 0.5 LOWER 2.5V TO 4.5

X14A/5

LIFT/LOWER SIGNAL

CONTROL HANDLE

KEY ON

2.5 V AT REST

2.48 VDC

LIFT 2.5V TO 0.5 LOWER 2.5V TO 4.5

X14A/6

LIFT/LOWER SENSOR NEGATIVE

CONTROL HANDLE

KEY ON

0V (NEGATIVE)

0.01

SET METER TO CONTINUITY

XA5_1/22

CENTER SWITCH

LOGICS UNIT

KEY ON

NONE

NONE IF LIFT/LOWER SENSOR IS NOT CENTRED, READING WILL BE 5V

CONTROL HANDLE (MAST OPERATION)

X14A/8

CENTER SWITCH

CONTROL HANDLE

KEY ON

NONE

X14A/7

CENTER SWITCH

CONTROL HANDLE

KEY ON

4.89 VDC

REFERENCE BATTERY NEG.

XA5_1/36

SS LEFT

LOGICS UNIT

KEY ON SWITCH OPEN

12 V

11.98 VDC

CLOSING SWITCH WILL PULL TO NEGATIVE. REFERENCE X14B/3

X14B/8

SS LEFT

CONTROL HANDLE

KEY ON SWITCH OPEN

12V

11.98VDC

CLOSING SWITCH WILL PULL TO NEGATIVE. REFERENCE X14B/3

XA5_1/37

SS RIGHT

LOGICS UNIT

KEY ON SWITCH OPEN

12 V

11.98 VDC

CLOSING SWITCH WILL PULL TO NEGATIVE. REFERENCE X14B/3

X14B/9

SS RIGHT

CONTROL HANDLE

KEY ON SWITCH OPEN

12 V

11.98 VDC

CLOSING SWITCH WILL PULL TO NEGATIVE. REFERENCE X14B/3

XA5_1/41

TILT UP

LOGICS UNIT

KEY ON SWITCH OPEN

12 V

11.98 VDC

CLOSING SWITCH WILL PULL TO NEGATIVE. REFERENCE X14B/3

X14B/6

TILT UP

CONTROL HANDLE

KEY ON SWITCH OPEN

12 V

11.98 VDC

CLOSING SWITCH WILL PULL TO NEGATIVE. REFERENCE X14B/3

XA5_1/40

TILT DOWN

LOGICS UNIT

KEY ON SWITCH OPEN

12 V

11.98 VDC

CLOSING SWITCH WILL PULL TO NEGATIVE. REFERENCE X14B/3

X14B/7

TILT DOWN

CONTROL HANDLE

KEY ON SWITCH OPEN

12 V

11.98 VDC

CLOSING SWITCH WILL PULL TO NEGATIVE. REFERENCE X14B/3

8-41

CONTROLLER

Pin by Pin Measurement Chart (continued) Component

CONTROL HANDLE (MAST OPERATION)

LABEL / PIN

NAME

LOCATION

CONDITION

READING

EXAMPLE

NOTES

XA5_1/48

REACH IN

LOGICS UNIT

KEY ON SWITCH OPEN

12 V

11.98 VDC

CLOSING SWITCH WILL PULL TO NEGATIVE. REFERENCE X14B/3

X14B/5

REACH IN

CONTROL HANDLE

KEY ON SWITCH OPEN

12 V

11.98 VDC

CLOSING SWITCH WILL PULL TO NEGATIVE. REFERENCE X14B/3

XA5_1/47

REACH OUT

LOGICS UNIT

KEY ON SWITCH OPEN

12 V

11.98 VDC

CLOSING SWITCH WILL PULL TO NEGATIVE. REFERENCE X14B/3

X14B/4

REACH OUT

CONTROL HANDLE

KEY ON SWITCH OPEN

12 V

11.98 VDC

CLOSING SWITCH WILL PULL TO NEGATIVE. REFERENCE X14B/3

XA5_1/12

HEIGHT ENCODER PHASE A

LOGICS UNIT

KEY ON

0/5 V

4.98 VDC

READING WILL ALTERNATE WITH MOVEMMENT

X46/2 (XB41/2)

HEIGHT ENCODER PHASE A

HEIGHT ENCODER

KEY ON

0/5 V

4.98 VDC

READING WILL ALTERNATE WITH MOVEMMENT

XA5_1/11

HEIGHT ENCODER PHASE B

LOGICS UNIT

KEY ON

0/5 V

4.98 VDC

READING WILL ALTERNATE WITH MOVEMMENT

X46/3 (XB41/3)

HEIGHT ENCODER PHASE B

HEIGHT ENCODER

KEY ON

0/5 V

4.98 VDC

READING WILL ALTERNATE WITH MOVEMMENT

XA5_1/10

SENSOR SUPPLY

LOGICS UNIT

KEY ON

12 V

10.5 VDC

NEGATIVE REFERENCE BATTERY NEGATIVE, XA5_1/43 OR XB41/4

X46/1 (XB41/1)

SENSOR SUPPLY

HEIGHT ENCODER

KEY ON

12 V

10.5 VDC

NEGATIVE REFERENCE BATTERY NEGATIVE, XA5_1/43 OR XB41/4

XA5_1/45

FREE LIFT SENSOR

LOGICS UNIT

KEY ON

12 V

10.5 VDC

ACTIVE SENSOR WILL PULL TO NEGATIVE. REFERENCE XA5_1/ 43 OR XS43/3

X46/6

FREE LIFT SENSOR

KEY ON

12 V

10.5 VDC

ACTIVE SENSOR WILL PULL TO NEGATIVE. REFERENCE XA5_1/ 43 OR XS43/3

X46/5 X4S43/1

FREE LIFT SENSOR SUPPLY

FREE LIFT SENSOR

KEY ON

12 V

10.5 VDC

REFERENCE XA5_1/43, X46/7 OR XS43/3

XA5_1/21

PRESSURE SENSOR

LOGICS UNIT

KEY ON

0-5 V

LINEAR WITH WEIGHT

REFERENCE XA5_1/43 OR XB42/ 3

XB42/2

PRESSURE SENSOR

KEY ON

0-5 V

LINEAR WITH WEIGHT

REFERENCE XA5_1/43 OR XB42/ 3

XB42/1

PRESSURE SENSOR

KEY ON

4.89 VDC

REFERENCE XA5_1/43 OR XB42/ 3

XB42/3

PRESSURE SENSOR

KEY ON

0V (NEGATIVE)

0.01VDC

SET METER TO CONTINUITY

XA4_1/23

LOWER/LIFT

RIO1 BOARD

KEY ON HANDLE ACTIVE

0-24 V

24 V

REFERENCE BATTERY NEG

XY41.1/2

LOWER

VALVE

KEY ON HANDLE ACTIVE

0-24 V

24 V

REFERENCE BATTERY NEG

XA4_1/22

LOWER

RIO1 BOARD

KEY ON HANDLE ACTIVE

0V (NEGATIVE)

24 V

REFERENCE BATTERY NEG

(continued)

HEIGHT ENCODER B41

FREE LIFT SENSOR S43

PRESSURE SENSOR B42

VALVE CONTROL, CHASSIS (R101)

8-42

CONTROLLER

Pin by Pin Measurement Chart (continued) Component

VALVE CONTROL, CHASSIS (R101)

LABEL / PIN

NAME

LOCATION

CONDITION

READING

EXAMPLE

NOTES

XY41.1/1

LOWER

VALVE

KEY ON HANDLE ACTIVE

XY41.2/2

LIFT

VALVE

KEY ON HANDLE ACTIVE

24 V

REFERENCE BATTERY NEG

XA4_1/21

LIFT

RIO1 BOARD

KEY ON HANDLE ACTIVE

0V (NEGATIVE)

0.01

REFERENCE BATTERY NEG

XY41.2/1

LIFT

VALVE

KEY ON HANDLE ACTIVE

0V (NEGATIVE)

0.01

REFERENCE BATTERY NEG

XA4_1/26

REACH, TILT AND SS DIRECTION

RIO1 BOARD

KEY ON HANDLE ACTIVE

24 V

REFERENCE BATTERY NEG

XY43.1/2

REACH, TILT AND SS DIRECTION

VALVE

KEY ON HANDLE ACTIVE

24 V

REFERENCE BATTERY NEG

XA4_1/24

REACH, TILT AND SS DIRECTION

RIO1 BOARD

KEY ON HANDLE ACTIVE

0V (NEGATIVE)

0.01

REFERENCE BATTERY NEG

XY43.1/1

REACH, TILT AND SS DIRECTION

VALVE

KEY ON HANDLE ACTIVE

0V (NEGATIVE)

0.01

REFERENCE BATTERY NEG

XY43.2/2

REACH, TILT AND SS DIRECTION

VALVE

KEY ON HANDLE ACTIVE

24 V

24 v

REFERENCE BATTERY NEG

XA4_1/25

REACH, TILT AND SS DIRECTION

RIO1 BOARD

KEY ON HANDLE ACTIVE

0V (NEGATIVE)

0.01

REFERENCE BATTERY NEG

XY43.2/2

REACH, TILT AND SS DIRECTION

VALVE

KEY ON HANDLE ACTIVE

0V (NEGATIVE)

0.01

REFERENCE BATTERY NEG

XA5_1/60

REACH

LOGIC BOARD

KEY ON HANDLE ACTIVE

0V (NEGATIVE)

0.01

REFERENCE BATTERY NEG

K3/1

REACH

K3 RELAY

KEY ON HANDLE ACTIVE

0V (NEGATIVE)

0.01

REFERENCE BATTERY NEG

XA5_1/61

SIDESHIFT

LOGIC BOARD

KEY ON HANDLE ACTIVE

0V (NEGATIVE)

0.01

REFERENCE BATTERY NEG

K4/1

SIDESHIFT

K4 RELAY

KEY ON HANDLE ACTIVE

0V (NEGATIVE)

0.01

REFERENCE BATTERY NEG

XA5_1/62

TILT/SIDESHIFT

LOGIC BOARD

KEY ON HANDLE ACTIVE

0V (NEGATIVE)

0.01

REFERENCE BATTERY NEG

K5/1

TILT/SIDESHIFT

K5 RELAY

KEY ON HANDLE ACTIVE

0V (NEGATIVE)

0.01

REFERENCE BATTERY NEG

K3/5,K4/ 5,K5/5

RELAY(S) POWER IN

RELAYS

KEY ON

B+ V

36 VDC

REFERENCE BATTERY NEG

(continued)

VALVE CONTROL, MAST (LOGICS UNIT)

8-43

CONTROLLER

Pin by Pin Measurement Chart (continued) Component

VALVE CONTROL, MAST

DRIVE CONTROL A1

LABEL / PIN

NAME

LOCATION

CONDITION

READING

EXAMPLE

NOTES

X41/1

MAST SUPPLY

MAST CONNECTOR

KEY ON

B+V

36VDC

REFERENCE BATTERY NEG

X41/2

REACH

MAST CONNECTOR

KEY ON

VARIABLE

20-24VDC

REFERENCE BATTERY NEG

X41/3

SIDESHIFT

MAST CONNECTOR

KEY ON

VARIABLE

20-24VDC

REFERENCE BATTERY NEG

X41/4

TILT/SIDESHIFT

MAST CONNECTOR

KEY ON

VARIABLE

20-24VDC

REFERENCE BATTERY NEG

X42/1

TILT ASSISTANT

MAST CONNECTOR

KEY ON

0V (NEGATIVE)

0.01

REFERENCE BATTERY NEG (11M2)

X42/2

TILT ASSISTANT

MAST CONNECTOR

KEY ON

B+V

36VDC

REFERENCE BATTERY NEG (11M2)

X41/5

TILT ASSISTANT

MAST CONNECTOR

KEY ON

B+V

36VDC

REFERENCE BATTERY NEG (11M2)

XY44.1:1

REACH

MAST VALVE

KEY ON

B+V

36VDC

REFERENCE BATTERY NEG (11M2)

XY44.2:2

REACH

MAST VALVE

KEY ON

B+V

36VDC

REFERENCE BATTERY NEG (11M2)

XY45.1:1

SIDESHIFT

MAST VALVE

KEY ON

B+V

36VDC

REFERENCE BATTERY NEG (11M2)

XY45.2:2

SIDESHIFT

MAST VALVE

KEY ON

B+V

36VDC

REFERENCE BATTERY NEG (11M2)

XY26.1:1

TILT/SIDESHIFT

MAST VALVE

KEY ON

B+V

36VDC

REFERENCE BATTERY NEG (11M2)

XY46.2:2

TILT/SIDESHIFT

MAST VALVE

KEY ON

B+V

36VDC

REFERENCE BATTERY NEG (11M2)

XY44.1:2

REACH

MAST VALVE (Y44)

KEY ON

VARIABLE

20-24VDC

REFERENCE BATTERY NEG

XY44.2:1

REACH

MAST VALVE (Y44)

KEY ON

VARIABLE

20-24VDC

REFERENCE BATTERY NEG

XY45.1:2

SIDESHIFT

MAST VALVE (Y45)

KEY ON

VARIABLE

20-24VDC

REFERENCE BATTERY NEG

XY45.2:1

SIDESHIFT

MAST VALVE (Y45)

KEY ON

VARIABLE

20-24VDC

REFERENCE BATTERY NEG

XY46.1:2

TILT/SIDESHIFT

MAST VALVE (Y46)

KEY ON

VARIABLE

20-24VDC

REFERENCE BATTERY NEG

XY46.2:1

TILT/SIDESHIFT

MAST VALVE (Y46)

KEY ON

VARIABLE

20-24VDC

REFERENCE BATTERY NEG

XA1_2/5

DRIVE ENCODER SUPPLY

TRACTION CONTROLLER

KEY ON

12 VDC

11.98 VDC

REFERENCE XA1_2/19 OR X35/3

X35/4

DRIVE ENCODER SUPPLY

TRACTION MOTOR

KEY ON

12 VDC

11.98 VDC

REFERENCE XA1_2/19 OR X35/3

XA1_2/7

PHASE A

TRACTION CONTROLLER

KEY ON

0/5 V

4.98 VDC

REFERENCE XA1_2/19 OR X35/3

X35/5

PHASE A

TRACTION MOTOR

KEY ON

0/5 V

4.98 VDC

REFERENCE XA1_2/19 OR X35/3

XA1_2/6

PHASE B

TRACTION CONTROLLER

KEY ON

0/5 V

4.98 VDC

REFERENCE XA1_2/19 OR X35/3

X35/6

PHASE B

TRACTION MOTOR

KEY ON

0/5 V

4.98 VDC

REFERENCE XA1_2/19 OR X35/3

XA1_2/19

DRIVE ENCODER SUPPLY

TRACTION CONTROLLER

KEY ON

0V (NEGATIVE)

0.01VDC

REFERENCE BATTERY NEG

X35/3

DRIVE ENCODER SUPPLY

TRACTION MOTOR

KEY ON

0V (NEGATIVE)

0.01VDC

REFERENCE BATTERY NEG

8-44

CONTROLLER

Pin by Pin Measurement Chart (continued) Component

LABEL / PIN

NAME

XA1_2/1 TO THERMAL SENSOR XA1_2/2

LOCATION

CONDITION

READING

EXAMPLE

NOTES

TRACTION CONTROLLER

KEY OFF

~600 OHMS (75F)

612 OHMS

SET METER TO OHMS AND MEASURE SENSOR RESISTANCE

X35/1 TO X35/2

THERMAL SENSOR

TRACTION MOTOR

KEY OFF

~600 OHMS (75F)

612 OHMS

SET METER TO OHMS AND MEASURE SENSOR RESISTANCE

XA1_2/3

CAN H

TRACTION CONTROLLER

KEY ON

0-5 V

5 VDC

NO TEST

DRIVE CONTROL A1

XA1_2/4

CAN L

TRACTION CONTROLLER

KEY ON

0-5 V

5 VDC

NO TEST

(continued)

XA1_2/16

DSP POWER SUPPLY

TRACTION CONTROLLER

KEY ON

15 VDC

12 VDC

REFERENCE XA1_2/20 OR BATTERY NEGATIVE

XA1_2/17

DSP POWER SUPPLY

TRACTION CONTROLLER

KEY ON

15VDC

12VDC

REFERENCE XA1_2/20 OR BATTERY NEGATIVE

XA1_2/18

DSP POWER SUPPLY

TRACTION CONTROLLER

KEY ON

5VDC

8VDC

REFERENCE XA1_2/20 OR BATTERY NEGATIVE

XA1_2/20

DSP POWER SUPPLY

TRACTION CONTROLLER

KEY ON

GND

0.01

REFERENCE XA1_2/20 OR BATTERY NEGATIVE

XA2_2/5

PUMP ENCODER SUPPLY

PUMP CONTROLLER

KEY ON

12 VDC

11.98 VDC

REFERENCE XA2_2/19 OR X36/3

X36/4

PUMP ENCODER SUPPLY

PUMP MOTOR

KEY ON

12 VDC

11.98 VDC

REFERENCE XA2_2/19 OR X36/3

XA2_2/6

PHASE A

PUMP CONTROLLER

KEY ON

0/5 V

4.98 VDC

REFERENCE XA2_2/19 OR X36/3

X36/5

PHASE A

PUMP MOTOR

KEY ON

0/5 V

4.98 VDC

REFERENCE XA2_2/19 OR X36/3

XA2_2/7

PHASE B

PUMP CONTROLLER

KEY ON

0/5 V

4.98 VDC

REFERENCE XA2_2/19 OR X36/3

X36/6

PHASE B

PUMP MOTOR

KEY ON

0/5 V

4.98 VDC

REFERENCE XA2_2/19 OR X36/3

XA2_2/19

PUMP ENCODER SUPPLY

PUMP CONTROLLER

KEY ON

GND

0.01VDC

REFERENCE XA1_2/20 OR BATTERY NEGATIVE

X36/3

PUMP ENCODER SUPPLY

PUMP MOTOR

KEY ON

GND

0.01VDC

REFERENCE XA1_2/20 OR BATTERY NEGATIVE

XA2_2/1

THERMAL SENSOR

PUMP CONTROLLER

KEY ON/OFF

~600 OHMS

612 OHMS

XA2_2/2

THERMAL SENSOR

PUMP CONTROLLER

KEY ON/OFF

~600 OHMS

612 OHMS

X36/1

THERMAL SENSOR

PUMP MOTOR

KEY ON/OFF

~600 OHMS

612 OHMS

X36/2

THERMAL SENSOR

PUMP MOTOR

KEY ON/OFF

~600 OHMS

612 OHMS

XA2_2/3

CAN H

PUMP CONTROLLER

KEY ON

0-5 V

5 VDC

NO TEST. 120 OHM TERMINATING RESISTOR

XA2_2/4

CAN L

PUMP CONTROLLER

KEY ON

0-5 V

5 VDC

NO TEST. 120 OHM TERMINATING RESISTOR

XA2_2/16

DSP POWER SUPPLY

PUMP CONTROLLER

KEY ON

15 VDC

12 VDC

REFERENCE XA2_2/20 OR BATTERY NEGATIVE

XA2_2/17

DSP POWER SUPPLY

PUMP CONTROLLER

KEY ON

15 VDC

12 VDC

REFERENCE XA2_2/20 OR BATTERY NEGATIVE

XA2_2/18

DSP POWER SUPPLY

PUMP CONTROLLER

KEY ON

5 VDC

8 VDC

REFERENCE XA2_2/20 OR BATTERY NEGATIVE

PUMP 1 CONTROL A2

8-45

SET METER TO OHMS AND MEASURE SENSOR RESISTANCE BETWEEN XA2_2/1 AND XA2_2/2 SET METER TO OHMS AND MEASURE SENSOR RESISTANCE BETWEEN X36/1 AND X36/2

CONTROLLER

Pin by Pin Measurement Chart (continued) Component PUMP 1 CONTROL A2

LABEL / PIN

NAME

LOCATION

CONDITION

READING

EXAMPLE

NOTES

XA2_2/20

DSP POWER SUPPLY

PUMP CONTROLLER

KEY ON

GND

0.01 VDC

REFERENCE XA2_2/20 OR BATTERY NEGATIVE

XA3_1/3

STEER ENCODER SUPPLY

STEER CONTROLLER

KEY ON

12 VDC

11.98 VDC

REFERENCE XA3_1/4 OR XM3/4

XM3/1

STEER ENCODER SUPPLY

STEER MOTOR

KEY ON

12 VDC

11.98 VDC

REFERENCE XA3_1/4 OR XM3/4

XA3_1/6

PHASE A

STEER CONTROLLER

KEY ON

0/5 V

4.98 VDC

REFERENCE XA3_1/4 OR XM3/4

XM3/3

PHASE A

STEER MOTOR

KEY ON

0/5 V

4.98 VDC

REFERENCE XA3_1/4 OR XM3/4

XA3_1/5

PHASE B

STEER CONTROLLER

KEY ON

0/5 V

4.98 VDC

REFERENCE XA3_1/4 OR XM3/4

XM3/2

PHASE B

STEER MOTOR

KEY ON

0/5 V

4.98 VDC

REFERENCE XA3_1/4 OR XM3/4

XM3/5 TO XM3/6

THERMAL SENSOR

STEER MOTOR

KEY ON/OFF

~600 OHMS

612 OHMS

SET METER TO OHMS AND MEASURE SENSOR RESISTANCE

(continued)

STEER CONTROL A3

RI01 POWER SUPPLY A4

XA3_1/16

THERMAL SENSOR

STEER CONTROLLER

KEY ON/OFF

~600 OHMS

612 OHMS

SET METER TO OHMS AND MEASURE SENSOR RESISTANCE. REFERENCE XA3_1/4 WITH STEER CONTROL CONTECTOR UNPLUGGED

XA3_1/23

CAN H

STEER CONTROLLER

KEY ON

0-5 V

5 VDC

NO TEST

XA3_1/15

CAN L

STEER CONTROLLER

KEY ON

0-5 V

5 VDC

NO TEST

XA3_1/1

KEY VOLTAGE IN

STEER CONTROLLER

KEY ON

B+ V

36 VDC

REFERENCE BATTERY NEG. FUSE 7F1

XA3_1/21

BRAKE CONTROL OUT

STEER CONTROLLER

KEY ON TRAVEL ACTIVE

B+ V

36 VDC

REFERENCE BATTERY NEG. LOGIC CONTROLS NEGATIVE VIA PIN XA5_1/64

XA3_1/10

STEPPER MOTOR A+

STEER CONTROLLER

KEY ON STEER ACTIVE

0-10 V

5 VDC

REFERENCE XA3_1/4, X11/3 OR X11/6

X11/1

STEPPER MOTOR A+

STEERING WHEEL SENSOR

KEY ON STEER ACTIVE

0-10 V

5 VDC

REFERENCE XA3_1/4, X11/3 OR X11/6

XA3_1/11

STEPPER MOTOR B+

STEER CONTROLLER

KEY ON STEER ACTIVE

0-10 V

5 VDC

REFERENCE XA3_1/4, X11/3 OR X11/6

X11/4

STEPPER MOTOR B+

STEERING WHEEL SENSOR

KEY ON STEER ACTIVE

0-10 V

5 VDC

REFERENCE XA3_1/4, X11/3 OR X11/6

XA3_1/19

STEER FEEDBACK SENSOR A (S31)

STEER CONTROLLER

KEY ON SENSOR ACTIVE

B+ V

36 VDC

REFERENCE BATTERY NEG. SENSOR ACTIVE WHEN LED IS ON. FUSE 10F1

XA3_1/13

STEER FEEDBACK SENSOR B (S34)

STEER CONTROLLER

KEY ON SENSOR ACTIVE

B+ V

36 VDC

REFERENCE BATTERY NEG. SENSOR ACTIVE WHEN LED IS ON. FUSE 10F1

XA4_1/13

CAN H

RI01 BOARD

KEY ON

0-5 V

5 VDC

NO TEST. 120 OHM TERMINATING RESISTOR

8-46

CONTROLLER

Pin by Pin Measurement Chart (continued) Component

RI01 POWER SUPPLY A4 (continued)

LABEL / PIN

NAME

LOCATION

CONDITION

READING

EXAMPLE

NOTES

XA4_1/14

CAN L

RI01 BOARD

KEY ON

0-5 V

5 VDC

NO TEST. 120 OHM TERMINATING RESISTOR

0.01

REFERENCE BATTERY NEGATIVE. SUPPLIED BY LOGIC UNIT POWER SUPPLY BOARD XA5_1P/11 AND XA5_1P/12

XA4_1/1 XA4_1/2

POWER INPUT (NEGATIVE)

RI01 BOARD

KEY ON

0V (NEGATIVE)

POWER INPUT (B+V)

RI01 BOARD

KEY ON

B+ V

36 VDC

SUPPLIED THROUGH FUSE 10F1.

POWER INPUT (B+V)

LOGIC UNIT SIDE CONNECTOR

KEY ON

B+ V

36 VDC

SUPPLIED THROUGH FUSE 10F1.

XA5_1P/16

POWER INPUT (NEGATIVE)

LOGIC UNIT SIDE CONNECTOR

KEY ON

0V (NEGATIVE)

0.01

REFERENCE BATTERY NEGATIVE.

XA5_1P/3

LOGIC UNIT SIDE CONNECTOR

KEY ON

15 V

12 VDC

REFERENCE XA5_1P/12 OR BATTERY NEGATIVE

XA5_1P/4

LOGIC UNIT SIDE CONNECTOR

KEY ON

4.98 VDC

REFERENCE XA5_1P/12 OR BATTERY NEGATIVE

XA5_1P/5

LOGIC UNIT SIDE CONNECTOR

KEY ON

15 V

4.98 VDC

REFERENCE XA5_1P/12 OR BATTERY NEGATIVE

XA5_1P/6

GND

LOGIC UNIT SIDE CONNECTOR

KEY ON

0V (NEGATIVE)

0.01

REFERENCE BATTERY NEGATIVE

XA5_1P/9

LOGIC UNIT SIDE CONNECTOR

KEY ON

15 V

12 VDC

REFERENCE XA5_1P/12 OR BATTERY NEGATIVE

XA5_1P/10

LOGIC UNIT SIDE CONNECTOR

KEY ON

4.98 VDC

REFERENCE XA5_1P/12 OR BATTERY NEGATIVE

XA5_1P/11

GND

LOGIC UNIT SIDE CONNECTOR

KEY ON

0V (NEGATIVE)

0.01

REFERENCE BATTERY NEGATIVE

XA5_1P/12

GND

LOGIC UNIT SIDE CONNECTOR

KEY ON

0V (NEGATIVE)

0.01

REFERENCE BATTERY NEGATIVE

XA5_1/1

POWER INPUT (GND)

LOGIC UNIT MAIN CONNECTOR

KEY ON

0V (NEGATIVE)

0.01

CHECK CONTINUITY TO XA5_1P/11

XA5_1/2

POWER INPUT (VL)

LOGIC UNIT MAIN CONNECTOR

KEY ON

15 V

12 VDC

REFERENCE XA5_1P/12 OR BATTERY NEGATIVE

XA5_1/3

POWER INPUT (GND)

LOGIC UNIT MAIN CONNECTOR

KEY ON

0V (NEGATIVE)

0.01

CHECK CONTINUITY TO AX5_1P/12

XA5_1/4

POWER INPUT (5V)

LOGIC UNIT MAIN CONNECTOR

KEY ON

4.98 VDC

REFERENCE XA5_1P/12 OR BATTERY NEGATIVE

XA5_1/5

CAN H

LOGIC UNIT MAIN CONNECTOR

KEY ON

0-5 V

5 VDC

NO TEST

XA5_1/6

CAN L

LOGIC UNIT MAIN CONNECTOR

KEY ON

0-5 V

5 VDC

NO TEST

XA5_1/63

KEY VOLTAGE IN

LOGIC UNIT MAIN CONNECTOR

KEY ON

B+ V

36 VDC

REFERENCE BATTERY NEG. FUSE 10F1

XA5_1/19

KEY VOLTAGE IN

LOGICS UNIT

KEY ON

B+ V

36 VDC

REFERENCE BATTERY NEG

XA5_1/59

MAIN CONT. CONTROL

LOGICS UNIT

KEY ON

0V (NEGATIVE)

0.01

SET METER TO CONTINUITY

XA4_1/3 XA4_1/4 XA4_1/5 XA4_1/6 XA4_1/7 XA4_1/8 XA5_1P/13 XA5_1P/14 XA5_1P/15

LOGIC BOARD (POWER SUPPLY) A5

8-47

CONTROLLER

Pin by Pin Measurement Chart (continued) Component

PUMP 2 CONTROL A6

DISPLAY A7

LABEL / PIN

NAME

LOCATION

CONDITION

READING

EXAMPLE

NOTES

XA6_2/5

PUMP ENCODER SUPPLY

PUMP CONTROLLER

KEY ON

12 VDC

11.98 VDC

REFERENCE XA6_2/19 OR X37/3

X37/4

PUMP ENCODER SUPPLY

PUMP MOTOR

KEY ON

12 VDC

11.98 VDC

REFERENCE XA6_2/19 OR X37/3

XA6_2/6

PHASE A

PUMP CONTROLLER

KEY ON

0/5 V

4.98 VDC

REFERENCE XA6_2/19 OR X37/3

X37/5

PHASE A

PUMP MOTOR

KEY ON

0/5 V

4.98 VDC

REFERENCE XA6_2/19 OR X37/3

XA6_2/7

PHASE B

PUMP CONTROLLER

KEY ON

0/5 V

4.98 VDC

REFERENCE XA6_2/19 OR X37/3

X37/6

PHASE B

PUMP MOTOR

KEY ON

0/5 V

4.98 VDC

REFERENCE XA6_2/19 OR X37/3

PUMP CONTROLLER

KEY ON/OFF

~600 OHMS

612 OHMS

SET METER TO OHMS AND MEASURE SENSOR RESISTANCE

XA6_2/1 TO THERMAL SENSOR XA6_2/2 X37/1 TO X37/2

THERMAL SENSOR

PUMP MOTOR

KEY ON/OFF

~600 OHMS

612 OHMS

SET METER TO OHMS AND MEASURE SENSOR RESISTANCE

XA6_2/3

CAN H

PUMP CONTROLLER

KEY ON

0-5 V

5 VDC

NO TEST

XA6_2/4

CAN L

PUMP CONTROLLER

KEY ON

0-5 V

5 VDC

NO TEST

XA6_2/16

DSP POWER SUPPLY

PUMP CONTROLLER

KEY ON

15 VDC

12 VDC

REFERENCE XA6_2/20 OR BATTERY NEGATIVE

XA6_2/17

DSP POWER SUPPLY

PUMP CONTROLLER

KEY ON

15 VDC

12 VDC

REFERENCE XA6_2/20 OR BATTERY NEGATIVE

XA6_2/18

DSP POWER SUPPLY

PUMP CONTROLLER

KEY ON

5 VDC

8 VDC

REFERENCE XA6_2/20 OR BATTERY NEGATIVE

XA6_2/20

DSP POWER SUPPLY

PUMP CONTROLLER

KEY ON

GND

0.01 VDC

REFERENCE XA6_2/20 OR BATTERY NEGATIVE

XA7-J1L/14 XH2/2

BUZZER OUTPUT

DISPLAY BUZZER

KEY ON

0V (NEGATIVE)

0.01

REFERENCE BATTERY NEG

XH2/1

BUZZER VOLTAGE

BUZZER

KEY ON

B+ V

36VDC

REFERENCE BATTERY NEG

X12/4

BUZZER VOLTAGE

KEYSWITCH

KEY ON

B+ V

36VDC

REFERENCE BATTERY NEG

XA7-J1L/17

DISPLAY NEGATIVE

DISPLAY

KEY ON/OFF

0V (NEGATIVE)

0.01

SET METER TO CONTINUITY

XA7-J1L2

DISPLAY NEGATIVE

DISPLAY

KEY ON/OFF

0V (NEGATIVE)

0.01

SET METER TO CONTINUITY

XA7-J2L/1 XA7_1/3

CAN H

DISPLAY

KEY ON

0-5 V

5 VDC

NO TEST

XA7-J2L/2 XA7_1/4

CAN L

DISPLAY

KEY ON

0-5 V

5 VDC

NO TEST

XA7-J1L/1 XA7_1/1

KEY VOLTAGE IN

DISPLAY

KEY ON

B+ V

36 VDC

REFERENCE BATTERY NEG

XA7-J1L/4

KEY VOLTAGE IN

DISPLAY

KEY ON

B+ V

36 VDC

REFERENCE BATTERY NEG

XA7-J1L/7

UP BUTTON INPUT

DISPLAY

KEY ON

B+ V

36 VDC

CLOSING SWITCH WILL PULL +36 VDC AT DISPLAY TERMINAL.

X10/3

UP BUTTON INPUT

DISPLAY

KEY ON

B+ V

36 VDC

CLOSING SWITCH WILL PULL +36 VDC AT DISPLAY TERMINAL.

8-48

CONTROLLER

Pin by Pin Measurement Chart (continued) Component

DISPLAY A7

LABEL / PIN

NAME

LOCATION

CONDITION

READING

EXAMPLE

NOTES

XA7-J1L/8

DOWN BUTTON INPUT

DISPLAY

KEY ON

B+ V

36 VDC

CLOSING SWITCH WILL PULL +36 VDC AT DISPLAY TERMINAL.

X10/4

DOWN BUTTON INPUT

DISPLAY

KEY ON

B+ V

36 VDC

CLOSING SWITCH WILL PULL +36 VDC AT DISPLAY TERMINAL.

XA7-J1L/9

LEFT BUTTON INPUT

DISPLAY

KEY ON

B+ V

36 VDC

CLOSING SWITCH WILL PULL +36 VDC AT DISPLAY TERMINAL.

X10/5

LEFT BUTTON INPUT

DISPLAY

KEY ON

B+ V

36 VDC

CLOSING SWITCH WILL PULL +36 VDC AT DISPLAY TERMINAL.

XA7-J1L/10

RIGHT BUTTON INPUT

DISPLAY

KEY ON

B+ V

36 VDC

CLOSING SWITCH WILL PULL +36 VDC AT DISPLAY TERMINAL.

X10/6

RIGHT BUTTON INPUT

DISPLAY

KEY ON

B+ V

36 VDC

CLOSING SWITCH WILL PULL +36 VDC AT DISPLAY TERMINAL.

XA7-J1L/11

ENTER BUTTON INPUT

DISPLAY

KEY ON

B+ V

36 VDC

CLOSING SWITCH WILL PULL +36 VDC AT DISPLAY TERMINAL.

X10/7

ENTER BUTTON INPUT

DISPLAY

KEY ON

B+ V

36 VDC

CLOSING SWITCH WILL PULL +36 VDC AT DISPLAY TERMINAL.

DISPLAY

KEY ON

B+ V

36 VDC

CLOSING SWITCH WILL PULL +36 VDC AT DISPLAY TERMINAL.

(continued)

XA7-J1L/12 ESC BUTTON INPUT

HORN CIRCUIT

TRAVEL ALARM

X10/8

ESC BUTTON INPUT

DISPLAY

KEY ON

B+ V

36 VDC

CLOSING SWITCH WILL PULL +36 VDC AT DISPLAY TERMINAL.

XA5_1/32 X14B/2

HORN

CONTROL HANDLE

KEY ON SWITCH OPEN

12 V

11.98 VDC

CLOSING SWITCH WILL PULL TO NEGATIVE. REFERENCE X14B/3

XA5_1/57

HORN RELAY CONTROL

LOGIC UNIT

HORN BUTTON CLOSED

B+V

36 VDC

REFERENCE BATTERY NEG.

XA5_1/58

HORN RELAY CONTROL

LOGIC UNIT

HORN BUTTON CLOSED

0.01

REFERENCE BATTERY NEG.

K32/3 K32/4

HORN RELAY CONTACTS

RELAY K32

RELAY ACTIVE CONTACTS CLOSED

B+V

36 VDC

K32/3 FEEDS THROUGH FUSE 11F1. k32/4 IS OUTPUT TO HORN POSITIVE TERMINAL.

XA5_1/44

MULTIPURPOSE OUTPUT

LOGIC UNIT

KEY ON

0V (GND)

0.01

K31/5 FEEDS THROUGH FUSE 11F1.

K31/1

MULTIPURPOSE OUTPUT

RELAY K31

KEY ON VARIABLE

0V (GND)

0.01

K31/5 FEEDS THROUGH FUSE 11F1.

K31/5

RELAY COIL INPUT

RELAY K31

KEY ON

B+V

36 VDC

REFERENCE BATTERY NEG. FEEDS THROUGH FUSE 11F1.

K31/3 K31/4

TRAVEL ALARM RELAY CONTACTS

RELAY K31

KEY ON

B+V

36 VDC

K31/3 FEEDS THROUGH FUSE 12F1. K31/4 IS OUTPUT TO ALARM POSITIVE TERMINAL.

8-49

CONTROLLER

Coil Resistances Resistance values with the machine turned off and the plus side unplugged.

Between

Resistance

Coils

F-5 and F-4

13.0 Ω

S7 and S8 in parallel

F-5 and F-3

16.0 Ω

S9 and S10 in parallel

F-5 and F-2

13.0 Ω

S5and S6 in parallel

G-16 and G-5

25.5 Ω

G-11 and G-6

25.5 Ω

G-10 and G-7

55.0 Ω

G-14 and G8

27.5 Ω

Temperature Sensors are 600W at 20°C (all)

+/– 2Ω Brake Coil = 19Ω

8-50

CONTROLLER

Checking Contactor

Checking Contactor Tip

Checking Contactor Coil

! CAUTION Disconnect the battery plug and discharge electric charges from all inverters and APS unit before working on electrical system. 208284

(1) Disconnect the lead wire of coil.

(1) Visually inspect the contactor tips for melting, adhesion, heat seizure and pitting corrosion.

(2) Set the multimeter to 200 ohm range. (3) Measure coil resistance. The resistance must be 44 ohm at -30°C (-22°F) to 65 ohm at 80°C (176°F). •

(2) To check for interference, press the tips and release them.

If the measured value deviates from the above range, replace the contactor assembly.

(4) With the lead wire of contactor coil connected, set the multimeter to 200-VDC range. (5) Connect the negative (–) terminal of the multimeter to the negative-side coil terminal (small fasten terminal) and the positive (+) terminal of the multimeter to the positive-side coil terminal (large fasten terminal).

(3) Visually inspect the contactor assemblies. Make sure there are no foreign materials in the assemblies to interfere with contactor movement. (4) Measure the gap at each contactor tips using a thickness gauge. It must be 3 ± 0.5 mm (0.12 ± 0.02 in.)

(6) Connect the battery, and operate the control device that activates the contactor. (7) The multimeter should indicate about 24V after the contactor operates. When the contactor is found normal in the coil resistance test and if the measured voltage is not this value, replace the logic card.

8-51

•

If you find any troubles, replace or repair contactor.

CONTROLLER

Checking Inverter

Regeneration Check The AC motor uses a common circuit for current flow in both loading and regeneration. This allows the following procedure to confirm regenerating.

! CAUTION Disconnect the battery plug and discharge electric charges from all inverters and APS unit before working on electrical system.

(1) Place the clamp ammeter onto the cable connected to the inverter’s P terminal (use DC current range). This is positive direction as current flows from the battery to the inverter.

Multimeter

Clamp ammeter setting direction

211917

(1) Disconnect all five power cables from P, N, U, V and W terminals (F, N, U, V and W terminals for the pump inverter).

Positive probe N U V W

211918

Negative probe Resistance (ohm) U V W 8k to 11k

(2) Run the truck forward. With the traction lever shifted in the forward position, release the traction pedal. Then perform a full-reverse operation.

(3) The clamp ammeter should show a negative value. This value becomes the regeneration current.

(2) Check the resistance between terminals shown in the following table. NOTICE: Short-circuit/disconnection of the inverter MOSFET can be confirmed by this check. Other fault cannot be determined.

Energy is generated when a motor is rotated with external force. The regeneration power is produced when this energy is larger than the one that is consumed by the controller and motor. This means that the regeneration current is not measured if the speed or load changes gradually.

8-52

TROUBLESHOOTING FOR CONTROL CIRCUITS General Information ...................................................................................... Before Replacing Devices........................................................................... Connection of the Service Tool ................................................................... How to Clean Harness Connectors and System Components...................... CAN-BUS Reach Truck AC .........................................................................

9-1 9-1 9-1 9-2 9-3

Troubleshooting ............................................................................................ 9-4 E0 Traction Motor, Overheating.................................................................. 9-4 E2 Pump Motor 1, Overheating ................................................................. 9-8 E3 Pump Motor 2, Overheating ................................................................. 9-11 E4 Steer Motor, Overheating ..................................................................... 9-14 E5 Traction Inverter, Overheating............................................................... 9-17 E7 Pump Inverter 1, Overheating .............................................................. 9-20 E8 Pump Inverter 2, Overheating .............................................................. 9-23 E9 Steer Inverter, Overheating .................................................................. 9-26 A5 Traction Motor, Over-Current ............................................................... 9-29 14 Traction Motor Current Sensor Fault ..................................................... 9-32 15 Traction Motor, Over-Current................................................................. 9-34 16 Traction Motor, Stall Timer Speed Fault ................................................ 9-37 34 Pump Motor 1, Current Sensor Fault .................................................... 9-39 35 Pump Motor 1, Over-Current ................................................................ 9-41 40 Line Contactor Fault ............................................................................. 9-44 45 Traction Motor Open ............................................................................. 9-46 47 Pump Motor 1, Open ............................................................................ 9-49 48 Pump Motor 2, Open ............................................................................ 9-52 49 Steer Motor, Open ................................................................................ 9-55 51 Traction Lever Sensor Fault .................................................................. 9-58 52 Traction Motor Pulse Input Fault ........................................................... 9-61 55 FC Solenoid Fault ................................................................................. 9-64 56 FC Solenoid Current Leak .................................................................... 9-67 57 Pump Motor 1 Pulse Input Fault ........................................................... 9-69 58 Pump Motor 2 Pulse Input Fault ........................................................... 9-72 59 Steer Motor Pulse Input Fault ............................................................... 9-75 60 Display Communication Fault ............................................................... 9-78 61 Parameter Write Fault ........................................................................... 9-81 62 Logics Fault .......................................................................................... 9-82 63 Traction Inverter Fault ........................................................................... 9-83 65 Pump Inverter 1 Fault ........................................................................... 9-86 66 Pump Inverter 2 Fault ........................................................................... 9-89 68 Output Unit Fault .................................................................................. 9-92 71 APS Controller Fault ............................................................................. 9-94 78 Battery Voltage Too Low ....................................................................... 9-96 79 Battery Voltage Too High ...................................................................... 9-98 81 Pressure Sensor Fault .......................................................................... 9-100 82 Steer Stepper Motor Fault .................................................................... 9-103

85 Brake Switch Fault ................................................................................ 9-105 86 Height Sensor Fault .............................................................................. 9-107 88 Logic Fault Multipurpose Output #1, Travel Alarm ................................ 9-110 88 Logic Fault Multipurpose Output #2, Horn ............................................ 9-112 94 Pump Motor 2, Current Sensor Fault .................................................... 9-114 95 Pump Motor 2, Over-Current ............................................................... 9-116 (E) Incorrect Start ...................................................................................... 9-119 (H1) Lift Lever, Faulty Setting .................................................................... 9-121 (H2) Tilt Switch, Faulty Setting................................................................... 9-123 (H3) Reach Switch, Faulty Setting ............................................................. 9-125 (H4) Sideshift Switch, Faulty Setting.......................................................... 9-127 (Lo) Battery Low ........................................................................................ 9-129 Component Identification............................................................................. 9-131 Electrical Schematic ..................................................................................... 9-135

TROUBLESHOOTING FOR CONTROL CIRCUITS

General Information Before replacing devices Do not replace devices casually even if replacement is required as a result of troubleshooting. Be sure to check the following items before replacing devices (logics unit, logic card, power supply card, inverters, inverter DSP cards, output units, display unit and APS unit). •

Loose battery connectors

•

Abnormal wire harness connections

•

Loose connectors

•

Broken, bent or loose connector pins

•

Dirty connectors If connectors are dirty, remove the connector and clean connectors. See “How to clean harness connectors and system components” on page 9-2.

•

Ensure that the main harness is not short-circuited to the truck body by using the following procedures.

•

Perform “Inspection before replacing controllers” described in the Removal and Installation of the controller. Disconnect battery plug and discharge the inverters and APS unit before working on electrical system. Disconnect power supply connector of logic unit. Check continuity between XA5_1P/13 and truck body (logic unit installation bolts, etc.). No continuity

Continuity

Normal

Repair or replace harness.

If any of these items (above items) is a source of the trouble, the device will be damaged even if it is replaced with a new one. Be sure to check the above items and replace carefully.

Connection of the service tool

Error code display

1. Turn off the truck power. 2. Remove the deck cover. 3. Find the connector to the service tool near the logics unit.

12345.6

02/27/2004

Logic unit

4. Remove the cover and connect the PC as shown. 5. Turn on the truck power. 6. Start the service tool software.

211793

9-1

TROUBLESHOOTING FOR CONTROL CIRCUITS

How to clean harness connectors and system components 1. Open-circuits are often caused by dirty harness connectors and components. Dust, together with greasy matter, forms grime which, in time, penetrates electrical connections, resulting in loose metal-to-metal contact or, for worse, electrical separation of surfaces in contact. For this reason, it is essential that the connectors and components be cleaned at each periodic inspection and at when servicing the truck. Instead of a commonly used solvent, use electronic parts cleaner (in the manner illustrated on the right). Electronic parts cleaner

Electronic parts cleaner 211359

Three Bond 29D or Pow-R-Wash CZ*

NOTE The cleaner liquid is volatile. All you have to do is just give a strong spray to wash off grime. No need to wipe off the sprayed liquid. 2. After checking the connector for continuity, wash it as shown. Then, uncouple the connector and spray contact surface activator onto contact surfaces. Install and remove the connector several times to wet the surfaces thoroughly with the activator liquid.

Electronic parts cleaner

After coupling up the connector, check to be sure that it is in locked state. Contact surface activator *:

Three Bond 2501S (aerosol) or Nyogel 760G*

Products contained in Terminal Maintenance Kit (SE000003)

NOTE Do not spray too much liquid into the connector. Cleaner liquid reacts differently with some resins (plastic materials).

Contact surface activator 205047

9-2

TROUBLESHOOTING FOR CONTROL CIRCUITS

CAN-BUS Reach Truck AC Pump inverter

Traction inverter

2nd Pump inverter

APS unit

Display unit

Logic unit

Output unit

CAN_H CAN_L

211835

Tests 1 and 2 performed at GSE connector X56 Positions 11 and 12 1. Test 1: (Traction Inverter: (right) P15 – Display P4 connectors are Plugged In) •

60 Ohms. CAN BUS circuit correct!

•

If the results are 120 Ohms, CAN BUS circuit Pump 1 Inverter or Output Unit resistor has failed open.

•

Go to test 2 and 3.

2. Test 2: (Output Unit XA4_1 Connector is Unplugged) •

120 Ohms. CAN BUS circuit Pump 1 Inverter: (right) resistor is good.

•

If the results are OL (Open) Ohms, CAN BUS Pump 1 Inverter resistor is failed open.

3. Test 3: (Pump Inverter: XA2_2 Connector is Unplugged.) •

120 Ohms. CAN BUS circuit Output Unit resistor is good.

•

Results (OL) (Open) Output Unit resistor is failed open.

X56 GSE CONNECTOR

9-3

TROUBLESHOOTING FOR CONTROL CIRCUITS

Troubleshooting Problem: Traction Motor, Overheating (E0) (1) Situation Controller/motor overheat indicator ON. Poor pulling power and acceleration. Normal pump motor and power steering operations. Service tool "Fault Status" and "E0" displayed. (2) Possible cause Overheating of traction motor, faulty traction motor or thermal sensor, faulty or open harness wiring, faulty traction inverter DSP card, abnormal power supply of logic unit, electromagnetic brake drag, abnormality in drive unit, faulty display unit. (3) How the error code is triggered Motor temperature is out of range of -25 C to 145 C (-13 F to 293 F). It becomes normal when motor temperature is in range of -20 C to 70 C (-4 F to 158 F). (4) Checks Let truck cool for 15 minutes. Overheat indicator ON

Overheat indicator OFF (5) Traction motor becomes normal. If problem recurs (6) Disconnect battery plug. Disengage electromagnetic brake, and check their drag. No drag Drag (7) Adjust brake. (8) Lift front wheels, and disengage electromagnetic brake. Turn off power, rotate front wheels. Confirm there is no difference in rotation load between right and left wheels. Difference No difference (9) Check if truck is operated on steep upgrade or used to pull large cargo load. Normal (10) Discharge electric charges from inverters and APS unit. See page 8-30. (11) Replace traction motor. See Chassis & Mast. Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

Without service tool

With service tool 9-4

(12) Replace traction motor or drive unit. See Chassis & mast. Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

TROUBLESHOOTING FOR CONTROL CIRCUITS

With service tool (13) Confirm temperature of traction motor with Input Monitor. -20 °C to 70 °C Less than -20 °C(-4 °F) (-4 °F to 158 °F) or more than 70 °C(158 °F)

Without service tool

(14) Disconnect battery plug. Wait until traction motor

(15) Disconnect battery plug.

temperature becomes close to room temperature.

(16) Discharge electric charges from inverters and APS unit. See page 8-30.

(17) Troubleshoot display unit by referring Display Communication Fault (60)-(4).

(18) Disconnect connector X35 of traction motor thermal sensor. Measure resistance between X35/1 and X35/2 at motor side. 581 at 20°C (68°F) (Min 555 , Max. 607 ) For resistance at temperature other than 20°C (68°F), see table on page 9-7. Out of Range Thermal (19) Disconnect connector XA1_2 of traction inverter Check continuity between XA1_2/1and X35/1 Check continuity between XA1_2/2and X35/2 Continuity

(20) Replace traction motor. See Chassis & Mast. Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

No continuity

Power supply (21) Disconnect Connector XA5_1P Check continuity between XA5_1P/3 and XA1_2/17 Check continuity between XA5_1P/6 and XA1_2/20 Continuity No continuity CAN (22) Disconnect connector XA5_1 of logic unit Check continuity between XA5_1/5 and XA1_2/3 Check continuity between XA5_1/6 and XA1_2/4

Continuity

No continuity (24) Repair or replace harness.

(23) Connect connector XA5_1P, then turn on power again. (25) Measure voltage between XA1_2/17 and XA1_2/20 Confirm value is 14V ± 2V. Abnormal Normal

(26) Disconnect battery plug. (27)Replace power supply card of logic unit. See page 8-37.

9-5

TROUBLESHOOTING FOR CONTROL CIRCUITS

(28) Ensure all connectors are connected. Check history folder data. See page 5-2. Not "E0" The latest data is "E0". (29) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(30)Troubleshoot display unit by referring to Display Communication Fault (60)-(4).

(31) Replace DSP card of traction inverter. See page 8-33.

9-6

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA1_2 Traction inverter (A1) 0 to 5V 0 to 5V

CAN 5 6

12V 14V 8V GND 5V * 1 GND GND +12V 0 to 5V 0 to 5V

5 Power 3 4 6 Power supply card XA5_1P

3 H Inside of 4 L cover 14 15 16 17 18 DSP 20 card 2 Temp 1 Sens Flat 19 cable 5 7 6

*1: With motor connector disconnected AMBIENT TEMPERATURE ( C) -30 -10 0 10 30 50 70 90 110 130 150

( F) -22 14 32 50 86 122 158 194 230 266 302

Fuse IMS card

Line contactor

425A

Battery (-)

U V W

Traction motor

P21 B 6 G 5 W 4 R 3 LB 2 L 1

Inside of case

BLU WHT RED BLK

X35

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

RESISTANCE MIN. 370 437 474 514 599 694 797 910 1029 1152 1282

TYP. 391 460 498 538 626 722 826 940 1062 1194 1334

MAX. 411 483 522 563 652 750 855 970 1096 1235 1385

211794-E0

9-7

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Motor 1, Overheating (E2) (1) Situation Controller/motor overheat indicator ON. Lifting speed slower than normal. Normal traction motor and power steering operations. Service tool "Fault Status" and "E2" displayed. (2) Possible cause Overheating of pump motor, faulty pump motor or thermal sensor, faulty or open harness wiring, faulty pump motor inverter DSP card, abnormal power supply of logic unit, abnormal oil pressure of gear pump or hydraulic lines, faulty display unit. (3) How the error code is triggered Motor temperature is out of range of -25 °C to 145 °C (-13 °F to 293 °F). It becomes normal when motor temperature is in range of -20 °C to 70 °C (-4 °F to 158 °F). (4) Checks Let truck cool for 15 minutes. Overheat indicator ON

Overheat indicator OFF (5) Pump motor becomes normal. If problem recurs (6) Check if truck is operated to lift large cargo load. Normal (7) Discharge electric charges from inverters and APS unit. See page 8-30. (8) Check oil pressure of gear pump and hydraulic lines. Abnormal Normal (9) Replace pump motor. See Chassis & Mast. Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

(10) Repair or replace gear pump or piping. See Chassis & Mast.

With service tool (11) Confirm temperature of pump motor 1 with Input Monitor. Less than -20 °C (-4 °F) -20 °C to 70 °C or more than 70 °C (158 °F) (-4°F 158 °F)

Without service tool

(12) Disconnect battery plug. Wait until pump motor temperature becomes close to room temperature.

(13) Disconnect battery plug.

(14) Discharge electric charges from inverters and APS unit. See page 8-30.

(15) Troubleshoot display unit by referring Display Communication Fault (60)-(4).

9-8

TROUBLESHOOTING FOR CONTROL CIRCUITS

(16) Disconnect connector X36 of pump motor thermal sensor. Measure resistance between X36/2 and X36/1. 581Ω at 20°C (68°F) (Min. 555 Ω, Max. 607Ω) For resistance at temperature other than 20°C (68°F), see table on page 9-10. Out of range Thermal (17) Disconnect connector XA2_2 of pump motor inverter. Check continuity between XA2_2/1 and X36/1 Check continuity between XA2_2/2 and X36/2 Continuity No Continuity

(18) Repair pump motor. See Chassis & Mast. Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

Power supply (19) Disconnect Connector XA5_1 Check continuity between XA5_1P/3 and XA2_2/17 Check continuity between XA5_1P/6 and XA2_2/20 Continuity No continuity CAN (20) Disconnect connector XA5_1P16 of logic unit. Check continuity between XA5_1/5 and XA2_2/3 Check continuity between XA5_1/6 and XA2_2/4 Continuity No continuity (21)Connect connector XA5_1P, then turn on power again.

(22)Repair or replace harness.

(23) Measure voltage beween XA2_2/17 and XA2_2/20. Confirm value is 14 ± 2V. Normal Abnormal (24) Disconnect battery plug. (26) Ensure all connectors are connected. Check history folder data. See page 5-2. The latest data is "E2".

(25)Replace power supply card of logic unit. See page 8-37.

Not "E2"

(28) Troubleshoot display (27) Disconnect battery plug, unit by referring Display then discharge electric Communication Fault charges from inverters and (60)-(4). APS unit. See page 8-30.

(29) Replace DSP card of pump motor inverter. See page 8-33.

9-9

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA2_2 Pump inverter 1 (A2) 0 to 5V 0 to 5V

CAN 5 6

12V 14V 8V GND 5V* 1 GND GND +12V 0 to 5V 0 to 5V

5 Power 3 4 6 Power supply card XA5_1P

*1: With motor connector disconnected AMBIENT TEMPERATURE ( C) -30 -10 0 10 30 50 70 90 110 130 150

( F) -22 14 32 50 86 122 158 194 230 266 302

3 Inside of 4 cover 14 15 16 17 18 DSP 20 card 2 Temp 1 Sens Flat 19 cable 5 6 A 7 B

P17 BLU 6 WHT 5 RED 4 BLK 3 2 1 X36

Inside of case

Fuse 425A

IMS card

Battery (-)

Line contactor

Pump motor 1 Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

RESISTANCE MIN. 370 437 474 514 599 694 797 910 1029 1152 1282

TYP. 391 460 498 538 626 722 826 940 1062 1194 1334

MAX. 411 483 522 563 652 750 855 970 1096 1235 1385

211796-E2

9-10

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Motor 2, Overheating (E3) (1) Situation Controller/motor overheat indicator ON. Lifting speed slower than normal. Normal traction motor and power steering operations. Service tool "Fault Status" and "E3" displayed. (2) Possible cause Overheating of pump motor, faulty pump motor or thermal sensor, faulty or open harness wiring, faulty pump motor inverter DSP card, abnormal power supply of logic unit, abnormal oil pressure of gear pump or hydraulic lines, faulty display unit. (3) How the error code is triggered Motor temperature is out of range of -25 °C to 145 °C (-13 °F to 293 °F). It becomes normal when motor temperature is in range of -20 °C to 70 °C (-4 °F to 158 °F). (4) Checks Let truck cool for 15 minutes. Overheat indicator ON

(10) Repair or replace gear pump or piping. See Chassis & Mast.

With service tool (11) Confirm temperature of pump motor 2 with Input Monitor. Less than -20 °C (-4 °F) -20 °C to 70 °C or more than 70 °C (158 °F) (-4°F 158 °F)

Without service tool

(12) Disconnect battery plug. Wait until pump motor temperature becomes close to room temperature.

(13) Disconnect battery plug.

(14) Discharge electric charges from inverters and APS unit. See page 8-30.

(15) Troubleshoot display unit by referring Display Communication Fault (60)-(4).

9-11

TROUBLESHOOTING FOR CONTROL CIRCUITS

(16) Disconnect connector X37 of pump motor thermal sensor. Measure resistance between X37/2 and X37/1. 581Ω at 20°C (68°F) (Min. 555 Ω, Max. 607Ω) For resistance at temperature other than 20°C (68°F), see table on page 9-13. Out of range Thermal (17) Disconnect connector XA6_2 of pump motor inverter. Check continuity between XA6_2/1 and X37/1 Check continuity between XA6_2/2 and X37/2 Continuity No Continuity

(18) Repair pump motor. See Chassis & Mast. Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

Power supply (19) Disconnect Connector XA5_1 Check continuity between XA5_1P/3 and XA6_2/17 Check continuity between XA5_1P/6 and XA6_2/20 Continuity No continuity CAN (20) Disconnect connector XA5_1 of logic unit. Check continuity between XA5_1/5 and XA6_2/3 Check continuity between XA5_1/6 and XA6_2/4 Continuity No continuity (21)Connect connector XA5_1P P, then turn on power again.

(22)Repair or replace harness.

(25)Replace power supply card of logic unit. See page 8-37.

Not "E3"

(28) Troubleshoot display (27) Disconnect battery plug, unit by referring Display then discharge electric Communication Fault charges from inverters and (60)-(4). APS unit. See page 8-30

(29) Replace DSP card of pump motor inverter. See page 8-33.

9-12

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA6_2 Pump inverter 2 (A6) 0 to 5V 0 to 5V

CAN 5 6

12V 14V 8V GND 5V* 1 GND GND +12V 0 to 5V 0 to 5V

5 Power 3 4 6 Power supply card XA5_1P

3 Inside of 4 cover 14 15 16 17 18 DSP 20 card 2 Temp 1 Sens Flat 19 cable 5 7 A 6 B

Inside of case

Fuse 425A

IMS card

Battery (-)

Line contactor

Pump motor 2

*1: With motor connector disconnected AMBIENT TEMPERATURE ( C) -30 -10 0 10 30 50 70 90 110 130 150

( F) -22 14 32 50 86 122 158 194 230 266 302

BLU 6 WHT 5 RED 4 BLK 3 2 1 X37

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

RESISTANCE MIN. 370 437 474 514 599 694 797 910 1029 1152 1282

TYP. 391 460 498 538 626 722 826 940 1062 1194 1334

MAX. 411 483 522 563 652 750 855 970 1096 1235 1385

211796-E3

9-13

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Steer Motor, Overheating (E4) (1) Situation Controller/motor overheat indicator ON. Normal traction motor and power steering operations. Service tool "Fault Status" and "E4" displayed. (2) Possible cause Overheating of steer motor, faulty steer motor or thermal sensor, faulty or open harness wiring, faulty steer motor inverter, faulty display unit.

(3) How the error code is triggered Motor temperature is out of range of -25 °C to 145 °C (-13 °F to 293 °F). It becomes normal when motor temperature is in range of -20 °C to 70 °C (-4 °F to 158 °F). (4) Checks Let truck cool for 15 minutes. Overheat indicator ON

Overheat indicator OFF (5) Steer motor becomes normal.

With service tool (6) Confirm temperature of steer motor 1 with Input Monitor. Less than -20 °C (-4 °F) -20 °C to 70 °C or more than 70 °C (158 °F) (-4°F 158 °F)

Without service tool

(7) Disconnect battery plug. Wait until steer motor temperature becomes close to room temperature.

(8) Disconnect battery plug.

(9) Discharge electric charges from inverters and APS unit. See page 8-30.

(10) Troubleshoot display unit by referring to Display Communication Fault (60)-(4).

9-14

TROUBLESHOOTING FOR CONTROL CIRCUITS

(16) Disconnect connector XM3 of steer motor thermal sensor. Measure resistance between XM3 and XM3/6. 581Ω at 20°C (68°F) (Min. 555 Ω, Max. 607Ω) For resistance at temperature other than 20°C (68°F). Normal Out of range Thermal (17) Disconnect connector XA3 of steer motor inverter. Check continuity between XA3_1/14 and XM3/5 Check continuity between XA3_1/16 and XM3/6 Continuity No Continuity

(18) Replace steer motor. See Chassis & Mast. Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

CAN (20) Disconnect connector XA5_1 of logic unit. Check continuity between XA5_1/5 and XA3_1/23 Check continuity between XA5_1/6 and XA3_1/15 Continuity No continuity (22)Repair or replace harness.

(24) Disconnect battery plug. (26) Ensure all connectors are connected. Check history folder data. See page 5-2. The latest data is "E4".

Not "E4"

(28) Troubleshoot display (27) Disconnect battery plug, unit by referring Display then discharge electric Communication Fault charges from inverters and (60)-(4). APS unit. See page 8-30.

(29) Replace steer motor inverter. See page 8-31.

9-15

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA3_1 Steer Controller (A3) 0 to 5V 0 to 5V

CAN 5 6

23 CAN H 15 CAN L Fuse 21 Brake Control +36V

7F1 K11

K12

10A GND 0 to 5V 0 to 5V +12V

1 KEY on +36V 16 Thermal Sensor 4

}

5 6 3

}

50A

P N

Battery (-)

Line contactor

Encodes

Steer motor A3 RED 1 WHT 3 BLU 2 BLK 4 5 6 XM3

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

211796-E4

9-16

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Inverter, Overheating (E5) (1) Situation Controller/motor overheat indicator ON. Poor pulling power and acceleration. Normal pump motor and power steering operations. Service tool "Fault Status" and "E5" displayed. (2) Possible cause Overheating of traction inverter, faulty traction inverter thermal sensor, open harness wiring, faulty traction inverter PC board, abnormal power supply of logic unit, faulty temperature of traction inverter, faulty display unit.

(3) How the error code is triggered Controller temperature is out of range of -25°C to 100°C (-13°F to 212°F). Capacitor temperature is out of range of -25°C to 110°C (-13°F to 230°F). It becomes normal when temperature is in range of -20°C to 70°C (-4°F to 158°F). (4) Checks Let truck cool for 15 minutes. Overheat indicator ON

Overheat indicator OFF (5) Traction inverter becomes normal. If problem recurs (6) Check if truck is operated on steep upgrade or to pull large cargo load. Normal (7) Discharge electric charges from inverters and APS unit. See page 8-30. Check thermal paste applied on inverter mounting surface. Thermal paste film should be thin and even. Abnormal Normal

With service tool Without service tool

(8) Replace traction inverter. (9) Clean mouning surface, See page 8-31. apply thermal paste, then reinstall inverter. See page 8-31. (10) Confirm temperature of controller and head capacitor with Input Monitor. -20°C to 70°C Less than -20°C (-4°C) (-4°F to 158°F) or more than 70°C (158°F)

(11) Disconnect battery plug. Wait until inverter temperature becomes close to room temperature.

(12) Disconnect battery plug. (14) Troubleshoot display unit by referring Display Communication Fault (60)-(4).

(13) Discharge electric charges from inverters and APS unit. See page 8-30. Thermal (15) Remove traction inverter DSP card cover, then check harness looseness or wire breakage. See page 8-33.

Normal

Abnormal

9-17

TROUBLESHOOTING FOR CONTROL CIRCUITS

Power supply (16) Disconnect connector XA1_2 of traction inverter. Disconnect connector XA1_2 of traction inverter. Check continuity between XA5_1P/3 and XA1_2/17. Check continuity between XA5_1P/6 and XA1_2/20. Continuity No continuity

(17) Secure harness if loose. Replace inverter if wire breaks. See page 8-31.

CAN (18) Disconnect connector XA5_1of logic unit. Check continuity between XA5_1/5 and XA1_2/3. Check continuity between XA5_1/6 and XA1_2/4. Continuity

No continuity

(19) Connect connector XA5_1P, then turn on power again.

(20) Repair or replace harness.

(21) Measure voltage between XA1_2/17 and XA1_2/20. Confirm value is 14V ± 2V. Normal Abnormal

(22) Disconnect battery plug.

(24) Ensure all connectors are connected. Check history folder data. See page 5-2. The latest data is "E5" Not "E5"

(23)Replace power supply card of logic unit. See page 8-37.

(26) Troubleshoot display (25) Disconnect battery plug, unit by referring Display then discharge electric Communication Fault charges from inverters and (60)-(4). APS unit. See page 8-30. (27) Replace DSP card of traction inverter. See page 8-33. If fault remains (28) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(29) Replace traction inverter. (DSP card is normal.) See page 8-31.

9-18

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA1_2 Traction inverter (A1) 0 to 5V 0 to 5V

CAN 5 6

5 Power 3 4 6 Power supply card XA5_1P

DSP flat cable Inverter case DSP card

+12V +14V +8V GND 5V * 1 GND GND +12V 0 to 5V 0 to 5V

3 Inside of 4 cover 14 15 16 17 18 DSP 20 card 2 Temp 1 Sens Flat 19 cable 5 7 6

Inside of case

Fuse Line contactor

IMS card

Battery (-)

Traction motor 6 BLU 5 WHT 4 RED 3 BLK 2 1 X35

Speed sensor

RTW RTV

RTU

IM Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

211798-E5

9-19

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Inverter 1, Overheating (E7) (1) Situation Controller/motor overheat indicator ON. Lifting speed slower than normal. Normal traction motor and power steering operations. Service tool "Fault Status" and "E7" displayed. (2) Possible cause Overheating of pump inverter, faulty pump inverter thermal sensor, open harness wiring, faulty pump inverter PC board, abnormal power supply of logic unit, faulty temperature of pump inverter, faulty display unit.

Overheat indicator OFF (5) Pump inverter becomes normal. If problem recurs (6) Check if truck is operated to lift large cargo load. Normal (7) Discharge electric charges from inverters and APS unit. See page 8-30. Check thermal paste applied on inverter mounting surface. Thermal paste film should be thin and even. Abnormal Normal (8) Replace pump inverter. See page 8-31. With service tool

Without service tool

(9) Clean mounting surface, apply thermal paste, then reinstall inverter. See page 8-31.

(10) Confirm temperature of controller and head capacitor with Input Monitor. -20°C to 70°C Less than -20°C (-4°C) (-4°F to 158°F) or more than 70°C (158°F) (11) Disconnect battery plug. Wait until inverter temperature becomes close to room temperature.

(12) Disconnect battery plug. (14) Troubleshoot display unit by referring Display Communication Fault (60)-(4).

(13) Discharge electric charges from inverters and APS unit. See page 8-30. Thermal (15) Remove pump inverter DSP card cover, then check harness looseness or wire breakage. See page 8-33.

Normal

Abnormal

9-20

TROUBLESHOOTING FOR CONTROL CIRCUITS

Power supply (16) Disconnect connector XA5_1P. Disconnect connector XA2_2 of pump inverter. Check continuity between XA5_1P/3 and XA2_2/17. Check continuity between XA5_1P/6 and XA2_2/20. Continuity No continuity

(17) Secure harness if loose. Replace inverter if wire breaks. See page 8-31.

CAN (18) Disconnect connector XA5_1 of logic unit. Check continuity between XA5_1/5 and XA2_2/3. Check continuity between XA5_1/16 and XA2_2/4. Check continuity between XA2_2/14 and XA2_2/15. Continuity No continuity

(19)Connect connector XA5_1P, then turn on power again.

(20) Repair or replace harness.

(21) Measure voltage between XA2_2/17 and XA2_2/20. Confirm value is 14V ± 2V. Normal Abnormal

(22) Disconnect battery plug.

(24) Ensure all connectors are connected. Check history folder data. See page 5-2. The latest data is "E7" Not "E7"

(23)Replace power supply card of logic unit. See page 8-37.

(26) Troubleshoot display (25) Disconnect battery plug, unit by referring Display then discharge electric Communication Fault charges from inverters and (60)-(4). APS unit. See page 8-30. (27) Replace DSP card of pump inverter. See page 8-33. If fault remains. (28) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(29) Replace pump inverter. (DSP card is normal.) See page 8-31.

9-21

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA2_2 0 to 5V 0 to 5V

CAN 5 6

5 Power 3 4 6 Power supply card XA5_1P

12V 14V 8V GND 5V GND GND +12V 0 to 5V 0 to 5V

Pump inverter 1 (A2)

3 Inside of 4 cover 14 15 16 17 18 DSP 20 card 2 Temp 1 Sens Flat 19 cable 5 6 A 7 B

Inside of case

Fuse 425A

Battery (-)

IMS card

U V W

Pump motor 1 DSP flat cable Inverter case DSP card

BLU 6 5 WHT 4 RED BLK 3 2 1 X36

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

211800-E7

9-22

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Inverter 2, Overheating (E8) (1) Situation Controller/motor overheat indicator ON. Lifting speed slower than normal. Normal traction motor and power steering operations. Service tool "Fault Status" and "E8" displayed. (2) Possible cause Overheating of pump inverter, faulty pump inverter thermal sensor, open harness wiring, faulty pump inverter PC board, abnormal power supply of logic unit, faulty temperature of pump inverter, faulty display unit.

Without service tool

(9) Clean mounting surface, apply thermal paste, then reinstall inverter. See page 8-31.

(12) Disconnect battery plug. (14) Troubleshoot display unit by referring Display Communication Fault (60)-(4).

(13) Discharge electric charges from inverters and APS unit. See page 8-30. Thermal (15) Remove pump inverter DSP card cover, then check harness looseness or wire breakage. See page 8-33.

Normal

Abnormal

9-23

TROUBLESHOOTING FOR CONTROL CIRCUITS

Power supply (16) Disconnect connector XA5_1P. Disconnect connector XA6_2 of pump inverter. Check continuity between XA5_1P/3 and XA6_2/17. Check continuity between XA5_1P/6 and XA6_2/20. Continuity No continuity

(17) Secure harness if loose. Replace inverter if wire breaks. See page 8-30.

CAN (18) Disconnect connector XA5_1 of logic unit. Check continuity between XA5_1/5 and XA6_2/3. Check continuity between XA5_1/16 and XA6_2/4. Check continuity between XA2_2/14 and XA6_2/15. Continuity No continuity

(19)Connect connector XA5_1P, then turn on power again.

(20) Repair or replace harness.

(21) Measure voltage between XA6_2/17 and XA6_2/20. Confirm value is 14V ± 2V. Normal Abnormal

(22) Disconnect battery plug.

(24) Ensure all connectors are connected. Check history folder data. See page 2-54. The latest data is "E8" Not "E8"

(23)Replace power supply card of logic unit. See page 8-37.

(26) Troubleshoot display (25) Disconnect battery plug, unit by referring Display then discharge electric Communication Fault charges from inverters and (60)-(4). APS unit. See page 8-30. (27) Replace DSP card of pump inverter. See page 8-33. If fault remains. (28) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(29) Replace pump inverter. (DSP card is normal.) See page 8-31.

9-24

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA2_2 0 to 5V 3 0 to 5V 4

CAN 5 6

5 Power 3 4 6 Power supply card XA5_1P

Pump inverter 2 (A6) Inside of cover

14 15 12V 16 14V 17 8V 18 DSP GND 20 card 5V* 1 2 Temp GND 1 Sens Flat GND 19 cable +12V 5 0 to 5V 7 A 0 to 5V 6 B

Inside of case

Fuse 425A

Battery (-)

IMS card

U V W

Pump motor 2 DSP flat cable Inverter case DSP card

BLU 6 5 WHT 4 RED BLK 3 2 1 X37

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

211800-E8

9-25

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Steer Inverter, Overheating (E9) (1) Situation Controller/motor overheat indicator ON. Normal traction motor and pump motor operations. Service tool "Fault Status" and "E9" displayed. (2) Possible cause Overheating of steer inverter, faulty steer inverter thermal sensor, open harness wiring, faulty temperature of steer inverter, faulty display unit.

Overheat indicator OFF (5) Steer inverter becomes normal.

With service tool Without service tool (6) Confirm temperature of controller with Input Monitor. -20°C to 70°C Less than -20°C (-4°C) (-4°F to 158°F) or more than 70°C (158°F) (9) Disconnect battery plug. Wait until inverter temperature becomes close to room temperature.

(7) Disconnect battery plug. (8) Troubleshoot display unit by referring to Display Communication Fault (60)-(4).

(10) Discharge electric charges from inverters and APS unit. See page 8-30. Thermal (11) Check harness looseness or wire breakage. See page 8-31.

Normal

Abnormal

9-26

TROUBLESHOOTING FOR CONTROL CIRCUITS

Power supply (13) Disconnect connector XA5_1P. Disconnect connector XA6_2 of pump inverter. Check continuity between XA5_1P/3 and XA6_2/17. Check continuity between XA5_1P/6 and XA6_2/20. Continuity No continuity

(12) Secure harness if loose.

CAN (14) Disconnect connector XA5_1 of logic unit. Check continuity between XA5_1/5 and XA6_2/3. Check continuity between XA5_1/16 and XA6_2/4. Check continuity between XA2_2/14 and XA6_2/15. Continuity No continuity (16) Ensure all connectors are connected. Check history folder data. See page 5-2. The latest data is "E9" Not "E9"

(15) Repair harness or replace fuse 7F1.

(17) Troubleshoot display (18) Disconnect battery plug, unit by referring to then discharge electric Display Communication charges from inverters and Fault (60)-(4). APS unit. See page 8-30. (19) Replace pump inverter. (DSP card is normal.) See page 8-31.

9-27

TROUBLESHOOTING FOR CONTROL CIRCUITS

To Logic Unit

S34

XY31/2 S31

M1 Safety Brake S31 XY31/1

10F1

K11

KEY SWITCH

Steering Stepper Motor

PNP

K12 S34

21 Brake

10 Signal A

4 Gnd

B-

PNP

7F1 10A

X11/6

BLU WH

B+

X11/4

YEL X11/3

BLK

A-

X11/1

RED

A+

11 Signal l B

13 Steering

Steer Motor Controller (APS)

9-28

19 Reference

1 Key

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Motor, Over-current (A5) (1) Situation Display: "A5".All truck operations except for "lower" inhibited. Line contactor OPEN. (2) Possible cause Faulty steer inverter, faulty steer motor, faulty contact or wire breakage of steer motor speed sensor harness, faulty main harness, faulty logic unit.

(3) How the error code is triggered The circuit, via hardware that limits the current in the motor is always active

(4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(5) Check steer motor and terminal for burning and smell. Abnormal Normal

(7) Replace steer motor. Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

(6) Confirm cable looseness and improper connections (U, V, W phases) for steer inverter and motor. Normal

Abnormal

(10) Confirm connection of steer motor speed sensor connector XM3. Abnormal Normal

(9) Secure cable if loose or connect cable correctly.

Sensor (12) Disconnect connectors XA3_1 and XM3. Check continuity between XA3_13 and XM3/1. Check continuity between XA3_1/5 and XM3/2. Check continuity between XA3_1/6 and XM3/3. Check continuity between XA3_1/4 and XM3/4. No continuity Continuity

(13) Connect connector securely.

9-29

TROUBLESHOOTING FOR CONTROL CIRCUITS

CAN (13) Disconnect connector XA5_1 of logic unit. Check continuity between XA5_1/5 and XA3_1/23. Check continuity between XA5_1/6 and XA3_1/15. Continuity

No continuity

(14) Repair or replace harness.

(15) Disconnect battery plug, then discharge electric charges from inverters and APS unit.

(16) Discharge electric charges from inverters and APS unit, then replace steer inverter. (DSP card is normal.) See page 8-30. If fault remains (17) Discharge electric charges from inverters and APS unit, then reinstall steer inverter and replace steer motor. Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

9-30

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA3_1 Steer Controller (A3) 0 to 5V 0 to 5V

CAN 5 6

23 CAN H 15 CAN L Fuse 21 Brake Control +36V

7F1 K11

K12

10A GND 0 to 5V 0 to 5V +12V

1 KEY on +36V 16 Thermal Sensor 4

}

5 6 3

}

50A

P N

Battery (-)

Line Contactor

Encodes

Steer Motor A3 RED 1 WHT 3 BLU 2 BLK 4 5 6 XM3

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

211796-A5

9-31

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Motor Current Sensor Fault (14) (1) Situation Display: "14". All truck operations except for "lower" inhibited. This fault occurs only when turning on power. Line contactor OPEN. (2) Possible cause Faulty contact or wire breakage of DSP flat cable in traction inverter, faulty DSP card of traction inverter, faulty traction inverter, faulty logic unit.

Abnormal

8V power supply (6) Disconnect Connector XA5_1P. Check continuity between XA5_1P/4 and XA1_2/18. Check continuity between XA5_1P/6 and XA1_2/20. Continuity Abnormal and continuity

(7) Secure DSP flat cable if loose. Replace inverter if wire breaks. See page 8-33.

CAN (8) Disconnect connector XA5_1 of logic unit. Check continuity between XA5_1/5 and XA1_2/3. Check continuity between XA5_1/6 and XA1_2/4. Continuity Abnormal and continuity (9) Connect connector XA5_1P to logic unit, then turn on power again.

(10) Repair or replace harness.

(11) Measure voltage between XA1_2/18 and XA1_2/20. Confirm value is 8V ± 2V. Abnormal Normal

(12) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(13) Replace DSP card of traction inverter. See page 8-33.

(14) Replace power supply card of logic unit. See page 8-37.

If fault remains (15) Discharge electric charges from inverters and APS unit, then replace traction inverter. (DSP card is normal.) See pages 8-30 and 8-31. 9-32

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA1_2 Traction inverter (A1) 0 to 5V 0 to 5V

CAN 5 6

5 Power 3 4 6 Power supply card XA5_1P

DSP flat cable Inverter case DSP card

+12V +14V +8V GND 5V * 1 GND GND +12V 0 to 5V 0 to 5V

3 Inside of 4 cover 14 15 16 17 18 DSP 20 card 2 Temp 1 Sens Flat 19 cable 5 7 6

Inside of case

Fuse IMS card

Line contactor

425A

Battery (-)

U V W

Traction motor 6 BLU 5 WHT 4 RED 3 BLK 2 1 X35

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

211798-14

9-33

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Motor, Over-current (15) (1) Situation Display: "15". All truck operations except for "lower" inhibited. Line contactor OPEN. (2) Possible cause Faulty contact or wire breakage of DSP flat cable in traction inverter, faulty DSP card of traction inverter, faulty traction inverter, faulty traction motor, faulty contact or wire breakage of traction motor speed sensor harness, faulty main harness, faulty logic unit. (3) How the error code is triggered Motor current is more than 707 Amps (Moment). Motor current is more than 557Amps (Fixed time 1). Motor current is more than 492 Amps (Fixed time 2). (4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(5) Check traction motor and terminal for burning and smell. Abnormal Normal

(7) Replace traction motor. Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

(6) Confirm cable looseness and improper connections (U, V, W phases) for right traction inverter and motor. Normal

Abnormal

(8) Disconnect connector XA1_2 of right traction inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Abnormal Normal

(9) Secure cable if loose or connect cable correctly.

(10) Confirm connection of right traction motor speed sensor connector X35. Abnormal Normal

(11) Secure DSP flat cable if loose. Replace inverter if wire breaks. See page 8-33.

Sensor (12) Disconnect connectors XA1_2 AND X35. Check continuity between XA1_2/5 and X35/4. Check continuity between XA1_2/6 and X35/6. Check continuity between XA1_2/7 and X35/5. Check continuity between XA1_2/19 and X35/3. Abnormal and Continuity Continuity

(13) Connect connector securely.

9-34

TROUBLESHOOTING FOR CONTROL CIRCUITS 8V power supply (14) Disconnect Connector XA5_1P. Check continuity between XA5_1P/4 and XA1_2/18. Check continuity between XA5_1P/6 and XA1_2/4. Continuity No continuity CAN (15) Disconnect Connector XA5_1. Check continuity between XA5_1/5 and XA1_2/3. Check continuity between XA5_1/6 and XA1_2/4. Continuity No continuity (16) Connect connector XA5_1P to logic unit, then turn on power again.

(17) Repair or replace harness.

(18) Measure voltage between XA1_2/18 and XA1_2/20. Confirm value is 8V ± 2V. Normal Abnormal

(19) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(21)Replace power supply card of logic unit. See page 8-37.

(20) Replace DSP card of right traction inverter. See page 8-33. If fault remains (22) Discharge electric charges from inverters and APS unit, then replace right inverter. (DSP card is normal.) See pages 8-30 and 8-31. If fault remains (23) Discharge electric charges from inverters and APS unit, then reinstall right inverter and replace traction motor. Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

9-35

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA1_2 Traction inverter (A1) 0 to 5V 0 to 5V

CAN 5 6

5 Power 3 4 6 Power supply card XA5_1P

DSP flat cable Inverter case DSP card

+12V +14V +8V GND 5V GND GND +12V 0 to 5V 0 to 5V

3 Inside of 4 cover 14 15 16 17 18 DSP 20 card 2 Temp 1 Sens Flat 19 cable 5 7 6

Inside of case

Fuse IMS card

Line contactor

425A

Battery (-)

U V W

Traction motor 6 BLU 5 WHT 4 RED 3 BLK 2 1 X35

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

211798-15

9-36

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Motor, Stall Timer Speed Fault (16) (1) Situation Display: "16". All truck operations except for "lower" inhibited. Line contactor OPEN. (2) Possible cause Stall current flowed more than set time in traction motor faulty traction inverter current sensor, shorted harness wiring, faulty traction inverter DSP card, faulty logic unit, faulty traction motor speed sensor, DSP ribbon cable loose or broken. (3) How error flowed code is more triggered Stallthe current thse time (#20) in traction motor, faulty right traction inverter current sensor, shorted Stall timerwiring, set time is measured whileinverter stalling.DSP card, faulty logic unit. harness faulty right traction (4) Checks Turn off power, then turn on power again. Confirm error code display. No error, problem recurs

Error code 14

(6) See troubleshooting for code "14". See page 9-32. (5) Check to see if truck is operated with heavy cargo load or on steps when motor stalls. Normal steps Heavy load

(7) Change set time.

(8) Check traction motor speed sensor. See troubleshooting for code "52". See page 9-61.

(10) Operate under normal condition.

Notice: The more stall occurs, the more overheating occurs. Operate truck under normal condition.

(9) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. (11) Disconnect connector XA1_2 of right traction inverter and remove DSP cover, then check DSP flat cable for looseness or wire breakage. See page 8-33. Normal Abnormal Power supply (12) Disconnect Connector XA5_1P Check continuity between XA5_1P/5 and XA1_2/16. Check continuity between XA5_1P/6 and XA1_2/20. Continuity No continuity

(13) Secure harness if loose. Replace traction inverter if wire breaks. See page 8-31.

CAN (14) Disconnect Connector XA5_1 Check continuity between XA5_1/5 and XA1_2/3. Check continuity between XA5_1/6 and XA1_2/4. Continuity

Abnormal and no continuity

(15)Connect connector XA5_1P to logic unit, then turn on power again.

(16) Repair or replace harness.

(17)Measure voltage between XA1_2/16 and XA1_2/20. Confirm value is 12V ± 1V. Abnormal Normal (18)Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. (19)Replace DSP card of right traction inverter. See page 8-33.

(20)Replace power supply card of logic unit. See page 8-37. 9-37

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1 CAN 5 6

5 Power 3 4 6 Power supply card XA5_1P

XA1_2 Traction inverter (right) (A1) 0 to 5V 0 to 5V

G 3 GW 4

Inside of cover

14 15 12V 6A WB 16 14V 4A WR 17 8V 5A WL 18 DSP GND 7B WG 20 card 5V L 2 GND LB TEMP 1 SENS Flat GND 19 cable +12V 5 0 to 5V 0 to 5V 6

Inside of case

Fuse IMS card

Line contactor

425A

Battery (-)

Traction motor B 4 G 37 2 36 W 3 R 1 35 LB 2 24 L 1 23 38

X35

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

211802-16

9-38

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Motor 1, Current Sensor Fault (34) (1) Situation Display: "34". All truck operations except for "lift down" inhibited. This fault occurs only when turning on power. OPEN.and steering contactor HOLD. Line contactor OPEN (2) Possible cause Faulty contact or wire breakage of DSP flat cable in pump inverter, faulty DSP card of pump inverter, faulty pump inverter, faulty main harness, faulty logic unit.

(3) How the error code is triggered When turning on power, current sensor voltage is out of range of -120A to 120A. (4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. (5) Disconnect connector XA2_2 of pump inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Abnormal Normal 8V power supply (6) Check continuity between XA5_1P/4 and XA2_2/18. Check continuity between XA5_1P/6 and XA2_2/20. Continuity No Continuity

(7) Secure DSP flat cable if loose. Replace pump inverter if wire breaks. See pages 8-31.

CAN (8) Disconnect connector XA5_1 of logic unit. Check continuity between XA5_1/5 and XA2_2/3. Check continuity between XA5_1/6 and XA2_2/4. Continuity

No Continuity

(9) Connect connector XA5_1P to logic unit, then turn on power again.

(10) Repair or replace harness.

(11) Measure voltage between XA2_2/18 and XA2_2/20. Confirm value is 8V ± 2V. Abnormal Normal

(12) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(14) Replace power supply card of logic unit. See page 8-37.

(13) Replace DSP card of pump inverter. See page 8-33. If fault remains (15) Discharge electric charges from inverters and APS unit, then replace pump inverter. (DSP card is normal.) See page 8-31. 9-39

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA2_2 0 to 5V 0 to 5V

CAN 5 6

5 Power 3 4 6 Power supply card XA5_1P

12V 14V 8V GND 5V GND GND +12V 0 to 5V 0 to 5V

Pump inverter 1 (A2)

3 Inside of 4 cover 14 15 16 17 18 DSP 20 card 2 Temp 1 Sens Flat 19 cable 5 6 A 7 B

Inside of case

Fuse 425A

Battery (-)

IMS card

Line contactor

U V W

Pump motor 1 DSP flat cable Inverter case DSP card

BLU 6 5 WHT 4 RED BLK 3 2 1 X36

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

211800-34

9-40

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Motor 1, Over-current (35) (1) Situation Display: "35". All truck operations except for "lower" inhibited. Line contactor OPEN. (2) Possible cause Faulty contact or wire breakage of DSP flat cable in pump inverter, faulty DSP card of pump inverter, faulty pump inverter, faulty pump motor, faulty contact or wire breakage of pump motor speed sensor harness, faulty main harness, faulty logic unit. (3) How the error code is triggered Motor current is more than 1018 Amps (Moment). Motor current is more than 990 Amps (Fixed time 1). Motor current is more than 985 Amps (Fixed time 2).

(4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. (5) Check pump motor and terminal for burning and smell. Normal

Abnormal

(6) Confirm cable looseness and improper connections (U, V, W phases) for pump inverter and motor. Abnormal Normal

(7) Replace pump motor. Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

(8) Disconnect connector XA2_2 of pump inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Abnormal Normal

(9) Secure cable if loose or connect cable correctly.

(10) Confirm connection of pump motor speed sensor connector X36. Abnormal Normal

(11) Secure DSP flat cable if loose. Replace pump inverter if wire breaks. See page 8-33.

Sensor (12) Disconnect connector XA2_2 and X36. Check continuity between XA2_2/5 and X36/4. Check continuity between XA2_2/6 and X36/5. Check continuity between XA2_2/7 and X36/6. Check continuity between XA2_2/19 and X36/3. Continuity

(13) Connect connector securely.

No continuity

8V power supply (14) Disconnect Connector XA5-1P Check continuity between XA5_1P/4 and XA2_2/18. Check continuity between XA5_1P/6 and XA2_2/20. Continuity

No continuity

9-41

TROUBLESHOOTING FOR CONTROL CIRCUITS

CAN (15) Disconnect connector XA5_1 of logic unit. Check continuity between XA5_1/5 and XA2_2/3. Check continuity between XA5_1/6 and XA2_2/4. Continuity No Continuity (16) Connect connector XA5_1P to logic unit, then turn on power again.

(17) Repair or replace harness.

(18) Measure voltage between XA2_2/18 and XA2_2/6. Confirm value is 8V ± 2V. Normal Abnormal

(19) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(21)Replace power supply card of logic unit. See page 8-37.

(20) Replace DSP card of pump inverter. See page 8-33. If fault remains (22) Discharge electric charges from inverters and APS unit, then replace pump inverter. (DSP card is normal.) See page 8-33. If fault remains (23) Discharge electric charges from inverters and APS unit, then reinstall pump inverter and replace pump motor. Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

9-42

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA2_2 0 to 5V 0 to 5V

CAN 5 6

5 Power 3 4 6 Power supply card XA5_1P

12V 14V 8V GND 5V GND GND +12V 0 to 5V 0 to 5V

Pump inverter 1 (A2)

3 Inside of 4 cover 14 15 16 17 18 DSP 20 card 2 Temp 1 Sens Flat 19 cable 5 6 A 7 B

Inside of case

Fuse 425A

Battery (-)

IMS card

Line contactor

U V W

Pump motor 1 DSP flat cable Inverter case DSP card

BLU 6 5 WHT 4 RED BLK 3 2 1 X36

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

211800-35

9-43

TROUBLESHOOTING FOR CONTROL CIRCUITS

(1) Situation Display: "40". All truck operations except for "lower" inhibited. Line contactor OPEN. (2) Possible cause Faulty line contactor K12, faulty main harness, faulty logic unit, faulty traction inverter, faulty pump inverter, blown 1F2 fuse, blown 10F1 fuse. (3) How the error code is triggered Inverter voltage data is checked when contactor is closed (400 ms). (4) Checks Turn off power, then turn on power again. Confirm error code display. Error code 40

(6) See troubleshooting for code "63", "65" or "66" See page 9-83, 9-86 or 9-89.

(5) Block wheels, then confirm line contactor operation in output check function. See page 8-52. Operated Not operated

Without service tool

With service tool

(7) Check DC voltage of pump and traction inverters with Input Monitor. These values should be same as battery voltage. Traction inverter value Pump inverter value abnormal abnormal (10)Disconnect battery (9) Disconnect battery plug, then discharge plug, then discharge electric charges from electric charges from inverters and APS inverters and APS unit. unit. See page 8-30. See page 8-30. (12) Replace traction inverter. See page 8-31.

Error code 63, 65 or 66

(13) Replace pump inverter. See page 8-31.

(8)Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(11) Replace traction inverter. See page 8-31. If fault remains (14) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. (15) Replace pump inverter. See page 8-31.

(16) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-31. (17) Check to see if line contactor tip moves smoothly. Check line contactor tip for melting. Abnormal Normal (18) Measure resistance of contactor coil. 44Ω at -30°C (-22°F) to 65Ω at 80°C (176°F) Out of range Within range (19) Disconnect connectors XA5_1, XA5-1P, and terminals A1 and A2 (K12 only). Check voltage at XA5_1P/13 and XA5_1P/14 (+36V) Check voltage at A1 (+36V). Check continuity between XA5_1/59 and A2. Check continuity between XA5_1P/15 and XA5_1P/16 to battery ground. Continuity/Voltage No Continuity/No Voltage

(20) Replace line contactor. See Chassis & Mast.

(21) Discharge electric charges from inverters and APS unit, then replace logic card of logic unit. See page 8-36.

(22) Repair or replace harness. Replace 10A fuse(s). 9-44

TROUBLESHOOTING FOR CONTROL CIRCUITS

2nd Pump Controller 3 4 A6

( HP Models Only )

Traction Controller 3 4 A1

425 A

Pump Controller 3 4 A2

425 A

Steer Controller 23 15 A3

50 A 11L1 10A + A1

– A2 + A1

10L1 10A 5

LOGIC CONNECTOR

LOGICS UNIT A5

KEY SWITCH

24R150

XA5.1 POWER SUPPLY CONNECTOR

1F1 10A

13 14 15 16

– A2

–

1F2 10A

XA5.1P

211804

9-45

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Motor Open (45) (1) Situation Display: "45". All truck operations except for "lower" inhibited. Line contactor OPEN. (2) Possible cause Faulty contact or wire breakage of traction motor cable, faulty traction motor, faulty contact or wire breakage of traction inverter connector, faulty contact of DSP flat cable in traction inverter, wire breakage of main harness, faulty power supply card of logic unit, faulty DSP card of traction inverter, faulty traction inverter. when restarting after motor shorted. (3) How the error code is triggered Motor voltage is abnormal when power is tuned on. Current does not flow when torque instruction is requested.

(4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. (5) Check traction inverter and motor for cable looseness and improper contact. Normal Abnormal

(6) Disconnect traction motor cables from inverter. Measure resistance of motor cables (U,V and W phases). 1Ω or more Less than 1Ω

(7) Secure cable if loose.

(8) Check connector XA1_2 of traction inverter for looseness. Normal Abnormal

(9) Measure resistance between terminals of both cable ends (between U and U, V and V, and W and W). 1Ω or more Less than 1Ω

(11) Connect connector securely.

(12) Replace traction motor.

(13) Replace motor cables.

Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

(10) Disconnect connector XA1_2 of traction inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Normal Abnormal Power supply (14) Disconnect Connector XA5_1P of power supply. Check continuity between XA5_1P/5 and XA1_2/16. Check continuity between XA5_1P/6 and XA1_2/20. Continuity No Continuity

(15) Secure DSP flat cable if loose. Replace inverter if wire breaks. See page 8-33.

9-46

TROUBLESHOOTING FOR CONTROL CIRCUITS

CAN (16) Disconnect connector XA5_1 of logic unit. Check continuity between XA5_1/5 and XA1_2/3. Check continuity between XA5_1/6 and XA1_2/4. Continuity

No Continuity

(17) Connect connector XA5_1P to logic unit, then turn on power again.

(18) Repair or replace harness.

(19) Measure voltage between XA1_2/16 and XA1_2/20. Confirm value is 12V ± 1V. Normal Abnormal

(20) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(21) Replace DSP card of right traction inverter. See page 8-33.

(22)Replace power supply card of logic unit. See page 8-37.

If fault remains (22) Discharge electric charges from inverters and APS unit, then replace traction inverter. (DSP card is normal.) See page 8-31.

9-47

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA1_2 Traction inverter (A1) 0 to 5V 0 to 5V

CAN 5 6

5 Power 3 4 6 Power supply card XA5_1P

DSP flat cable Inverter case DSP card

+12V +14V +8V GND 5V GND GND +12V 0 to 5V 0 to 5V

3 Inside of 4 cover 14 15 16 17 18 DSP 20 card 2 Temp 1 Sens Flat 19 cable 5 7 6

Inside of case

Fuse IMS card

Line contactor

425A

Battery (-)

Traction motor 6 BLU 5 WHT 4 RED 3 BLK 2 1 X35

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

211798-45

9-48

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Motor 1 Open (47) (1) Situation Display: "47". All truck operations except for "lower" inhibited. Line contactor OPEN. (2) Possible cause Faulty contact or wire breakage of pump motor cable, faulty pump motor, faulty contact or wire breakage of pump inverter connector, faulty contact of DSP flat cable in pump inverter, wire breakage of main harness, faulty power supply card of logic unit, faulty DSP card of pump inverter, faulty pump inverter, when restarting after motor shorted. (3) How the error code is triggered Motor voltage is abnormal when power is tuned on. Current does not flow when rotational speed instruction is requested. (4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. (5) Check pump inverter and motor for cable looseness and improper contact. Normal Abnormal

(6) Disconnect pump motor cables from inverter. Measure resistance of motor cables (U,V and W phases). 1Ω or more Less than 1Ω

(7) Secure cable if loose.

(8) Check connector XA2_2 of pump inverter for looseness. Normal Abnormal

(9) Measure resistance between terminals of both cable ends (between U and U, V and V, and W and W). 1Ω or more Less than 1Ω

(11) Connect connector securely.

(10) Disconnect connector XA2_2 of pump inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Normal Abnormal

Power supply (14) Disconnect Connector XA5_1P of power supply. Check continuity between XA5_1P/5 and XA2_2/16. Check continuity between XA5_1P/6 and XA2_2/20. Continuity No Continuity

(12) Replace pump motor. Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

(13) Replace motor cables.

(16) Secure DSP flat cable if loose. Replace inverter if wire breaks. See page 8-31.

9-49

TROUBLESHOOTING FOR CONTROL CIRCUITS

CAN (16) Disconnect connector XA5_1 of logic unit. Check continuity between XA5_1/5 and XA2_2/3. Check continuity between XA5_1/6 and XA2_2/4. Check continuity between XA2_2/14 and XA2_2/15. Check continuity between XA2_2/9 and XA2_2/11. Continuity No Continuity

(17) Connect connector XA5_1P to logic unit, then turn on power again.

(18) Repair or replace harness.

(19) Measure voltage between XA2_2/16 and XA2_2/20. Confirm value is 12V ± 1V. Normal Abnormal

(20) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(22) Replace power supply card of logic unit. See page 8-37.

(21) Replace DSP card of pump inverter. See page 8-33. If fault remains (23) Discharge electric charges from inverters and APS unit, then replace pump inverter. (DSP card is normal.) See page 8-31.

9-50

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA2_2 0 to 5V 0 to 5V

CAN 5 6

5 Power 3 4 6 Power supply card XA5_1P

12V 14V 8V GND 5V GND GND +12V 0 to 5V 0 to 5V

Pump inverter 1 (A2)

3 Inside of 4 cover 14 15 16 17 18 DSP 20 card 2 Temp 1 Sens Flat 19 cable 5 6 A 7 B

Inside of case

Fuse 425A

Battery (-)

IMS card

Line contactor

U V W

Pump motor 1 DSP flat cable Inverter case DSP card

BLU 6 5 WHT 4 RED BLK 3 2 1 X36

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

211800-47

9-51

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Motor 2 Open (48) (1) Situation Display: "48". All truck operations except for "lower" inhibited. Line contactor OPEN. (2) Possible cause Faulty contact or wire breakage of pump motor cable, faulty pump motor, faulty contact or wire breakage of pump inverter connector, faulty contact of DSP flat cable in pump inverter, wire breakage of main harness, faulty power supply card of logic unit, faulty DSP card of pump inverter, faulty pump inverter, when restarting after motor shorted. (3) How the error code is triggered Motor voltage is abnormal when power is tuned on. Current does not flow when rotational speed instruction is requested. (4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. (5) Check pump inverter and motor for cable looseness and improper contact. Normal Abnormal

(6) Disconnect pump motor cables from inverter. Measure resistance of motor cables (U,V and W phases). 1Ω or more Less than 1Ω

(7) Secure cable if loose.

(8) Check connector XA6_2 of pump inverter for looseness. Normal Abnormal

(9) Measure resistance between terminals of both cable ends (between U and U, V and V, and W and W). 1Ω or more Less than 1Ω

(11) Connect connector securely.

(10) Disconnect connector XA6_2 of pump inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Normal Abnormal

Power supply (14) Disconnect Connector XA5_1P of power supply. Check continuity between XA5_1P/5 and XA6_2/16. Check continuity between XA5_1P/6 and XA6_2/20. Continuity No Continuity

(12) Replace pump motor. Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

(13) Replace motor cables.

(15) Secure DSP flat cable if loose. Replace inverter if wire breaks. See page 8-33.

9-52

TROUBLESHOOTING FOR CONTROL CIRCUITS

CAN (16) Disconnect connector XA5_1 of logic unit. Check continuity between XA5_1/5 and XA6_2/3. Check continuity between XA5_1/6 and XA6_2/4. Check continuity between XA6_2/8, XA6_2/9 and XA6_2/11. Continuity No Continuity

(17) Connect connector XA5_1P to logic unit, then turn on power again.

(18) Repair or replace harness.

(19) Measure voltage between XA6_2/16 and XA6_2/20. Confirm value is 12V ± 1V. Normal Abnormal

(20) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(22) Replace power supply card of logic unit. See page 8-37.

(21) Replace DSP card of pump inverter. See page 8-33. If fault remains (23) Discharge electric charges from inverters and APS unit, then replace pump inverter. (DSP card is normal.) See page 8-31.

9-53

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA6_2 0 to 5V 0 to 5V

CAN 5 6

5 Power 3 4 6 Power supply card XA5_1P

12V 14V 8V GND 5V GND GND +12V 0 to 5V 0 to 5V

Pump inverter 2 (A6)

3 Inside of 4 cover 14 15 16 17 18 DSP 20 card 2 Temp 1 Sens Flat 19 cable 5 6 B 7 A

Inside of case

Fuse 425A

Battery (-)

IMS card

Line contactor

U V W

Pump motor 2 DSP flat cable Inverter case DSP card

BLU 6 5 WHT 4 RED BLK 3 2 1 X37

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

211800-48

9-54

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Steer Motor Open (49) (1) Situation Display: "49". All truck operations except for "lower" inhibited. Line contactor OPEN. (2) Possible cause Faulty contact or wire breakage of steer motor cable, faulty steer motor, faulty contact or wire breakage of steer inverter connector, wire breakage of main harness, faulty power supply card of logic unit, faulty steer inverter, when restarting after motor shorted, blown 10A fuse (7F1).

(3) How the error code is triggered Motor voltage is abnormal when power is tuned on. Current does not flow when torque instruction is requested.

(4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. (5) Check steer inverter and motor for cable looseness and improper contact. Normal Abnormal

(6) Disconnect steer motor cables from inverter. Measure resistance of motor cables (U,V and W phases). 1Ω or more Less than 1Ω

(7) Secure cable if loose.

(8) Check connector XA3_1 of steer inverter for looseness. Normal Abnormal

(9) Measure resistance between terminals of both cable ends (between U and U, V and V, and W and W). 1Ω or more Less than 1Ω

(11) Connect connector securely.

(12) Replace steer motor. Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

Gate power supply (14) Check voltage at XA3_1/1 (key +36V) Continuity

No voltage

9-55

(13) Replace motor cables.

TROUBLESHOOTING FOR CONTROL CIRCUITS

CAN (15) Disconnect Connector XA5_1 Check continuity between XA5_1/5 and XA3_1/23. Check continuity between XA5_1/6 and XA3_1/15. Continuity No Continuity

(16) Repair or replace harness. Check Fuse 7F1. (17) Discharge electric charges from inverters and APS unit, then replace steer inverter. (DSP card is normal.) See pages 8-30 and 8-31.

9-56

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5-1

XA3_1 Steer Controller (A3)

CAN 5 6

23 CAN H 15 CAN L Fuse 7F2 1

+36V 10A K12

Line contactor

50A

Battery (-)

16 Motor Temp 4 6 5 3

GND SIGNAL A SIGNAL B +12V

Steer motor (M3) 1 RED 2 WHT 3 BLU 4 BLK 5 6

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

XM3

211799-49

9-57

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Lever Sensor Fault (51) (1) Situation Display: "51". All truck operations except for "lower" inhibited. Line contactor OPEN.

(2) Possible cause Faulty traction lever sensor, faulty main harness, faulty logic unit.

(3) How the error code is triggered Traction lever sensor voltage is out of range of 0.05V to 4.95V.

(4) Checks Raise drive wheel until they clear floor. Without service tool (5) Disconnect battery plug.

With service tool (6) Check traction lever sensor voltage with Input Monitor and confirm value is in range of 0.05V to 4.95V. Abnormal signal Interrupted (7) Disconnect battery plug.

(9) Discharge electric charges from inverters and APS unit. See page 8-30.

(10) Disconnect connector XA5_1 of logic unit. Disconnect connector X14A of traction lever.

(11) Check continuity between XA5_1/20 and X14A/2. (Sensor voltage) Continuity No continuity

(12) Check continuity between XA5_1/26 and X14A/1. Check continuity between XA5_1/25 and X14A/3. Continuity No continuity

(13) Repair or replace harness.

With service tool Without service tool

9-58

(8) Check joystick.

TROUBLESHOOTING FOR CONTROL CIRCUITS

Without service tool

With service tool (15) Connect connector XA5_1. Turn on power and check voltage between X14A/1 and X14A/3. Not 5 V 5V

(14) Replace traction lever. If fault remains (16) Disconnect battery plug.

(17) Turn off power. Short-circuit X14A/1 and X14A/2. Turn on power and check traction lever voltage with Input Monitor. Not 5 V 5V

(18) Reinstall traction lever, then replace logic card of logic unit. See page 8-36.

(19) Turn off power. Open X14A/1 and X14A/2. Short-circuit X14A/2 and X14A/3. Turn on power and check traction lever voltage with Input Monitor. 0V Not 0 V

(20) Replace traction lever.

(21) Disconnect battery plug. (22) Replace logic card of logic unit.

9-59

TROUBLESHOOTING FOR CONTROL CIRCUITS

Traction speed and Direction

X14A

Logic XA5_1 26 20 25

View Opposite Wire Entry 5V 0.5 to 4.5V GND

RED 1 WHT 2 BRN 3 X14A 211806-51

9-60

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Motor Pulse Input Fault (52) (1) Situation Display: "52". All truck operations except for "lift down" inhibited. Line contactor OPEN. (2) Possible cause Faulty contact of traction inverter connector, faulty connection of traction motor connector and cable, faulty 12V input voltage of traction inverter, faulty contact or wire breakage of traction motor speed sensor harness, faulty traction motor speed sensor. (3) How the error code is triggered Motor rotation speed is more than 5800 rpm. (4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. (5) Check to see if traction motor cables (U, V and Wphases) are connected to traction inverter properly. Abnormal Normal (6) Check to see if connector XA1_2 of traction inverter is fastened securely. Normal

(7) Connect cables properly.

Abnormal

(8) Check to see if connector X35 of traction motor speed sensor is fastened securely. Normal Abnormal

(9) Fasten connector securely.

Sensor (10) Disconnect connector XA1_2 and X35. Check continuity between XA1_2/5 and X35/4. Check continuity between XA1_2/6 and X35/6. Check continuity between XA1_2/7 and X35/5. Check continuity between XA1_2/19 and X35/3. Continuity No Continuity

(11) Fasten connector securely.

Power supply (12) Disconnect connector XA5_1P of power supply. Check continuity between XA5_1P/3 and XA1_2/17. Check continuity between XA5_1P/6 and XA1_2/20.

CAN (13) Disconnect connector XA5_1 of logic unit. Check continuity between XA5_1/5 and XA1_2/3. Check continuity between XA5_1/6 and XA1_2/4.

(15)

(14) Connect connector XA5-1P to logic unit, then turn on power again.

9-61

Repair or replace harness.

TROUBLESHOOTING FOR CONTROL CIRCUITS

(16) Measure voltage between XA1_2/17 and XA1_2/20. Confirm value is 14V ± 2V. Normal Abnormal (17) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(18) Replace traction inverter. See page 8-31.

(19) Replace power supply card of logic unit. See page 8-38.

If fault remains (20) Discharge electric charges from inverters and APS unit, then replace traction motor. Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

9-62

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1 CAN 5 6

5 Power 3 4 6 Power supply card XA5_1P

XA1_2 Traction inverter (A1) 0 to 5V 0 to 5V

12V 14V 8V GND 5V GND GND +12V 0 to 5V 0 to 5V

3 Inside of 4 cover 14 15 16 17 18 DSP 20 card 2 TEMP 1 SENS Flat 19 cable 5 7 6

Inside of case

Fuse IMS card

Line contactor

425A

Battery (-)

Traction motor 6 5 4 3 2 1

Blu Wht Red Blk

X35

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

211802-52

9-63

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: FC Solenoid Fault (55) (1) Situation Display: "55". Related lever operation inhibited. Normal traction motor and power steering operations. (2) Possible cause Faulty lift solenoid, faulty tilt solenoid, faulty reach and side shift solenoids, faulty main harness, faulty output unit, blown fuse. (3) How the error code is triggered When signal is outputted, current is out of range of 0.16A to 1.9A. (4) Checks Operate all hydraulic functions to find faulty solenoid. Inspect by checking pump motor running sound if attachment is not installed. Found Not found, with service tool (5) Find faulty solenoid with Output Monitor. Solenoid current should flow when hydraulic lever is operated. (6) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. (7) Disconnect connectors XA4_1, XA5_1 and X41 of output unit. Disconnect connectors K3/1, K4/1, and K5/1 of relays. Direction of Lift/Lower Reach Sideshift Tilt/Sideshift Reach, Tilt, SS (8) Check continuity between XA4_1/21 and XY41_2/1, XA4_1/22 and XY41_1/1, XA4_1/23 and XY41_1/2 and XY41_2/2.

(10) Check continuity between XA5_1/60 and K3/1. X41/1 and XY44_1/1 and XY44_2/2. X41/2 and XY44_1/2 and XY44_2/1. XA5_1/53 and K3/3. Check Voltage K3/5 = +36V. K3/4 = Batt Negative.

(12) Check continuity between XA5_1/62 and K5/1. X41/4 and XY46_1/2 and XY46_2/1. X41/1 and XY46_1/1 and XY46_2/2. XA5_1/55 and K5/3. Check Voltage K5/5 = +36V. K5/4 = Batt Negative.

Continuity

No Continuity

(9) Check continuity between XA4_1/24 and XY43_1/1, XA4_1/25 and XY43_2/1, XA4_1/26 and XY43_1/2 and XY43_2/2.

Continuity

No Continuity

(11) Check continuity between XA5_1/61 and K4/1. X41/3 and XY45_1/2 and XY45_2/1. X41/1 and XY45_1/1 and XY45_2/2. XA5_1/54 and K4/3. Check Voltage K4/5 = +36V. K4/4 = Batt Negative. Continuity No Continuity

No Continuity

No Voltage Check/Replace Fuse 11F2 9-64

TROUBLESHOOTING FOR CONTROL CIRCUITS

(13) Measure resistance of solenoid coil. 30 Ω ± 10 % at 20°C (68°F) Normal

(14) Repair or replace harness. Abnormal

(15) Replace related solenoid. (16) Lift: Lower: Reach, Tilt, Side Shift:

Check short circuit between XA4_1/21 and XA4_1/23. Check short circuit between XA4_1/22 and XA4_1/23. Check short circuit between XA4_1/24 and XA4_1/26. Check short circuit between XA4_1/25 and XA4_1/26.

Not Shorted (17) Replace output unit. See page 8-38.

Short (18) Repair or replace harness.

9-65

TROUBLESHOOTING FOR CONTROL CIRCUITS

5R6/50W 2

F103

F104

2 4

2,2u 63V

120R

K3 5

2 1

2,2u 63V

120R

K4 5

1 0-24V

XA5_1/55

1/26

F105

2,2u 63V

120R

K5 5

X111

0-24V

XA5_1/62

XA5_1/54

XA5_1/53

0V 11M1

1/26

XA5_1/61

+36V 11L2

XA5_1/60

XA4_1/25

XA4_1/26

XA4_1/24

LOGIC BOARD

XA4_1/21

XA4_1/22

+ 11M2 1/26

X112

X113

A1 FW, L DN B1 BW, R UP DIRECTION OF REACH, TILT, SSHIFT

(S6)

REACH

9-66

Y45.1

Y45.2

(S9)

(S10)

Y46.1

XY46.2: 1

XY46.1: 2

GRY/BWN

XY45.2: 1

XY45.1: 2

GRY/GRN

Y44.2

(S5)

Y46

Y46.2

(S7)

SIDESHIFT

36V TILT ASSISTANT

(S8)

XY46.2: 2

Y45

XY46.1: 1

XY45.1: 1

Y44.1

XY44.2: 1

GRY/YEL

XY44.1: 2

BLK/GRY (m4)

XY44.2: 2

LIFT

Y43.2

Y44

XY44.1: 1

XY41.2/ 2

LOWER

Y43.1

(m3)

XY43.2/ 2

XY41.1/ 2

(m2)

Y43

XY43.2/ 1

XY43.1/ 1

Y41.2

(m1)

XY43.1/ 2

XY41.2/ 1

XY41.1/ 1 Y41.1

Y41

TILT/SIDESHIFT

GRN

X41/5

X42/2

X42/ 1 E56

20-24V

X88

20-24V

GRY

X41/ 4

GRY/GRN

IN THE MAST

20-24V

X79

X41/ 3

GRY/YEL

X41/ 2

BLK/BRN

X41/ 1

0-24V

XY45.2: 2

XA4_1/23

RIO1 BOARD

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: FC Solenoid Current Leak (56) (1) Situation Display: "56". Pump motor operations inhibited "lower" operation enabled. Line contactor HOLD.

(2) Possible cause Faulty lift solenoid, faulty tilt solenoid, faulty reach and side shift solenoids, faulty main harness, faulty output unit.

(3) How the error code is triggered When signal is not outputted, current is more than 0.18A.

(4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(5) Disconnect connector XA4_1. Disconnect connectors XY41_1, XY41_2, XY43_1 and XY43_2 of solenoids.

(6) Check short circuit between all pin patterns. XA4_1/21 to XA4_1/26 and at solenoid connectors on chassis valve. Not shorted Shorted

(7) Measure solenoid coil resistance. 30 Ω ± 10 % at 20°C (68°F) Normal

(8) Repair or replace harness.

Abnormal

(9) Replace output unit. See page 8-38.

(10) Replace related solenoid.

9-67

TROUBLESHOOTING FOR CONTROL CIRCUITS

0-24V

Lower

Lift 1

Reach

0-24V

XY41.1/1

XY41.2/1

Y41.2

XY41.2/2

XY41.2/1

Y41.1

XY41.2/2

XY41.1/1

0-24V

XY41.1/2

Y41.1

Y41.2

Tilt

Sideshift

XY43.2/2

OUTPUT 23 UNIT XA4_1

211807-56

9-68

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Motor 1 Pulse Input Fault (57) (1) Situation Display: "57". All truck operations except for "lower" inhibited. Line contactor OPEN.

(2) Possible cause Faulty contact of pump inverter connector, faulty connection of pump motor connector and cable, faulty 12V input voltage of pump inverter, faulty contact or wire breakage of pump motor speed sensor harness, faulty DSP card of pump inverter, faulty pump motor speed sensor. (3) How the error code is triggered Motor rotation speed is more than 4000 rpm. Motor rotation speed is zero while current flows to motor. Motor rotates in reverse. (4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. (5) Check to see if pump motor cables (U, V and W-phases) are connected to pump inverter properly. Abnormal Normal (6) Check to see if connector XA2_2 of pump inverter is fastened securely. Normal Abnormal

(7) Connect cables properly.

(8) Check to see if connector X36 of pump motor speed sensor is fastened securely. Normal Abnormal

(9) Fasten connector securely.

(10) Disconnect connector XA2_2 and X36. Check continuity between XA2_2/5 and X36/4. Check continuity between XA2_2/6 and X36/5. Check continuity between XA2_2/7 and X36/6. Check continuity between XA2_2/19 and X36/3. Continuity No Continuity Power Supply

(11) Fasten connector securely.

(12) Disconnect connector XA5_1P of power supply. Check continuity between XA5_1P/3 and XA2_2/17. Check continuity between XA5_1P/6 and XA2_2/20. Continuity No Continuity CAN (13) Disconnect connector XA5_1 of logic unit. Check continuity between XA5_1/5 and XA2_2/3. Check continuity between XA5_1/6 and XA2_2/4. Continuity

No Continuity

(14) Connect connector XA5_1P to logic unit, then turn on power again.

(15) Repair or replace harness.

9-69

TROUBLESHOOTING FOR CONTROL CIRCUITS

(16) Measure voltage between XA2_2/17 and XA2_2/20. Confirm value is 14V ± 2V. Abnormal Normal (17) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(18) Replace DSP card of pump inverter. See page 8-33.

(19) Replace power supply card of logic unit. See page 8-37.

If fault remains (20) Discharge electric charges from inverters and APS unit, then replace pump motor. (DSP card is normal.) Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

9-70

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1 G CAN 5 GW 2C 3C 6

5 Power 3 4 6 Power supply card XA5_1P

XA2_2 Pump inverter 1 (A2) 0 to 5V 0 to 5V

G 3 GW 3D 4 14 15 12V 16 14V 17 8V 18 DSP GND 20 card 5V 2 GND 1 GND 19 +12V 5 0 to 5V 6 A 0 to 5V 7 B 2D

Inside of cover

Inside of case

Fuse

IMS card

Flat cable

425A

Battery (-)

Line contactor

Pump motor 1 6 5 4 3 2 1 X36

BLU WHT RED BLK

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

211808-57

9-71

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Motor 2 Pulse Input Fault (58) (1) Situation Display: "57". All truck operations except for "lower" inhibited. Line contactor OPEN.

(2) Possible cause Faulty contact of pump inverter connector, faulty connection of pump motor connector and cable, faulty 12V input voltage of pump inverter, faulty contact or wire breakage of pump motor speed sensor harness, faulty DSP card of pump inverter, faulty pump motor speed sensor. (3) How the error code is triggered Motor rotation speed is more than 4000 rpm. Motor rotation speed is zero while current flows to motor. Motor rotates in reverse. (4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. (5) Check to see if pump motor cables (U, V and W-phases) are connected to pump inverter properly. Abnormal Normal (6) Check to see if connector XA6_2 of pump inverter is fastened securely. Normal Abnormal

(7) Connect cables properly.

(8) Check to see if connector X37 of pump motor speed sensor is fastened securely. Normal Abnormal

(9) Fasten connector securely.

(10) Disconnect connector XA6_2 and X37. Check continuity between XA6_2/5 and X37/4. Check continuity between XA6_2/6 and X37/6. Check continuity between XA6_2/7 and X37/5. Check continuity between XA6_2/19 and X37/3. Continuity No Continuity Power Supply

(11) Fasten connector securely.

(12) Disconnect connector XA5_1P of power supply. Check continuity between XA5_1P/3 and XA6_2/17. Check continuity between XA5_1P/6 and XA6_2/20. Continuity No Continuity CAN (13) Disconnect connector XA5_1 of logic unit. Check continuity between XA5_1/5 and XA6_2/3. Check continuity between XA5_1/6 and XA6_2/4. Continuity

No Continuity

(14) Connect connector XA5_1P to logic unit, then turn on power again.

(15) Repair or replace harness.

9-72

TROUBLESHOOTING FOR CONTROL CIRCUITS

(16) Measure voltage between XA6_2/17 and XA6_2/20. Confirm value is 14V ± 2V. Abnormal Normal (17) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(18) Replace DSP card of pump inverter. See page 8-33.

(19) Replace power supply card of logic unit. See page 8-37.

9-73

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1 G CAN 5 GW 2C 3C 6

5 Power 3 4 6 Power supply card XA5_1P

XA6_2 0 to 5V 0 to 5V

12V 14V 8V GND 5V GND GND +12V 0 to 5V 0 to 5V

Pump inverter 2 (A6)

3 4 14 15 16 17 18 DSP 20 card 2 1 19 5 B 7 6 A

Inside of cover

Inside of case

Fuse

IMS card

Flat cable

425A

Battery (-)

Line contactor

Pump motor 2 6 5 4 3 2 1 X37

BLU WHT RED BLK

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

211808-58

9-74

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Steer Motor Pulse Input Fault (59) (1) Situation Display: "59". All truck operations except for "lower" inhibited. Line contactor OPEN.

(2) Possible cause Faulty connection of steer motor connector and cable, faulty 12V input voltage of steer inverter, faulty contact or wire breakage of steer motor speed sensor harness, faulty steer motor speed sensor, motor turning in opposite direction of command. (3) How the error code is triggered Motor rotation speed is more than 4000 rpm. Motor rotation speed is zero while current flows to motor. Motor rotates in reverse. (4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. (5) Check to see if steer motor cables (U, V and W-phases) are connected to steer inverter properly. Abnormal Normal (6) Check to see if connector XA3_1 of steer inverter is fastened securely. Normal Abnormal

(7) Connect cables properly.

(8) Check to see if connector XM3 of pump motor speed sensor is fastened securely. Normal Abnormal

(9) Fasten connector securely.

Sensor (10) Disconnect connector XA3_1 and XM3. Check continuity between XA3_1/3 and XM3/1. Check continuity between XA3_1/6 and XM3/3. Check continuity between XA3_1/5 and XM3/2. Check continuity between XA3_1/4 and XM3/4. Continuity No Continuity

(11) Fasten connector securely.

(12) Repair or replace harness.

9-75

TROUBLESHOOTING FOR CONTROL CIRCUITS

(13) Measure voltage between XA3_1/3 and XA3_1/4. Confirm value is 14V ± 2V. Abnormal Normal (14) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(15) Replace power steer controller. See page 8-39. If fault remains (16) Discharge electric charges from inverters and APS unit, then replace steer motor. (DSP card is normal.) Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

9-76

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA3_1 Steer Controller (A3) 0 to 5V 0 to 5V

CAN 5 6

23 CAN H 15 CAN L Fuse 21 Brake Control +36V

7F1 K11

K12

10A GND 0 to 5V 0 to 5V +12V

1 KEY on +36V 16 Thermal Sensor 4

}

5 6 3

}

50A

P N

Battery (-)

Line contactor

Encodes

Steer motor A3 RED 1 WHT 3 BLU 2 BLK 4 5 6 XM3

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

211796-59

9-77

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Display Communication Fault (60) or (LOGIC FAULT) (1) Situation Display: "60" or "LOGIC FAULT." Truck operation inhibited.

(2) Possible cause Faulty main harness, faulty display unit, faulty logic unit, faulty K11 contactor, blown 1F1/1F2 fuse.

(3) How the error code is triggered CAN communication is impossible.

(4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. CAN (5) Disconnect connector XA5_1 of logic unit. Disconnect connector XA7_J1L of display unit. Check voltage at XA7_J1L/1 and XA7_J1L/13 = +36 VDC. Check continuity between XA7_J1L/2 and NEG (Inverter). Check continuity between XA7_J1L/17 and NEG (Inverter). Check continuity between XA7_J2L/1 and XA5_1/5. Check continuity between XA7_J2L/2 and XA5_1/6.

Continuity

No Continuity/Voltage

(6) Repair or replace harness. (7) Disconnect connectors XA1_2 of traction inverter, XA2_2 of pump inverter 1, XA6_2 of pump inverter 2, XA5_1 of logics, XA7_J1L of display and XA3_1 of APS unit. Measure resistance of CAN between X56/11 and X56/12. 120 Ω + 5%

Out of Range

(9) Connect connector XA2_2 of pump inverter 1, then measure resistance of CAN between X56/11 and X56/12. Out of range 60 Ω ± 5 %

(8) Perform CAN check of output unit.

(10) Replace Pump Inverter 1.

9-78

TROUBLESHOOTING FOR CONTROL CIRCUITS

(11) Disconnect connector XA2_2 of pump inverter 1. Connect one connector of connectors disconnected from controllers, then measure resistance of CAN between X56/11 and X56/12. 60 Ω ± 5%

60 Ω ± 5% in all connectors

Repeat above for all connectors.

(12) Check CAN harness of controller for abnormality. Normal Abnormal

(13) Replace controller.

(15) Check to see if these are shorted to other signal cables. Not shorted

Out of range

Shorted

(16) Replace output unit.

(17) Repair or replace harness.

If fault remains (18) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(19) Replace logic card of logic unit. See page 8-37.

9-79

(14) Repair or replace harness.

TROUBLESHOOTING FOR CONTROL CIRCUITS

Can H

XA2-2

Pump Inverter 1

120Ω

4 A2 Can L

3 Pump Inverter 2

XA6-2

4 A6

E stop Key Switch

1F1 Traction Inverter 1

XA1-2

10A

4 A1

23 APS

XA3-1

15 A3

5 Logics

XA5-1

6 A5

1 Display

1 13 2

2 A7

XA7-J1L

Filter

Can L

24R 50W

3 120Ω

1F2 10A

Output Unit 4 A4

Can H

To Truck Components K12 K11

9-80

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Parameter Write Fault (61) (1) Situation Display: "61". All truck operations inhibited. Line contactor OPEN and steering contactor OPEN.

(2) Possible cause Writing parameter to eeprom memory failed. Faulty Setup Option data, faulty logic unit. (3) How the error code is triggered Setup Options

(4) Checks Set Setup Option Group 3 data. See page 5-3.

(5) Turn off power.

(6) Turn on power. If fault remains (7) With service tool, set Setup Option data.

If fault remains (8) Disconnect battery plug.

(9) Replace logic unit. See page 8-35.

9-81

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Logics Fault (62) (1) Situation Display: "62". All truck operations inhibited. Line contactor OPEN.

(2) Possible cause Faulty EEPROM data, faulty logic unit.

(3) How the error code is triggered ROM SUM value of logic card is different from check data. EEPROM SUM value of logic card is different from check data. RAM of logic card is faulty.

(4) Checks Set Setup Options. See page 5-3.

(5) Turn off power.

(6) Turn on power. Error code "61" If fault remains "62" (7) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(8) See troubleshooting for code "61". See page 9-81.

(9) Replace logic card of logic unit. See page 8-36.

9-82

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Inverter Fault (63) (1) Situation Display: "63". All truck operations except for "lower" inhibited. Line contactor OPEN. (2) Possible cause Faulty contact or wire breakage of DSP flat cable in traction inverter, faulty DSP card of traction inverter, faulty traction inverter, faulty main harness, faulty logic unit. (3) How the error code is triggered Traction inverter is connected as pump inverter 1 (XA1_2/9 is connected to GND) or pump inverter 2 (XA6_2/8 and XA6_2/9 are connected to GND). ROM SUM value of traction inverter is different from check data. RAM of traction inverter is faulty. Communication with traction inverter is impossible. (4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. (5) Disconnect connector XA1_2 of traction inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Abnormal Normal Power supply (6) Disconnect connector XA5_1P of power supply. Check continuity between XA5_1P/4 and XA1_2/18. Check continuity between XA5_1P/6 and XA1_2/20. Continuity No Continuity

(7) Refasten flat cable or replace inverter. See page 8-31.

CAN (8) Disconnect connector XA5_1 Check continuity between XA5_1/5 and XA1_2/3. Check continuity between XA5_1/6 and XA1_2/4. Continuity

No Continuity

(9) Measure resistance of CAN with connectors XA1_2 and XA5_1 disconnected. Resistance between X56/11 and X56/12. 60Ω + 5% Other than 60Ω + 5%

(10) Perform CAN check of pump inverter 1 (65) or output unit fault (68).

9-83

TROUBLESHOOTING FOR CONTROL CIRCUITS

(11) Connect connector XA1_2 of traction inverter. Measure resistance of CAN with connector XA5_1 disconnected. Resistance between X56/11 and X56/12 60 Ω ± 5%

Other than 60 Ω ± 5%

(12) Repair or replace harness.

(13) Connect connector XA5_1P to logic unit, then turn on power again.

(14) Repair or replace harness.

(15) Measure voltage between XA1_2/18 and XA1_2/20. Confirm value is 8V ± 2V. Abnormal Normal (16) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(18) Replace power supply card of logic unit. See page 8-37.

(17) Replace DSP card of traction inverter. See page 8-33.

9-84

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA2_1 Traction inverter (A1) 0 to 5V 0 to 5V

CAN 5 6

12V 14V 8V GND

5 Power 3 4 6 Power supply card XA5_1P

3 Inside of 4 cover 14 15 16 17 18 DSP 20 card 8 9 Flat cable

Inside of case

IMS card

N U V W

DSP flat cable Inverter case DSP card

211810-63

9-85

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Inverter 1 Fault (65) (1) Situation Display: "65". All truck operations except for "lower" inhibited. Line contactor OPEN and steering contactor HOLD. (2) Possible cause Faulty contact or wire breakage of DSP flat cable in pump inverter 1, faulty DSP card of pump inverter 1, faulty pump inverter 1, faulty main harness faulty logic unit. (3) How the error code is triggered Pump inverter 1 is connected as traction inverter (XA2_2/9 is opened) or pump inverter 2 (XA2_2/9 and XA2_2/8 are connected to GND). ROM SUM value of pump inverter is different from check data. RAM of pump inverter is faulty. Communication with pump inverter is impossible. (4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. (5) Disconnect connector XA2_2 of pump inverter 1 and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Abnormal Normal Power supply (6) Check continuity between XA5_1P/4 and XA2_2/18. Check continuity between XA5_1P/6 and XA2_2/20. Continuity No Continuity

(7) Refasten flat cable or replace inverter. See page 8-31.

CAN (8) Disconnect connector XA5_1 of logic unit. Check continuity between XA5_1/5 and XA2_2/3. Check continuity between XA5_1/6 and XA2_2/4. Continuity No Continuity (9) Measure resistance of CAN with connectors XA2_2 and XA5_1 disconnected. Resistance between X56/11 and X56/12. 120Ω + 5% Other than 60Ω + 5%

(10) Perform CAN check of Output Unit Fault (68).

9-86

TROUBLESHOOTING FOR CONTROL CIRCUITS

(11) Connect connector XA2_2 of pump inverter 1. Measure resistance of CAN with connector XA5_1 disconnected. Resistance between X56/11 and X56/12 60 Ω ± 5%

Other than 60 Ω ± 5%

(12) Replace DSP card of pump inverter 1. See page 8-33. Mode (13) Check continuity between XA2_2/11 and XA2_2/9. No continuity Continuity

(14) Connect connector XA5_1P to logic unit, then turn on power again.

(16) Repair or replace harness.

(15) Measure voltage between XA2_2/18 and XA2_2/20. Confirm value is 8V ± 2V. Normal Abnormal (16) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(17) Replace DSP card of pump inverter 1. See page 8-33.

(18) Replace power supply card of logic unit. See page 8-37.

9-87

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA2_2 Pump inverter 1 (A2)

CAN 5 6

0 to 5V 0 to 5V

5 Power 3 4 6

12V 14V 8V GND

Power supply card XA5_1P

3 120Ω Inside of 4 cover 14 15 16 17 18 DSP 20 card 8 mode 1 9 mode 2 Flat cable

Inside of case

IMS card

N U V W

11 GND

DSP flat cable Inverter case DSP card

211812-65

9-88

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Inverter 2 Fault (66) (1) Situation Display: "66". All truck operations except for "lower" inhibited. Line contactor OPEN. (2) Possible cause Faulty contact or wire breakage of DSP flat cable in pump inverter 2, faulty DSP card of pump inverter 2, faulty pump inverter 2, faulty main harness, faulty logic unit.

(3) How the error code is triggered Pump inverter is connected as pump inverter 1 (XA6_2/9 is connected to GND and XA6_2/8 is opened) or traction inverter (XA6_2/8 and XA6_2/9 are opened). ROM SUM value of pump inverter 2 is different from check data. RAM of pump inverter 2 is faulty. Communication with pump inverter 2 is impossible.

(4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. (5) Disconnect connector XA6_2 of pump inverter 2 and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Abnormal Normal

Power supply (6) Check continuity between XA5_1P/4 and XA6_2/18. Check continuity between XA5_1P/6 and XA6_2/20. Continuity

(7) Refasten flat cable or replace inverter. See page 8-31.

No Continuity

CAN (8) Disconnect connector XA5_1 of logic unit. Check continuity between XA5_1/5 and XA6_2/3. Check continuity between XA5_1/6 and XA6_2/4. Continuity No Continuity (9) Measure resustance of CAN with connectors XA6_2 and XA5_1 disconnected. Resistance between X56/11 and X56/12 60 Ω ± 5%

Other than 60 Ω ± 5%

(10) Perform CAN check of pump inverter 1. Fault (65) or Output Unit Fault (68).

9-89

TROUBLESHOOTING FOR CONTROL CIRCUITS

Mode (11) Check continuity between XA6_2/11, and XA6_2/8 and XA6_2/9. No continuity Continuity

(13) Connect connector XA5_1P to logic unit, then turn on power again.

(12) Repair or replace harness.

(14) Measure voltage between XA6_2/18 and XA6_2/20. Confirm value is 8V ± 2V. Normal Abnormal (15) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(16) Replace DSP card of pump inverter 1. See page 8-33.

(17) Replace power supply card of logic unit. See page 8-37.

9-90

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA6_2 Pump inverter 2 (A6)

CAN 5 6

0 to 5V 0 to 5V

5 Power 3 4 6

12V 14V 8V GND

Power supply card XA5_1P

3 Inside of 4 cover 14 15 16 17 18 DSP 20 card 8 mode 1 9 mode 2 Flat cable

Inside of case

IMS card

N U V W

11 GND

DSP flat cable Inverter case DSP card

211811-66

9-91

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Output Unit Fault (68) (1) Situation Display: "68". Pump motor operations inhibited. Line contactor HOLD. (2) Possible cause Faulty remote output unit, faulty main harness, faulty logic unit. (3) How the error code is triggered Emergency switch is detected. ROM/RAM SUM value of output unit is different from check data. Communication with output unit is impossible. (4) Checks Without service tool

With service tool (5) Check output unit status with Output Monitor. Error

Normal

(7) Disconnect battery plug, then replace output unit. See page 8-38.

(6) Turn off power.

(8) Disconnect connector XA4_1 of output unit, then measure voltage between XA4_1/20 and XA4_1/1 Confirm value is 14V + 2V. Normal Abnormal (9) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. CAN (11) Disconnect connector XA5_1 of logic unit. Check continuity XA5_1/5 and XA4_1/13 Check continuity XA5_1/6 and XA4_1/14 Continuity No Continuity

(12) Check continuity between XA5_1P/11, XA4_1/1 and XA4_1/2. Check continuity between XA5_1P/12, XA4_1/3 and XA4_1/4. Check continuity between XA5_1P/9 and XA4_1/20. Continuity No Continuity

(15) Measure resistance of CAN of connectors XA4_1 disconnected. Resistance between X56/11 and X56/12. 120Ω + 5%

(10) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(13) Replace power supply card of logic unit. See page 8-37.

Other than 120Ω + 5%

(14) Repair or replace main harness.

(16) Connect connector XA4_1 of output unit. Measure resistance of CAN. Resistance between X56/11 and X56/12. 60Ω + 5% Other than 60Ω + 5% (17) Perform CAN check of pump inverter 1 fault (65). (18) Replace output unit. (19) Check proper insertion of pins XA4_1/15 and XA4_1/16. Normal Abnormal 9-92

(20) Repair or replace main harness.

TROUBLESHOOTING FOR CONTROL CIRCUITS

XA4-1

P13 Power Supply 4

XA5_1P

GND

Output unit 1 20

+VL

2 SEL 0 36 SEL 1 37 GND

38 120 Ω

CAN 15

Logic XA5_1

16 Battery voltage 5 6 7 8

K11 T5

T18

Key switch 24R 50W

Battery -

E-Stop

10F1

211813-68

9-93

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: APS Controller Fault (71) (1) Situation Display: "71". Pump motor operations except for “lower” inhibited. Line contactor HOLD.

(2) Possible cause Faulty APS, faulty main harness, faulty steer sensor, no communication, incorrect start sequence, blown 7F1 fuse, faulty logic unit. (3) How the error code is triggered Steering feedback sensor out of range. Key voltage not reaching nominal voltage within 10 seconds. Controller initiation fault. (4) Checks

Reference codes 49, 59, and 82 Without service tool

With service tool (5) Check output unit status with Output Monitor. Error Normal (7) Disconnect battery plug, then replace APS controller. See page 8-39.

(6) Turn on power. (8) Disconnect connector XA3_1 of APS, then measure voltage at XA3_1/1. Confirm value is +36 VDC. Normal Abnormal

(13) Check Steering feedback sensor's connectors are fully inserted.

(10) Check 7F1 Fuse. Fuse Good

(14) Disconnected connector XA5_1 of logic unit. Check continuity between XA5_1/5 and XA3_1/23. Check continuity between XA5_1/6 and XA3_1/15.

(11) Repair main harness.

Blown

(12) Replace fuse.

(15) Turn on power. Check voltage at XA3_1/21. Confirm value is +36 VDC. Normal Abnormal

(16) Check continuity between XA3_1/21 and XY31/1 (brake connector). Continuity

No Continuity

(17) Replace output unit 2. See page 8-39.

(18) Repair or replace main harness.

9-94

TROUBLESHOOTING FOR CONTROL CIRCUITS

To Logic Unit

S34

XY31/2 S31

M1 Safety Brake S31 1

XY31/1

10F1

K11 4

Steering Stepper Motor

PNP

SWITCH

K12 S34 A+

A-

B-

B+

21 Brake

4 Gnd

7F1 10A

X11/6

BLU WH ORG X11/4

YEL

BLK

10 Signal A

X11/3

X11/1

RED

4 PNP

11 Signal B

13 19 Steering Reference

Steer Motor Controller (APS)

9-95

KEY

1 Key

XA3-1

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Battery Voltage Too Low (78) (1) Situation Display: "78". All truck operations except for "lower" inhibited. Line contactor OPEN.

(2) Possible cause Faulty or discharged battery, low voltage battery, improper battery voltage adjustment setting (BDI reset), faulty main harness, faulty logic unit, blown 1F1 fuse.

(3) How the error code is triggered Battery voltage is too low. Battery voltage is corrected with #46 value. 36 V battery: less than 32.4 VDC

(4) Checks Disconnect battery plug. Measure battery voltage with multimeter. Abnormal

32 V to 42 V

(5) #3 of setup option Group 1 (BDI Reset).

(6) Charge battery or replace with proper battery.

(7) Turn off power and turn on power again. If fault remains (8) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(9) Check continuity between XA5_1/19 and contactor X12/2 (key switch). No continuity Continuity

(10) Check fuse 1F1 Fuse Good

Blown (11) Replace fuse.

(12) Discharge electric charges from inverters and APS unit, then replace logic card of logic unit. See page 8-36.

(13) Repair or replace main harness.

9-96

TROUBLESHOOTING FOR CONTROL CIRCUITS

Line contactor K11 Logic XA5_1

24Ω/50W

Key Switch

19 1F1 10A

POS

Battery

211818-78

9-97

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Battery Voltage Too High (79) (1) Situation Display: "79". All truck operations except for "lower" inhibited. Line contactor OPEN.

(2) Possible cause Faulty or highly charged battery, high voltage battery, improper battery voltage adjustment setting (BDI Reset), faulty logic unit. (3) How the error code is triggered Battery voltage is too high. 36 V battery: more than 43.2 VDC

(4) Checks Disconnect battery plug. Measure battery voltage with multimeter. Abnormal

42 V to 43 V

(5) #3 of setup option Group 1 (BDI Reset).

(6) Replace with proper battery.

(7) Turn off power and turn on power again. If fault remains (8) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(9) Check continuity between XA5_1/19 and contactor X12/2 (key switch). Continuity No continuity

(10) Discharge electric charges from inverters and APS unit, then replace logic card of logic unit. See page 8-36.

9-98

(11) Repair or replace main harness.

TROUBLESHOOTING FOR CONTROL CIRCUITS

Line contactor K11 Logic XA5_1

24Ω/50W

Key Switch

19 1F1 10A

POS

Battery

211818-79

9-99

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pressure Sensor Fault (81) (1) Situation Display: "81". Reduced performance. (2) Possible cause Faulty load sensor, faulty main harness, faulty logic unit. (3) How the error code is triggered Load sensor voltage is out of range of 0.1 V to 4.9 V.

(4) Checks Check to see if load sensor is installed. Installed

Not installed (5) Install sensor. (6) Turn off power, then turn on power again. Check to see if fault remains. Fault remains Fault disappears Normal operation With service tool

Without service tool (8) Check load sensor voltage with Input Monitor and confirm value is in range of 0.1V to 4.9V.

(7) Disconnect battery plug.

Abnormal signal

(9) Disconnect battery plug.

(11) Discharge electric charges from inverters and APS unit. See page 8-30.

(12) Disconnect connectors XA5_1 of logic unit. Disconnect connector XB42 of load sensor. (13) Check continuity between XB42/2 and XA5_1/21. (Sensor signal) Continuity No continuity

9-100

Interrupted

(10) Adjust load sensor installation.

TROUBLESHOOTING FOR CONTROL CIRCUITS

(14) Check continuity between XB42/1 and XA5_1/26. Check continuity between XB42/3 and XA5_1/25. No continuity Continuity

(15) Repair or replace harness. With service tool Without service tool (17) Connect connectors XA5_1. Turn on power and check voltage between XB4/1 and XB42/3. Not 5 V 5V

(16) Replace load sensor. If fault remains (18) Disconnect battery plug.

(19) Turn off power. Short-circuit XB42/1 and XB42/12. Turn on power and check load sensor voltage with Input Monitor. Not 5 V 5V

(20) Reinstall load sensor, then replace logic card of logic unit. See page 8-36.

(21) Turn off power. Open XB42/1 and XB42/2. Short-circuit XB42/2 and XB42/3. Turn on power and check load sensor voltage with Input Monitor. 0V Not 0 V (22) Replace load sensor.

(23) Disconnect battery plug. (24) Replace logic card of logic unit.

9-101

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1 26

XB42 +5V

Signal

L+

OUT

GND

Pressure Sensor P

S42

GND

211819-81

9-102

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Steer Stepper Motor Fault (82) (1) Situation Display: "82". Inhibited truck operation. (2) Possible cause Faulty stepper motor, faulty main harness, faulty steer controller. (3) How the error code is triggered Stepper motor error due to shorted or broken wire or open phase.

(4) Checks Checks to see if stepper motor connector (X11) is connected. Connected (5) With connector X11 connected, probe position X11/1 with positive lead of multimeter. Probe X11/3 with negative lead. Check voltage. Correct readings will be between 0 t0 10 VAC as the steer tiller is being operated. Repeat procedure while probing X11/4 (+) and X11/6 (-). Normal readings Abnormal (6) Replace Stepper Motor.

(7) Disconnect connectors X11 and XA3_1. Check continuity between X11/1 and XA3_1/10. Check continuity between X11/6 and XA3_1/11. Check continuity between X11/3 and XA3_1/4. Check continuity between X11/6 and XA3_1/4. Continuity No Continuity (8) Repair harness. (9) Discharge electric charges from inverters and APS.

(10) Replace Steer Controller.

9-103

TROUBLESHOOTING FOR CONTROL CIRCUITS

To Logic Unit

S34

XY31/2 S31

M1 Safety Brake S31 1

XY31/1

10F1

K11 4

Steering Stepper Motor

PNP

SWITCH

K12 S34 A+

A-

B-

B+

21 Brake

4 Gnd

7F1 10A

X11/6

BLU WH ORG X11/4

YEL

BLK

10 Signal A

X11/3

X11/1

RED

4 PNP

11 Signal B

13 19 Steering Reference

Steer Motor Controller (APS)

9-104

KEY

1 Key

XA3-1

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Brake Switch Fault (85) (1) Situation Display: "85". All truck operations except for "lower" inhibited. Line contactor OPEN.

(2) Possible cause Faulty OPP (operator prsence pedal), faulty brake switch, faulty regeneration switch, faulty main harness, faulty logic unit. (3) How errorflowed code ismore triggered Stallthe current thse time (#20) in traction motor, faulty right traction inverter current sensor, shorted Presence switch isfaulty turned off traction and regeneration switch is turned on. unit. harness wiring, right inverter DSP card, faulty logic (4) Checks Disconnect battery plug.

(5) Discharge electric charges from inverters and APS unit. See page 8-30.

(6) Disconnect connectors X13thse OPPtime and(#20) XA5_1 of logic motor, unit. faulty right traction inverter current sensor, shorted Stall current flowed more in traction Check continuity of between XA5_1/38 and X13/4, XA5_1/39 and X13/3, harness wiring, faulty right traction inverter DSP card, faulty logic unit. XA5_1/30 and X13/2, and XA5_1/9 and X13/1. Continuity No continuity (7) Measure resistance between the following terminals. • When pedal is released. Between XA5_1/38 and XA5-1/9 Open. Between XA5_1/39 and XA5-1/9 0 Ω. Between XA5_1/30 and XA5-1/9 Open. • When pedal is slightly depressed. Between XA5_1/38 and XA5-1/9 Open. Between XA5_1/39 and XA5-1/9 0 Ω. Between XA5_1/30 and XA5-1/9 0 Ω. • When pedal is fully depressed. Between XA5_1/38 and XA5-1/9 0Ω. Between XA5_1/39 and XA5-1/9 Open. Between XA5_1/30 and XA5-1/9 0 Ω. Normal Abnormal

(8) Repair or replace harness.

(9) Replace logic card of logic unit.

(10)Repair or replace OPP.

9-105

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

Operator presence pedal (OPP) X13 S12

2 3 4 GND 1

30 39 38

Operator presence Regen breaking

S11

OPP Operator presence

OFF Pedal released OFF

Regen switch ON

Operator presence switch

ON Pedal depressed Regen switch 211821-85

9-106

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Height Sensor Fault (86) (1) Situation Display: "86". Inhibited truck operation, except for “lower”. (2) Possible cause Faulty height sensor, faulty pulse encoder, faulty main harness, faulty logic unit.

(3) How the error code is triggered No pulse input movement detected when it should be charging. Encoder pulses detected before mast height reference state change is detected. (4) Check to see if height sensor is setup. Setup

Not Setup (5) Setup option #22 to correct height. Normal operation

(7) Fault remains

(8) Disconnect battery plug.

(10) Check height sensor for installation. Normal

Abnormal (11) Adjust height sensor installation.

(14) Discharge electric charges from inverters and APS unit. See page 8-30.

(15) Disconnect connector XA5_1 of logic unit Disconnect connector XB41 (pulse encoder) and XS43 (Free height sensor). (16) Check continuity between XA5_1/10 and XB41/1, and XA5_1/10 and XS43/1.

9-107

TROUBLESHOOTING FOR CONTROL CIRCUITS

(17) Check continuity between XA5_1/43 and XB41/4. Check continuity between XA5_1/43 and XS43/3. Check continuity between XA5_1/12 and XB41/2. Check continuity between XA5_1/11 and XB41/3. Check continuity between XA5_1/45 and XS43/2. Continuity

No Continuity

(18) Repair or replace harness. With service tool Without service tool (20) Connect connectors XA5_1, XB41 and XS43. Turn on power and check free height sensor signal. 0V Not 0 V

(19) Replace height sensor and/or pulse encoder. If fault remains (21) Disconnect battery plug.

(22) Turn off power. Short-circuit X46/6 and X46/7. Turn on power and check height sensor signal with input monitor. 0V Not 0 V

(23) Reinstall height sensor and/or pulse encoder, then replace logic unit. See page 8-36.

(24) Replace load sensor.

(25) Disconnect Disconnect battery battery plug. plug. (26) Replace logic unit.

9-108

TROUBLESHOOTING FOR CONTROL CIRCUITS

B41 out

S43 V+

XS43/1

XS43/2

XS43/3

X46/5

X46/6

X46/7

XB41/3 X46/3

XB41/4

XB41/2 X46/2

BRN BLK BLU

X46/4

XB41/1 X46/1

RED WHT BLU BLK

LOGIC BOARD

10 12 11 12V sensor supply

NPN

43 GND

45 XA5-1

9-109

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Logic Fault Multipurpose Output #1, Travel Alarm (88) (1) Situation Display: “88”. Travel alarm output OFF. Normal pump motor, traction motor and power steering operations.

(2) Possible cause Faulty travel alarm, faulty main harness, faulty logic unit, faulty K31 relay.

(3) How the error code is triggered With short circuit detection signal of logic card.

(4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(5) Disconnect connector XA5_1 of logic unit. Disconnect terminals K31/5 and K31/1 of horn relay (K31).

(6) Check short circuit between K31/5 and K32/1 on harness side. Not shorted

(7) Repair main harness.

(9) Disconnect terminal K31/3 of travel alarm relay.

Shorted

(8) Check short circuit between travel alarm side connectors. Measure coil resistance. [Approx. 1.6MΩ] Connect positive (+) terminal of multimeter to (+) and negative (-) terminal to (-). Normal Abnormal

(10) Replace travel alarm.

(11) Check short circuit between K31/3 and ground. Shorted

Not Shorted

(12) Repair main harness. Check fuse 12 F2.

(13) Check short circuit between travel alarm relay tabs 1 and 5. Measure coil resistance. [Approx. 1.2kΩ] Normal Abnormal

(14) Replace logic card of logic unit. See page 8-36

(15) Replace travel alarm relay.

9-110

TROUBLESHOOTING FOR CONTROL CIRCUITS

11F1 10A

Logic XA5-1

12F1 10A

12F2 10A

XESS +

1 -

Travel alarm (Backup alarm)

211817-88

9-111

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Logic Fault Multipurpose Output #2, Horn (88) (1) Situation Display: "88". Chime output OFF . Normal pump motor, traction motor and power steering operations. (2) Possible cause Faulty horn, faulty main harness, faulty logic unit, faulty K32 relay.

(3) How the error code is triggered With short circuit detection signal of logic card.

(4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(5) Disconnect connector XA5_1 of logic unit. Disconnect terminals K32/5 and K32/1 of horn relay (K32).

(6) Check short circuit between K32/5 and K32/1 on harness side. Shorted

Not shorted

(8) Measure coil resistance. [Approx. 1.2KΩ] Connect positive (+) terminal of multimeter to K32/1 and negative (-) terminal to K32/5 of relay.

(7) Repair main harness.

Shorted

(9) Replace relay.

9-112

Not Shorted

(10) Replace logic unit. See page 8-35.

TROUBLESHOOTING FOR CONTROL CIRCUITS

11F1 10A Logic XA5_1

K32 Relay + 5

57 58

1 4 To Horn

211816-88

9-113

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Motor 2, Current Sensor Fault (94) (1) Situation Display: "34". All truck operations except for "lower" inhibited. This fault occurs only when turning on power. Line contactor OPEN. (2) Possible cause Faulty contact or wire breakage of DSP flat cable in pump inverter, faulty DSP card of pump inverter, faulty pump inverter, faulty main harness, faulty logic unit.

(3) How the error code is triggered When turning on power, current sensor voltage is out of range of -120A to 120A. (4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. (5) Disconnect connector XA6_2 of pump inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Abnormal Normal 8V power supply (6) Check continuity between XA5_1P/4 and XA6_2/18. Check continuity between XA5_1P/6 and XA2_2/20. Continuity

(7) Secure DSP flat cable if loose. Replace pump inverter if wire breaks. See pages 8-33.

No continuity

CAN (8) Disconnect connector XA5_1 of logic unit. Check continuity between XA5_1/5 and XA6_2/3. Check continuity between XA5_1/6 and XA6_2/4. Continuity

No continuity

(9) Connect connector XA5_1P to logic unit, then turn on power again.

(10) Repair or replace harness.

(11) Measure voltage between XA6-2/18 and XA6-2/20. Confirm value is 8V ± 2V. Abnormal Normal

(12) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(14) Replace power supply card of logic unit. See page 8-37.

(13) Replace DSP card of pump inverter. See page 8-33. If fault remains (15) Discharge electric charges from inverters and APS unit, then replace pump inverter. (DSP card is normal.) See page 8-31.

9-114

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA6_2 0 to 5V 0 to 5V

CAN 5 6

5 Power 3 4 6 Power supply card XA5_1P

Pump inverter 2 (A6)

3 Inside of 4 cover 14 15 12V 16 14V 17 8V 18 DSP GND 20 card 5V* 2 Temp GND 1 Sens Flat GND 19 cable +12V 5 0 to 5V 7 B 0 to 5V 6 A

Inside of case

Fuse 425A

Battery (-)

IMS card

Line contactor

U V W

Pump motor 2 DSP flat cable Inverter case DSP card

BLU 4 2 WHT 3 RED BLK 1 2 1 X36

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

211800-94

9-115

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Motor 2, Over-current (95) (1) Situation Display: "95". All truck operations except for "lower" inhibited. Line contactor OPEN. (2) Possible cause Faulty contact or wire breakage of DSP flat cable in pump inverter, faulty DSP card of pump inverter, faulty pump inverter, faulty pump motor, faulty contact or wire breakage of pump motor speed sensor harness, faulty main harness, faulty logic unit. (3) How the error code is triggered Motor current is more than 1018 Amps (Moment). Motor curret is more than 990 Amps (Fixed time 1). Motor current is more than 985 Amps (Fixed time 2).

(4) Checks Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30. (5) Check pump motor and terminal for burning and smell. Normal

Abnormal

(7) Replace pump motor. Notice: Before replacing motor, be sure to check it. If motor is normal, perform troubleshooting again from the first step.

(6) Confirm cable looseness and improper connections (U, V, W phases) for pump inverter and motor. Abnormal Normal (8) Disconnect connector XA6_2 of pump inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Abnormal Normal

(9) Secure cable if loose or connect cable correctly.

(10) Confirm connection of pump motor speed sensor connector X37. Abnormal Normal

(11) Secure DSP flat cable if loose. Replace pump inverter if wire breaks. See page 8-33.

Sensor (12) Disconnect connector XA6_2 and X37. Check continuity between XA6_2/5 and X37/4. Check continuity between XA6_2/6 and X37/6. Check continuity between XA6_2/7 and X37/5. Check continuity between XA6_2/19 and X37/3. Continuity

(13) Connect connector securely.

No continuity

8V power supply (14) Disconnect Connector XA5-1P Check continuity between XA5_1P/4 and XA6_2/18. Check continuity between XA5_1P/6 and XA6_2/20. Continuity No Continuity

9-116

TROUBLESHOOTING FOR CONTROL CIRCUITS

(15) Disconnect connector XA5_1 of logic unit. Check continuity between XA5_1/5 and XA6_2/3. Check continuity between XA5_1/6 and XA6_2/4. Continuity No continuity (16) Connect connector XA5_1P to logic unit, then turn on power again.

(17) Repair or replace harness.

(18) Measure voltage between XA6_2/18 and XA6_2/20. Confirm value is 8V ± 2V. Normal Abnormal

(19) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(21)Replace power supply card of logic unit. See page 8-37.

9-117

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

XA6_2 0 to 5V 3 0 to 5V 4

CAN 5 6

5 Power 3 4 6 Power supply card XA5_1P

Pump inverter 2 (A6) Inside of cover

14 15 12V 16 14V 17 8V 18 DSP GND 20 card 5V * 2 Temp GND 1 Sens Flat GND 19 cable +12V 5 0 to 5V 7 B 0 to 5V 6 A

Inside of case

Fuse 425A

Battery (-)

IMS card

Line contactor

U V W

Pump motor 2 DSP flat cable Inverter case DSP card

BLU 6 5 WHT 4 RED BLK 3 2 1 X37

Speed sensor

V U

Thermal sensor 391 [-30 C(-22 F)] to 1407 [160 C(320 F)]

211800-95

9-118

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Incorrect Start (E) (1) Situation Display: "E" flickering. All truck operations inhibited. Line contactor OPEN when turning on power, Line contactor OPEN (when truck stops). (2) Possible cause Power turned on while depressing OPP, power turned on while operating traction lever, traction lever operated before depressing OPP, presence pedal not depressed, faulty OPP switch, faulty traction lever sensor, faulty main harness, faulty logic unit. (3) How the error code is triggered Stall current flowedsignal more0aaa00 thsmeon (#20) in traction motor, faulty right traction inverter current sensor, shorted Detects following when turning power. harness wiring, faulty right traction inverter DSP logic ±uni Traction lever voltage:card Lessfaulty than 2.3V 0.2V or 2.7V ± 0.2V or more OPP : ON (4) Checks Release OPP and release traction lever to neutral. If fault remains (5) Turn off power. Release OPP, release traction lever to neutral, then turn on power again. Without service tool With service tool (6) Check OPP and traction lever operations with Input Monitor.

(7) Confirm input signals of OPP and traction lever with data monitor function.

(8) Turn off power.

(faulty unit only) Traction lever

Traction pedal (9) Disconnect connector X13 of traction pedal, then measure resistance between between following terminals. • When OPP is released. Between X13/2 and X13/1: Open. Between X13/4 and X13/1: Open. • When OPP is pressed. Between X13/2 and X13/1: 0Ω. Between X13/4 and X13/1: 0Ω. Normal Abnormal

(10) Refer to error code "51". See page 9-58.

(12) Disconnect connectors XA5_1 of logic unit

(11) Replace traction pedal.

(13) Check short circuit between X13/2 and XA5_1/30, X13/4 and XA5_1/38. Not shorted Shorted (14) Disconnect battery plug.

(15) Repair or replace main harness.

(16) Replace logic card of logic unit. See page 8-36. 9-119

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

Operator presence pedal (OPP) X13 S12

2 3 4 GND 1

30 39 38

Operator presence Regen breaking

S11

Traction speed and Direction

X14A 5

View opposite wire entry Logic XA5_1 26 20 25

X14A 5V 0.5 to 4.5V GND

1 2 3

RED WHT BRN

211822-E

9-120

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Lift Lever, Faulty Setting ((H1)) (1) Situation Display: "H1" flickering. All truck operations inhibited. Line contactor OPEN when turning on power. Line contactor OPEN (when truck stops).

(2) Possible cause Power turned on while operating lift lever, presence pedal pressed while operating lift lever, faulty lift lever sensor, faulty main harness, faulty logic unit. (3) How the error code is triggered Detects lift lever sensor signal when turning on power. Lift lever sensor voltage: Less than 2.3V ± 0.2V or 2.7V ± 0.2V or more. (4) Checks If this fault occurred during pump motor operation

If this fault occurred when turning on power

(5) Turn on presence pedal, then stop pump motor operation. Normal If fault remains Fail-safe function (6) Turn off power. Release presence pedal, then turn on power again without lift operation. If fault remains

(7) Check continuity between X14A/8 and X14A/7: Open Check voltage at X14A5: Neutral = 2.5V, Lower = 4.5v and Lift = 0.5V. Normal Abnormal

(8) Replace logics unit.

(9) Replace lift lever.

9-121

TROUBLESHOOTING FOR CONTROL CIRCUITS

Lower

X14A

Logic XA5_1 26

View opposite wire entry +5V

Lift

Logic XA5_1 22 Joystick X14A

Logic XA5_1 26 27 25

+5V 0.5V to 4.5V GND

7 8 4 5 6 211820-H1

9-122

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Tilt Switch, Faulty Setting ((H2)) (1) Situation Display: "H2" flickering. All truck operations inhibited. Line contactor OPEN when turning on power. Line contactor OPEN (when truck stops).

(2) Possible cause Power turned on while operating tilt switch, presence pedal pressed while operating tilt switch, faulty tilt switch, faulty main harness, faulty logic unit. (3) How the error code is triggered Detects tilt switch when turning on power.

(4) Checks If this fault occurred during pump motor operation

If this fault occurred when turning on power

(5) Release presence pedal, then stop pump motor operation. If fault remains Normal

Fail-safe function (6) Turn off power. Release presence pedal, then turn on power again without tilt operation. If fault remains

(7) Turn off power.

(8) Disconnect connector X14B of handle. Turn on presence pedal, then turn on power again. If fault remains Normal (9) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(10) Check handle.

(11) Check continuity between X14B/3 and XA5_1/43. Check continuity between X14B/6 and XA5_1/41. Check continuity between X14B/7 and XA5_1/40. Check short between X14B/6 and XA5_1/43. Check short between X14B/7 and XA5_1/43. Continuity, not shorted No continuity, shorted

(12) Disconnect battery plug.

(13) Repair or replace main harness.

(14) Replace logic card of logic unit. See page 8-36. 9-123

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

Joystick X14B

41 40

6 7 3

GND

Tilt Up Tilt Down

Logic XA5_1 43

X14B 5

View opposite wire entry

211823-H2

9-124

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Reach Switch, Faulty Setting ((H3)) (1) Situation Display: "H3" flickering. All truck operations inhibited. Line contactor OPEN when turning on power. Line contactor OPEN (when truck stops). (2) Possible cause Power turned on while operating reach switch, presence pedal pressed while operating reach switch, faulty reach switch, faulty main harness, faulty logic unit. (3) How the error code is triggered Detects reach switch when turning on power. (4) Checks If this fault occurred during pump motor operation

If this fault occurred when turning on power

(5) Release presence pedal, then stop pump motor operation. Normal If fault remains

Fail-safe function (6) Turn off power. Release presence pedal, then turn on power again without reach operation. If fault remains

(7) Turn off power.

(8) Disconnect connector X14B of handle. Turn on presence pedal, then turn on power again. If fault remains Normal

(9) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 2-71.

(10) Check handle.

(11) Check continuity between X14B/4 and XA5_1/47. Check continuity between X14B/5 and XA5_1/48. Check continuity between X14B/3 and XA5_1/43. Check short between X14B/4 and XA5_1/43. Check short between X14B/5 and XA5_1/43. Continuity, not shorted

No continuity, shorted

(12) Disconnect battery plug.

(13) Repair or replace main harness.

(14) Replace logic card of logic unit. See page 8-35. 9-125

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

Joystick X14B

47 48 36 37 GND

Logic XA5_1 43

Reach Out

4 5 8 9 3

Reach In SShift Left SShift Right

X14B 5

View opposite wire entry

211824-83

9-126

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Sideshift Switch, Faulty Setting ((H4)) (1) Situation Display: "H4" flickering. All truck operations inhibited. Line contactor OPEN when turning on power. Line contactor OPEN (when truck stops).

(2) Possible cause Power turned on while operating sshift selector switch, presence pedal pressed while operating sshift switch, faulty sshift selector switch, faulty main harness, faulty logic unit.

(3) How the error code is triggered Detects sshift switch when turning on power. (4) Checks If this fault occurred during pump motor operation

If this fault occurred when turning on power

(5) Release presence pedal, then stop pump motor operation. If fault remains Normal

Fail-safe function (6) Turn off power. Release presence pedal, then turn on power again without sshift operation. If fault remains (7) Turn off power. (8) Disconnect connector X14B of switch. Release presence pedal, then turn on power again. If fault remains Normal

(9) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.

(10) Check handle.

(11) Check continuity between X14B/8 and XA5_1/36. Check continuity between X14B/9 and XA5_1/37. Check continuity between X14B/3 and XA5_1/43. Check short between X14B/8 and XA5_1/43. Check short between X14B/9 and XA5_1/43. Continuity, not shorted

No continuity, shorted

(12) Disconnect battery plug.

(13) Repair or replace main harness.

(14) Replace logic card of logic unit. See page 8-36. 9-127

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic XA5_1

Joystick X14B

47 48 36 37 GND

Logic XA5_1 43

Reach Out

4 5 8 9 3

Reach In SShift Left SShift Right

X14B 5

View opposite wire entry

211824-84

9-128

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Battery Low ((Lo)) (1) Situation Display: "Lo" flickering. All truck operations except for "lowerî inhibited. Line contactor OPEN.

(2) Possible cause Extremely consumed battery, faulty main harness, faulty logic unit.

(3) How the error code is triggered Corrected battery voltage is less than 15.5V. Battery voltage is corrected with #3 (BDI Reset) value.

(4) Checks Disconnect battery plug.

(5) Check battery voltage. 15.5V or more

Less than 15.5V

(7) Charge battery or replace with new battery.

(6) Set #3 of Setup Option Group 1. See page 5-2. If fault remains (8) Discharge electric charges from inverters and APS unit. See page 8-30.

(9) Check continuity between XA5_1/19 and contactor X12/2 (key switch). No continuity Continuity

(10) Check fuse 1F1 Fuse good

Blown

(12) Replace logic card of logic unit. See page 8-36.

(11) Replace fuse.

(13) Repair or replace main harness.

9-129

TROUBLESHOOTING FOR CONTROL CIRCUITS

Line contactor K11 Logic XA5_1

24Ω/50W

Key Switch

19 1F1 10A

POS

Battery

211818-Lo

9-130

TROUBLESHOOTING FOR CONTROL CIRCUITS

Component Identification Identifier

Description

1F1

B + (10A) fuse to Key Switch

1F2

B - (10A) fuse to Key Switch

2F1

B + K12 (425A) fuse to Drive Motor Controller

3F1

B + (10A) fuse to Auxiliary Devices

3F2

B - (10A) fuse to Auxiliary Devices

4F1

B + K12 (425A) fuse to Pump Motor Controller

5F1

B + K12 (50A) fuse to Steer Motor Controller

6F1

B + K12 (325A) fuse to 2nd Pump Motor Controller*

9F1

B + K11 (10A) fuse to Controller Circuit

10F1

B + K11 (10A) fuse to Controller Circuit

11F1

B + K11 (10A) fuse to Controller Circuit

12F1

B + (10A) fuse Auxiliary Control Devices

12F2

B - (10A) fuse to Auxiliary Control Devices

Traction Motor Controller

Pump Motor Controller

Steer Motor Controller

RT01 Valve Controller

Logics Controller

2nd Pump Motor Controller

Display Unit

B11

Steering Wheel Sensor

B21

Traction Speed and Direction Sensor

B31

Speed and Direction Encoder (Drive motor)

B32

Speed Encoder (Hydraulic Pump Motor)

B33

Speed Encoder (Steer Motor)

B34

Speed Encoder (2nd Hydraulic Pump Motor)*

B41

Pulse Encoder Level Sensor (Option)

B42

Pressure Sensor (Future Option)

E51

Cabin Light (Option)

E52

Working Light (Option)

E53

Working Light (Option)

E54

Warning Light (Option)

E55

Reverse Travel/Horn (Option)

F101

K11 coil

G1 36V

Battery 36 volt

Horn

SICOS/Display Unit Buzzer

H55

Reverse Travel/Horn (Option)

K11

K11 Contactor Tips (B +) to 9F1, 10F1, 11F1, 12F1

* High Performance only. 9-131

TROUBLESHOOTING FOR CONTROL CIRCUITS

Identifier

Description

K11 (24V in box)

K11 Coil

K12

K12 Contactor Tips (B +) to 3F1, 4F1, 5F1, 6F1, 8F1

K12 (24V in box)

K12 Coil

K32

Horn B + Tips in K32 Relay

K32 (box)

K11 Coil

Traction Motor

Hydraulic Pump Motor

Steer Motor

2nd Hydraulic Pump Motor*

Motor Compartment Fan Fan

Controller Fan

El-Panel Input Fan

M10

El-Panel Output Fan

M51

Driver Fan

25R/50W Resistor (K11 Coil)

56R/10W Resistor (Motor Comp Fan)

56R/10W Resistor (Controller Fan)

R10

25R/10W Resistor (Controller Fan)

R31

Temperature Sensor (Traction Motor)

R32

Temperature Sensor (Hydraulic Pump Motor)

R33

Temperature Sensor (2nd Hydraulic Pump Motor)*

R34

Temperature Sensor (Steer Motor)

R51

56R/10W Resistor (Driver Fan)

R343

120R Heater (Steering Wheel) Cold Storage

R344

120R Heater (Brake Pedal) Cold Storage

Emergency Stop Switch

Key Switch

S11

Brake Pedal Switch

S12

Operator Presence Switch

S13

Horn Button

S14

Reach (Out) Switch

S15

Reach (In) Switch

S16

Tilt (Up) Switch

S17

Tilt (Down) Switch

S18

Sideshift (Left) Switch

S19

Sideshift (Right) Switch

S36

Battery Lock Switch (Option)

S43

Lifting Height Reference Sensor (Option)

S51

Cabin Light Switch (Option)

* High Performance only. 9-132

TROUBLESHOOTING FOR CONTROL CIRCUITS

Identifier

Description

S52

Working Light Switch (Option)

S53

Undefined Switch (Option)

S54

Driver Fan Switch (Option)

S55

(_) Up Key on the Display

S56

(_) Down Key on the Display

S57

(__) Down/Left Enter Key on the Display

S58

(-) Right Key on the Display

S59

(-) Enter Key on the Display

S60

(X) Escape Key on the Display

S531

Steering End Limit Sensor (Sensor A)

S534

Steering Feedback Sensor (Sensor B)

S342

Switch steering wheel heater

SM2

+ 50° C. N/O Thermostat

X1: -

Battery SB Connector (Negative)

X1: +

Battery SB Connector (Positive)

X2: -

Battery Negative (Panel Ground)

Y31 (36V in box)

Service Brake Coil

Y41

Lift/Lower Solenoid Coil (M1-M2 Coil)

Y43

Direction of Sideshift, Tilt, Reach (DIRA-DIRB)

Y44

Reach/Retract Solenoid (S5-S6)

Y45

Sideshift Solenoid (S7-S8)

Y46

Tilt/Sideshift

Zener Diode (12 volt / 5W)

* High Performance only.

9-133

Electrical Schematic

MIT

97h04-00000

ESR15N-36V ESR18N-36V ESR20N-36V ESR23N-36V 99759-7D100 EDR13N-36V EDR15N-36V ESS15N-36V ESS20N-36V

Pub. No. 99759-7D100 9 - 135

2SR3800900-up 4SR3800900-up 5SR3800900-up 7SR3800900-up 1DR3800900-up 2DR3800900-up

2SS3800900-up 5SS3800900-up

PLANNED MAINTENANCE Maintenance Locations ................................................................................ 10-1 Maintenance Intervals .................................................................................. 10-2 Service Data Recommended Lubricants .......................................................................... 10-3 Fluid Capacities .......................................................................................... 10-3

PLANNED MAINTENANCE

Maintenance Locations 16

7, 8

6 14 20

12, 13, 17

9 11

9, 18

4 9, 18

10-1

PLANNED MAINTENANCE

Maintenance Intervals

Item 1

10 Service Hours or Daily whichever comes first

Component

Check

Battery

Charge. Cleanliness. Water level.

One Month or 200 Service Hours whichever comes first

No damage, solid electrical connections, EPO shuts down power.

X X

Battery Gates & Restraints

L shaped restraints in place and secured on both sides. Gates locked into place securely on both sides.

X X

Operator Presence Pedal (Brakes)

Smooth action, no binding, stops reach truck within specific limits, disables travel function when pedal is released.

Contactor Tips

Pitting, burning, insufficient contact material

Cable /Hoses/ Tension Springs

Hoses and cables in good condition. Spring tension adjusted properly.

Mast

Inspect inside upright channels for lubrication. Lubricate inside upright channels. Inspect lift cylinders and hydraulic hoses for damage or leaking hydraulic fluid.

Inspect chains for lubrication and visible damage. Lubricate chains. Inspect chains for proper tension and position. Adjust chains for proper tension and position.

Lubrication Points Load Wheels (4) (1 per wheel) Casters (2) Radial Gear on Drive Unit (2) Pantograph-Single Reach (14) Pantograph-Double Reach (16) Drive Unit

Check fluid level. Change fluid.

Forks

Check for cracks and distortions-check welds. Stopper pins properly engaged.

X X X X

Horn

Sounds when activated.

All Hydraulic Cons.

No leaks.

Hydraulic Reservoir

Check fluid level. Change filter. Change fluid.

18 19

Function Controls

Lights

X X X X X

Lubricate. Lubricate. Lubricate. Lubricate. Lubricate.

2000 Service Hours or 12 Months whichever comes first

Battery Connector

Lift Chains

1000 Service Hours or 6 Months whichever comes first

500 Service Hours or 3 Months whichever comes first

Travel, lift/lower & extend/retract control their perspective function.

X X

All lights should function.

Switches

Control assigned function.

Load Wheels, Drive Tires

No cracks, no flat spots or missing chunks, no bond failure—tire surface in good condition.

Static Strap (beneath reach truck)

Check for missing and damaged straps. Check for wear. Keep straps clean. Replace if necessary.

X X

Overhead Guard

Inspect for damage and cracks

Check for loose components and hardware

Check for tightness or damage

Decals and Warning Labels

In place and legible.

Fire Extinguisher (optional)

Check charge. Replace if low.

Ventilation Slots

Make sure slots are free of obstructions.

***Mast Mounting Bolts (8) ***Overhead Guard (4) ***Motor Mounts

Torque check. Torque check. Torque check.

*Pump Splines

Apply molybdenum Type G anti-seize compound

X X X X

***Note: Check bolt torque after the first 50 hours of operation. *Note: Apply molybdenum Type G anti-seize compound to both pump motor splines every 2000 hours. Sufficiently pack the cavity beyond the motor spline so as to prevent run-off of the compound from the splines into the cavity.

10-2

PLANNED MAINTENANCE

Service Data Recommended Lubricants

•

Avoid mixing lubricants. In some cases, different brands of lubricant are not compatible with each other and deteriorate when mixed. It is best to stick with the same brand at successive service intervals.

•

Brands of oil are subject to change without notice.

•

When you purchase oil—select recommended brands and check specifications.

Fluid Capacities ITEM Refill Capacities Approx U.S. gal

Gear Box

1.2 (4.5)

Hydraulic System

8.7 (33)

10-3

Service Manual Chassis, Mast & Options ESR15N-36V ESR18N-36V ESR20N-36V ESR20HN-36V ESR23N-36V ESR23HN-36V EDR13N-36V EDR15N-36V EDR15HN-36V ESS15N-36V ESS20N-36V

2SR3300700-up 4SR3300700-up 5SR3300700-up 6SR3300700-up 7SR3300700-up 8SR3300700-up 1DR3300700-up 2DR3300700-up 3DR3300700-up 2SS3300700-up 5SS3300700-up

WENB2900-03

SAFETY PRECAUTIONS Mitsubishi Forklift Trucks Important Safety Information

CAUTION

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules and precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury, or damage to your machine. It may also be used to alert against unsafe practices.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Attention! Become Alert! Your Safety is involved.

! WARNING The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.

Mitsubishi Caterpillar Forklift America Inc. cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all-inclusive. If a tool, procedure, work method or operating technique not specifically recommended by Mitsubishi Caterpillar Forklift America Inc. is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

The following safety signs and NOTICES are used in this manual to emphasize important and critical instructions.

! The above safety alert symbol is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job.

DANGER

Indicates a imminently hazardous situation which, if not avoided, will result in death or serious injury.

Mitsubishi forklift truck dealers have the most current information available.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

TABLE OF CONTENTS 1.

INSTALLATION INSTRUCTIONS Truck How the Truck is Shipped ................................................................................................................... Uprighting a Cradled Truck ................................................................................................................. Option 1: Uprighting with Two Chain Hoist ......................................................................................... Option 2: Uprighting with One Chain Hoist and a Forklift Truck ......................................................... Mast Installation Instructions Truck System Requirements............................................................................................................... Mast Inspection .................................................................................................................................. Chain Lubrication................................................................................................................................ Upright and Carriage Position, Chain Tension.................................................................................... Channel Lubrication............................................................................................................................ Mast Mounting Bolts and Torque Specifications................................................................................. Overhead Guard Mounting Bolts and Torque Specifications.............................................................. Hydraulic Fluid Level .......................................................................................................................... Hydraulic Functions ............................................................................................................................ Pump Intake Coupling (Bleed Points).................................................................................................

1-1 1-1 1-1 1-2 1-3 1-3 1-3 1-3 1-3 1-4 1-5 1-6 1-6 1-6

GENERAL INFORMATION & FEATURES Glossary.................................................................................................................................................. 2-1 Reach Truck Serial Number Definition .................................................................................................... 2-3 General Overview ................................................................................................................................... 2-4 Jacking Truck........................................................................................................................................... 2-7 Load Wheel Replacement Guide ............................................................................................................ 2-8 Caster Adjustment .................................................................................................................................. 2-9 Brake Assembly Inspection and Adjustment........................................................................................... 2-10 Adjustment of Air Gap with Brake Applied.............................................................................................. 2-10 Friction Disc Replacement ...................................................................................................................... 2-10 Drive Assembly ....................................................................................................................................... 2-12

THEORY OF OPERATIONS How to Determine whether it is a 4 Valve Truck or a 6 Valve Truck.................................................. 3-1 4 Valve Configuration ........................................................................................................................... 3-2 Solenoid Valve Activation Chart .............................................................................................................. 3-2 Main Hydraulic Manifold ..................................................................................................................... 3-2 6 Valve Configuration ........................................................................................................................... 3-3 Solenoid Valve Activation Chart .............................................................................................................. 3-3 Main Hydraulic Manifold ..................................................................................................................... 3-3 Theory of Operation.............................................................................................................................. 3-4 Plugging in the Battery............................................................................................................................ 3-4 B- feed to ............................................................................................................................................ 3-4 Additional Safety Circuit (Emergency Power Off) .............................................................................. 3-4 Turning Key Switch (S2) ON............................................................................................................... 3-4 Can Bus Communications .................................................................................................................. 3-5 Stepping on the Operator Presence Pedal ............................................................................................. 3-5 Steer Request ......................................................................................................................................... 3-6 Electric Steer Controller .......................................................................................................................... 3-6 Travel Request .................................................................................................................................... 3-7 Plugging Request ............................................................................................................................... 3-8 Regenerative Braking ......................................................................................................................... 3-9 Lift Activation ...................................................................................................................................... 3-10 Lower Activation ................................................................................................................................. 3-10 Auxiliary Functions ............................................................................................................................. 3-11 Tilt Request ........................................................................................................................................ 3-12 Tilt Activation........................................................................................................................................... 3-12 ii

TABLE OF CONTENTS 3.

THEORY OF OPERATIONS (continued) Reach/Retract and Side Shift Activation ............................................................................................ 3-12 Side Shift Activation............................................................................................................................ 3-12 Lift Pressure Adjustment .................................................................................................................... 3-13 Emergency Lowering .......................................................................................................................... 3-13

OPERATOR DISPLAY Operator Display ..................................................................................................................................... Battery State-of-Charge .......................................................................................................................... Parking Brake.......................................................................................................................................... Clock ....................................................................................................................................................... Mode of Operation .................................................................................................................................. Travel Direction ....................................................................................................................................... Travel Speed Indicator ............................................................................................................................ Text Messaging ....................................................................................................................................... Height Selector Levels (optional) ........................................................................................................... Load Weight Display ............................................................................................................................... Thermal Monitoring .................................................................................................................................

OPERATOR DISPLAY INFORMATION & PROGRAMMING Note on Passwords ................................................................................................................................. Programming and Set Up of Performance Values .................................................................................. Console Switches and Functions............................................................................................................ Main Menu Items .................................................................................................................................... Main Menu I Parameters.............................................................................................................................................. Parameter 1 ........................................................................................................................................ Parameter 2 ........................................................................................................................................ Parameter 3 ........................................................................................................................................ Tester Master (Diagnostics) .................................................................................................................... Tester 1 ............................................................................................................................................... Tester 2 ............................................................................................................................................... Tester Slave ............................................................................................................................................ Tester 1 ............................................................................................................................................... Tester 2 ............................................................................................................................................... Tester 3 ............................................................................................................................................... Tester 4 ............................................................................................................................................... Tester 5 ............................................................................................................................................... Tester 6 ............................................................................................................................................... To Access AutoTeaching (Option)........................................................................................................... Alarms..................................................................................................................................................... To Access Alarms ............................................................................................................................... To Access Lift Limit (Option)............................................................................................................... Main Menu II Insert Password ...................................................................................................................................... Program Password.................................................................................................................................. Adjust Time and Date ............................................................................................................................. Language Select ..................................................................................................................................... Main Menu III Service Mode ..........................................................................................................................................

4-1 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-3 4-4

5-1 5-1 5-1 5-1 5-2 5-2 5-2 5-2 5-2 5-3 5-3 5-3 5-3 5-4 5-4 5-4 5-4 5-4 5-4 5-5 5-5 5-5 5-6 5-6 5-7 5-7 5-8

iii

6-1 6-1

TABLE OF CONTENTS 6.

SETTINGS AND PARAMETERS (continued) Handset—Tree Diagram.......................................................................................................................... 6-1 Handset—Menu Description ................................................................................................................... 6-1 PC Software / Handset for the 36V A/C Reach Truck To Change Controllers using the PC .................................................................................................. 6-2 To Change Parameters....................................................................................................................... 6-2 To Change Controllers using Handset................................................................................................ 6-2 SICOS Display Controller (SICOS) Flow Chart .............................................................................................. 6-8 Default Settings (Display Controller “SICOS”) .................................................................................... 6-9 Parameter Change (Display Controller “SICOS”).............................................................................. 6-11 Tester (Display Controller “SICOS”).................................................................................................... 6-12 Alarms (Display Controller “SICOS”) .................................................................................................. 6-13 Set Options (Display Controller “SICOS”) .......................................................................................... 6-14 Adjustments (Display Controller “SICOS”) ......................................................................................... 6-15 MHYRIO Valve Controller (MHYRIO) Flowchart................................................................................................ 6-16 Default Settings (Valve Controller “MHYRIO”).................................................................................... 6-17 Parameter Change (Valve Controller “MHYRIO”)............................................................................... 6-18 Tester (Valve Controller “MHYRIO”) ................................................................................................... 6-20 Alarms (Valve Controller “MHYRIO”).................................................................................................. 6-22 Set Options (Valve Controller “MHYRIO”) .......................................................................................... 6-23 Traction Controller (AC2) Traction Controller Flow Chart............................................................................................................ 6-24 Default Settings (Traction Controller).................................................................................................. 6-25 Parameter Change (Traction Controller)............................................................................................. 6-26 Tester (Traction Controller) ................................................................................................................. 6-27 Alarms (Traction Controller)................................................................................................................ 6-28 Set Options (Traction Controller) ........................................................................................................ 6-30 Adjustments (Traction Controller) ....................................................................................................... 6-31 Pump Controller (AC2/AC3) Pump Controller Flow Chart ............................................................................................................... 6-32 Default Settings (Pump Controller)..................................................................................................... 6-33 Parameter Change (Pump Controller)................................................................................................ 6-35 Tester (Pump Controller) .................................................................................................................... 6-36 Alarms (Pump Controller) ................................................................................................................... 6-37 Set Options (Pump Controller) ........................................................................................................... 6-39 Adjustments (Pump Controller) .......................................................................................................... 6-39 EPS Controller Electric Steer Controller (EPS) Flow Chart ........................................................................................ 6-40 Default Setting (Electric Steer Controller “EPS”)................................................................................ 6-41 Parameter Changes (Electric Steer Controller “EPS”) ....................................................................... 6-42 Tester (Electric Steer Controller “EPS”).............................................................................................. 6-43 Alarms (Electric Steer Controller “EPS”) ............................................................................................ 6-44 Set Options (Electric Steer Controller “EPS”)..................................................................................... 6-46 Adjustments (Electric Steer Controller “EPS”).................................................................................... 6-47

7-1 7-1 7-1 7-1 7-2 7-2

TABLE OF CONTENTS 7.

SET UP AND OPTION INSTALLATION (continued) Enabling the Maintenance Alarm ....................................................................................................... 7-3 Setting Hours for the Maintenance Alarm .......................................................................................... 7-3 Metric or English Values Displayed .................................................................................................... 7-3 Audible Travel Alarm (Optional) .......................................................................................................... 7-4 Forward Steering Kit........................................................................................................................... 7-5 Free Lift Sensor Height Detection Overview ................................................................................................................. 7-6 Height Detection Installation............................................................................................................... 7-7 Height Display Activation .................................................................................................................... 7-8 Pre-Height Selector Activation............................................................................................................ 7-8 Auto Teaching (Option) ....................................................................................................................... 7-8 Operation Instructions for Pre-Selected Shelf Height Selector .......................................................... 7-9 Lift Limit with Bypass.......................................................................................................................... 7-10 Load Weight Load Weight Installation ..................................................................................................................... 7-10 Weight Function.................................................................................................................................. 7-10 Maximum Weight Setting.................................................................................................................... 7-11 Minimum Load Adjustment ................................................................................................................. 7-11 Maximum Load Adjustment ................................................................................................................ 7-11 Keyless Entry Option Keyless Entry Programming Guide .................................................................................................... 7-13 Keyless Entry Schematic.................................................................................................................... 7-16 Cold Storage Option ............................................................................................................................. 7-17

TABLE OF CONTENTS MAST (continued) Upright Disassembly Rail Cylinders—Rollers and Shims .................................................................................................... 8-33 Cable, Hose and Chain Sheaves ....................................................................................................... 8-33 Free Lift Cylinder ................................................................................................................................ 8-33 Cable and Chain Sheaves .................................................................................................................. 8-34 Shimming............................................................................................................................................ 8-35 Lift Bracket Assembly Checks and Adjustments.................................................................................................................... 8-36 Shimming Roller Clearance Inspection—Service................................................................................................ 8-41 Checking Lower Roller Clearance with upright 6" from fully retracted position ................................. 8-41 When using a Pry Bar ........................................................................................................................ 8-41 “C” Clamp Method .............................................................................................................................. 8-42 Determining the Number of Shims needed to make roller adjustment .............................................. 8-47 Shim Adjustment ................................................................................................................................ 8-48 Lift Bracket & Fork Carriage Assembly .............................................................................................. 8-48 Fork Removal ........................................................................................................................................ 8-49 Lift Bracket Service—Fork Carriage Removal Models Equipped with Side Shift Only ............................................................................................... 8-49 Model Equipped with Tilt Only ............................................................................................................ 8-50 Servicing Lift Bracket Arm Rollers...................................................................................................... 8-51 Tilt Cylinder Overhaul—Cylinder Removal......................................................................................... 8-53 ITA Lift Bracket with Side Shifter ........................................................................................................ 8-53 ITA Lift Bracket without Side Shifter ................................................................................................... 8-54 Cylinder Removal ............................................................................................................................... 8-54 Disassembly ....................................................................................................................................... 8-55 Retainer Assembly.............................................................................................................................. 8-55 Piston Rod and Piston........................................................................................................................ 8-55 Cleaning and Inspection ..................................................................................................................... 8-56 Reassembly ........................................................................................................................................ 8-56 Retainer Assembly.............................................................................................................................. 8-56 Reach Cylinder Overhaul—Cylinder Removal Remove the Fork Carriage ................................................................................................................. 8-57 Preparation, Cleaning And Inspection ................................................................................................ 8-57 Disassembly ....................................................................................................................................... 8-59 Retainer Assembly.............................................................................................................................. 8-59 Piston Rod and Piston........................................................................................................................ 8-59 Cleaning and Inspection ..................................................................................................................... 8-59 Reassembly ........................................................................................................................................ 8-60 Retainer Assembly.............................................................................................................................. 8-60 Sideshift Cylinder Overhaul—Cylinder Removal Remove Forks .................................................................................................................................... 8-61 Preparation, Cleaning And Inspection ................................................................................................ 8-61 Disassembly ....................................................................................................................................... 8-61 Retainer Assembly.............................................................................................................................. 8-61 Cleaning and Inspection ..................................................................................................................... 8-63 Reassembly ........................................................................................................................................ 8-63 Reach and Side Shift Selector Valve Preparation ......................................................................................................................................... 8-63 Hydraulic Schematic For Mast model S/N 40HR-MT-001 through 40HR-MT-111 and For Mast model S/N 45HR-MT-001 through 45HR-MT-102 ............................................................... 8-65 For Mast model S/N 40HR-MT-112 through Present and For Mast model S/N 45HR-MT-103 through Present ......................................................................... 8-66 vi

TABLE OF CONTENTS MAST (continued) Reach and Tilt Selector Valve Disassembly ....................................................................................................................................... 8-67 Mounting Selector Valve ..................................................................................................................... 8-67 Connecting Hydraulic Plumbing ......................................................................................................... 8-68 Lift Bracket Service Side Shifter Solenoid Control Valve.................................................................................................... 8-68 Installation—Mount Selector Valve ..................................................................................................... 8-69 Install Hoses ....................................................................................................................................... 8-69 Connect Coils ..................................................................................................................................... 8-69 Servicing a Double Reach Lift Bracket............................................................................................... 8-70 Double Reach Without Sideshifter...................................................................................................... 8-70 Installing Reach Cylinders ................................................................................................................... 8-72 Reach and Tilt Selector Valve Service Disassembly ....................................................................................................................................... 8-73 Cleaning.............................................................................................................................................. 8-74 Reassembly—Solenoid Valves ........................................................................................................... 8-75 Reassembly Counterbalance Valves .................................................................................................. 8-77 Installation........................................................................................................................................... 8.77 Side Shift Selector Valve Service Disassembly ....................................................................................................................................... 8-78 Cleaning.............................................................................................................................................. 8-78 Reassembly ........................................................................................................................................ 8-79 Mast Triline Hose / Cable Routing ....................................................................................................... 8-80 Mast to Pantograph Cable Assembly.................................................................................................. 8-80 Field Replacement of Mast Triline Hoses ........................................................................................... 8-81 Mast “Auxiliary” Hydraulic Flushing Procedure ................................................................................ 8-83

HYDRAULIC SCHEMATICS Hydraulic Legend .................................................................................................................................... 4 Valve Hydraulic Schematic................................................................................................................... 6 Valve Hydraulic Schematic...................................................................................................................

9-1 9-2 9-3

10. ELECTRICAL Diagram of Controllers ............................................................................................................................ 10-1 How to Use Schematic ........................................................................................................................... 10-1 Standard Performance Schematic—Power Supply 36 Volt (1/12) .......................................................... 10-2 Standard Performance Schematic—Main Power Circuits (2/12) ............................................................ 10-3 Standard Performance Schematic—Drive Circuits (3/12)....................................................................... 10-4 Standard Performance Schematic—Steering Circuits (4/12) ................................................................. 10-5 Standard Performance Schematic—Hydraulic Control Circuits (5/12) ................................................... 10-6 Standard Performance Schematic—Hydraulic Control Output Circuits—4 Valve (6/12) (a)................... 10-7 Standard Performance Schematic—Hydraulic Control Output Circuits—6 Valve (6/12) (b)................... 10-8 Standard Performance Schematic—Keypad Switches Hydraulic Sensing Circuits (7/12) ..................... 10-9 Standard Performance Schematic—Pump & Traction Encoders/Temp Sensing Circuits (8/12) ............10-10 Standard Performance Schematic—Communications Connections (9/12) ............................................10-11 Standard Performance Schematic—Horn, Lights and Travel Alarm (10/12) ..........................................10-12 Standard Performance Schematic—Fans (11/12) ..................................................................................10-13 Standard Performance Schematic—Cold Storage Use—Option (12/12) ...............................................10-14 High Performance Schematic—Power Supply 36 Volt (1/12) .................................................................10-15 High Performance Schematic—Main Power Circuits (2/12) ...................................................................10-16 High Performance Schematic—Drive Circuits (3/12)..............................................................................10-17 High Performance Schematic—Steering Circuits (4/12).........................................................................10-18 High Performance Schematic—Hydraulic Control Circuits (5/12) ..........................................................10-19

vii

TABLE OF CONTENTS High Performance Schematic—Hydraulic Control Output Circuits—4 Valve (6/12) (a) ..........................10-20 High Performance Schematic—Hydraulic Control Output Circuits—6 Valve (6/12) (b) ..........................10-21 High Performance Schematic—Keypad Switches Hydraulic Sensing Circuits (7/12).............................10-22 High Performance Schematic—Pump & Traction Encoders/Temp Sensing Circuits (8/12)....................10-23 High Performance Schematic—Communications Connections (9/12) ...................................................10-24 High Performance Schematic—Horn, Lights and Travel Alarm (10/12)..................................................10-25 High Performance Schematic—Fans (11/12) .........................................................................................10-26 High Performance Schematic—Cold Storage Use—Option (12/12) ......................................................10-27 Standard 14.25 Schematic—Power Supply 36 Volt (1/12) .....................................................................10-28 Standard 14.25 Schematic—Main Power Circuits (2/12)........................................................................10-29 Standard 14.25 Schematic—Drive Circuits (3/12) ..................................................................................10-30 Standard 14.25 Schematic—Steering Circuits (4/12) .............................................................................10-31 Standard 14.25 Schematic—Hydraulic Control Circuits (5/12)...............................................................10-32 Standard 14.25 Schematic—Hydraulic Control Output Circuits—4 Valve (6/12) (a) ..............................10-33 Standard 14.25 Schematic—Hydraulic Control Output Circuits—6 Valve (6/12) (b) ..............................10-34 Standard 14.25 Schematic—Keypad Switches Hydraulic Sensing Circuits (7/12).................................10-35 Standard 14.25 Schematic—Pump & Traction Encoders/Temp Sensing Circuits (8/12)........................10-36 Standard 14.25 Schematic—Communications Connections (9/12)........................................................10-37 Standard 14.25 Schematic—Horn, Lights and Travel Alarm (10/12) ......................................................10-38 Standard 14.25 Schematic—Fans (11/12)..............................................................................................10-39 Standard 14.25 Schematic—Cold Storage Use—Option (12/12)...........................................................10-40

11. TROUBLESHOOTING Display Information Example .................................................................................................................. 11-1 Sicos Alarms and Warnings (MOD #1)................................................................................................... 11-1 AC-2 Alarms and Warnings (MOD #2) (MOD #5) .................................................................................. 11-2 EPS Alarms and Warnings (MOD #6) .................................................................................................... 11-4 MHYRIO Alarms and Warnings (MOD #9) ............................................................................................. 11-5 Pin by Pin Voltages ................................................................................................................................. 11-8 Coil Resistances ..................................................................................................................................... 11-18

12. PLANNED MAINTENANCE Maintenance Locations ........................................................................................................................... 12-1 Maintenance Intervals............................................................................................................................. 12-2 Recommended Oils ................................................................................................................................ 12-3 Fluid Capacities ...................................................................................................................................... 12-3

viii

INSTALLATION INSTRUCTIONS 1.

1-1 1-1 1-1 1-2 1-3 1-3 1-3 1-3 1-3 1-4 1-5 1-6 1-6 1-6

MAST INSTALLATION INSTRUCTIONS MAST INSTALLATION INSTRUCTIONS

• Anyone involved in setting up this unit should wear gloves, safety glasses, steel-toed boots, and a safety helmet. • There should be no distractions during setup of this truck. • Do not allow observers to stand nearby.

This section of the manual provides the installation instructions.

How the Truck is Shipped Before doing the inspection, take note of how the truck was prepared for shipping from the factory: • The Mast/Tractor Assembly is laid down on a skid (this is known as cradling). Usually if the Overall Lowered Height (OAL) is 107 in. (2717.8 mm) or more, the truck will be secured to a cradle and shipped lying down (with its mast horizontal). Instructions for uncradling a truck are detailed in “Uprighting a Cradled Truck” on this page. • The carriage is strapped to the truck’s baselegs (for cradled trucks). In the battery compartment. • A glass mast guard is installed (if used). • Two battery doors are strapped in place.

Items Needed To upright the truck, you will need: • A hoist with a minimum working capacity of 5 tons (4536 kg). • An assembly area with a ceiling clearance in excess of the truck’s collapsed height. • A hoist sling for the mast.

2. Position the cradled truck so it is lying directly beneath and parallel to the chain hoist rail. 3. Attach the first chain hoist to the upper cross piece of the cradled truck’s mast.

Warnings and Cautions Be sure to follow these important warnings and cautions before uprighting a cradled truck:

4. Attach the second chain hoist to the baselegs of the cradled truck. 5. Slowly raise each chain until all slack is gone.

CAUTION

Two technicians are required for erecting and assembling the unit.

! !

WARNING

CAUTION

Remove all jewelry from hands and wrists before doing the installation.

Begin lifting the chain attached to the upper cross piece of the cradled truck’s mast.

WARNING

7. Once the lifting chain reaches a certain point, the center of gravity will shift, causing the weight of the cradled truck to shift to the chain hoist attached to the baselegs.

To prevent possible injury or damage to the unit, use extreme caution when handling a cradled forklift truck. Place the mast, truck, and pallets in an open area where it will be safe to work. The truck components are heavy, unstable, and difficult to handle. Use extreme care when lifting and assembling this truck. Proceed with extreme caution.

1-1

MAST INSTALLATION INSTRUCTIONS 8. Once the weight has shifted, continue to lower the truck with the baseleg chain hoist until it is standing on the floor in the upright position.

9. Remove the chains from the base legs. 10. Remove the chain from the upper cross piece of the truck’s mast and attach it to the upper cross piece of the cradle. 11. Remove the bolts from the bottom cradle cross piece that secures the cradle to the truck’s front bumper.

6. Begin to raise the upper end of the cradle with the forks of the lifting truck. 7. Once the forks have lifted the cradle to a certain point, the center of gravity will shift. This causes the weight of the cradled truck to shift to the chain hoist.

12. Lift the cradle up and away from the truck and slowly lower it to the floor.

Option 2:Uprighting with One Chain Hoist and a Forklift Truck

8. Once the weight has shifted, continue to lower the truck with the chain hoist until the truck is standing on the floor in the upright position.

Use this procedure when one chain hoist is available. This procedure uses a forklift truck and a chain hoist, both of suitable weight capacity.

9. Remove the chain between the lifting truck carriage and the upper cross piece of the cradle. Back the lifting truck away.

1. Before lifting the truck into the upright position, remove the forks from the cradle. Use a lifting device to prevent personal injury because the forks weigh more than 50 lbs. (23 kg) each.

10. Remove the chain from the baselegs and attach it to the upper cross piece of the cradle.

2. Position the cradled truck so it is lying directly beneath and parallel to the chain hoist rail.

11. Loosen and remove the nuts holding the wooden cradle cross piece to the mast, then remove the wooden cross piece.

3. Position the forks of the forklift truck you’re using to upright the truck under the upper cross piece of the cradle.

WARNING

12. With the chain still attached to the cradle, lift the cradle up and away from the truck and slowly lower it to the floor.

WARNING

4. Attach the chain hoist to the baselegs of the cradled truck. 5. Slowly raise the chain hoist until all slack is gone.

1-2

MAST INSTALLATION INSTRUCTIONS INSTALLATION INSTRUCTIONS Truck System Requirements IMPORTANT: The mast is compatible with SAE 10W petroleum base oil per Mil. Spec. MIL-0-5606 or MIL-0-2104B only. Use of synthetic or aqueous base hydraulic oil is not recommended. The recommended hydraulic oil is Caterpillar HYDO. See service data chart in section 12 of the Planned Maintenance Section for oils required for nonstandard applications.

Chains are adjusted at the chain anchors (see Section 8, page 8-19 through 8-26). To determine equal tension, extend the unloaded mast to put the chains under tension. Then press the center of the strand with your thumb. Then press at the same place on the other chain of the pair. Each chain in a pair should have equal “give”. If the uprights or carriage are not in correct adjustment, or if the chain pairs do not have equal tension, perform the Main Lift and Free Lift Chain Adjustments.

Mast Inspection

Channel Lubrication

Check each of the following before using the Mast for the first time.

Inspect the upright channels for lubrication. If necessary, lubricate the full length of each upright channel with chassis lube or Kendall SR12X.

1. Inspect all chains for lubrication. 2. Inspect all chains for any visible damage. 3. Inspect the main lift chain adjustment for proper tension and upright position.

Mast Skewing

4. Inspect the free lift chain adjustment for proper tension and carriage position.

To adjust the Mast to eliminate skewing, perform the Mast Skewing Adjustment as described below.

5. Inspect for lubrication in the Mast upright channels.

• Extend the mast to full lift height and inspect for mast skewing.

6. Check for Mast skewing.

• If the mast bends to the right at full extension, a shim(s) needs to be removed from the left main lift cylinder rod.

Chain Lubrication The main and free lift chains have been factory lubricated using heat and pressure to force the lubrication thoroughly into the chain links. Avoid removal or contamination of this factory-applied lubrication. Do not wash, sand blast, etch, steam clean, or paint the chains for initial Mast installation. If chains need lubrication, refer to Page 8-15 Periodic Inspection Chain Lubrication.

• If the mast bends to the left at full extension, a shim(s)needs to be installed on the left main lift cylinder rod.

Snap Ring Washer

Upright and Carriage Position, Chain

Intermediate Upright

Shim

Tension Cylinder

Alignment Pin Tab

MA0980.eps

Alignment Pin

All chains should also be adjusted for equal tension of the pairs to ensure proper load distribution and mast operation.

Figure 1.11 Shimming ML Cylinders 1-3

MAST INSTALLATION INSTRUCTIONS Mast Mounting Bolts and Torque Specifications

Figure 1.2 Mast is mounted with M16 bolts from top and with M20 bolts from below. The M16 bolts are assembled from the mast side and the M20 bolts are assembled from the chassis side.

Bolt type

Torque [Nm]

Quantity [pcs]

M16 x 45 DIN 912 8.8

200(147.5122ft lbs.)

Mast from the top

Washer 16 DIN 127

Mast from the top

M20 x 40 DIN 933 8.8

400(295.02 ft. lbs.)

Mast from below

Washer 20 DIN 127

Mast from below

1-4

MAST INSTALLATION INSTRUCTIONS Overhead Guard Mounting Bolts and Torque Specifications

Figure 1.3

Bolt type M20 x 40 DIN 933 10.9

Torque [Nm]

Quantity [pcs]

400 (292.0244 ft. lbs.)

Washer, Lock 20

1-5

MAST INSTALLATION INSTRUCTIONS Hydraulic Functions

Hydraulic Fluid Level Refer to Service Data in Section 12—Planned Maintenance for recommended oils and fluid capacities.

Trucks that are transported laying down have the hydraulic oil removed. New oil must be added and air will be trapped in the system, resulting in no hydraulic function.

Note: The mast must be in the fully lowered position before filling the hydraulic tank or bleeding the hydraulic system.

Bleed out the air from the hydraulic system before putting into service. The bleed points can be found in the battery compartment as shown in the following picture.

Oil Tank, filling hole

The battery will have to be pushed aside to get to this area.

Pump Intake Coupling The picture below shows the pumps intake couplings, labeled bleed point A (standard and high performance model) and bleed point B (high performance model only), which are located in the battery compartment. To make sure the pump receives oil immediately and doesn’t run dry the first time it is turned on—loosen nut A and wait until you see oil dripping out of it. Then retighten the nut.

Oil Level

On the high performance models, both A and B need to be loosened until oil is dripping out of them. Then both nuts should be retightened.

1-6

GENERAL INFORMATION & FEATURES 2.

GENERAL INFORMATION & FEATURES Glossary Activate A component or circuit that is “activated” from its normal condition because of an application of force or electricity.

Contact Tips or Contacts The portion of a switch, relay or contactor where the circuit can be opened or closed. Contactor Assembly An electrical component consisting of an electromagnetic coil and a set of heavy contact tips.

Auxiliary Function A vehicle function other than lift/lower or travel. These include reaching, retracting, tilting and side shifting.

Contactor Coil An electromagnet used to close or open contact tips in a contactor assembly.

Battery Two or more cells connected together to a supply of electric current.

Continuity The ability to allow current flow.

BDI (Battery Discharge Indicator) An electrically controlled display showing the operator the state of battery charge.

Control Circuits Wires and components carrying low current used to signal the controllers, turn on main components, or support optional components.

Bus A data path shared by many devices (e.g. , multipoint line) with one or more conductors for transmitting signals, data, or power.

Controller A device with multiple inputs and outputs used to control a particular system or sub-system.

Bus Bar A heavy electrical conductor that carries high current from one point to another and other smaller wires are connected.

Controller Area Network (CAN) A communication protocol developed for “noisy” environments. It is used to establish an open communication system between intelligent devices.

Current The movement or flow of electricity through a conductor. A circuit must be complete for current to flow. Deactivate To change from the activated condition back to the normal (deactivated) condition. It can be caused by the application of force, the removal of force, or the removal of electricity.

Closed Circuit Wiring or components in a circuit that have a continuous path for current. Coil A component made from many circles or turns of wire used to concentrate a magnetic field.

Digital Signal A signal in which the elements may be either of two distinct values. For example high voltage, low voltage.

Conduct To allow the flow of current. Conductor A material that provides a path for current flow.

Display An electrical device that converts voltage inputs to a visual output.

Connector Part of a wire assembly or harness that connects with another wire assembly or harness. Used for ease of assembly and disassembly.

Electric Motor A device that changes electrical energy into mechanical energy to do work.

2-1

GENERAL INFORMATION & FEATURES Glossary (continued) Electrical Braking Electrically trying to rotate the drive motor opposite to the direction of truck movement.