PDF Mitsubishi Forklift Truck EDR13N-24V ESR15N-24V ESR20N-24V ESS15N-24V Service Manual by www.heydownloads.com

Service Manual Chassis, Mast & Options EDR13N-24V ESR15N-24V ESR18N-24V ESR20N-24V ESS15N-24V ESS20N-24V

1DR2300700-up 2SR2300700-up 4SR2300700-up 5SR2300700-up 2SS2300700-up 5SS2300700-up

WENB2902-01

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 Plugging in the Battery............................................................................................................................ 3-1 B+ Feed to .............................................................................................................................................. 3-1 B- Feed to ............................................................................................................................................... 3-1 Additional Safety Circuit (Emergency Power Off) .............................................................................. 3-1 Turning Key Switch (S2) ON............................................................................................................... 3-1 RS485 Bus Communications.............................................................................................................. 3-2 Stepping on the Operator Presence Pedal ............................................................................................. 3-2 Steer Request ......................................................................................................................................... 3-3 Steer Motor Controller............................................................................................................................. 3-4 Travel Request .................................................................................................................................... 3-5 Plugging Request ............................................................................................................................... 3-6 Regenerative Braking ......................................................................................................................... 3-7 Lift/Lower Request.............................................................................................................................. 3-8 Lift Activation ...................................................................................................................................... 3-8 Lower Activation ................................................................................................................................. 3-8 Auxiliary Functions ............................................................................................................................. 3-9 Tilt Request ........................................................................................................................................ 3-9 Tilt Activation ...................................................................................................................................... 3-9 Reach/Retract Request ...................................................................................................................... 3-9 Side Shift Request.............................................................................................................................. 3-9 Reach/Retract and Side Shift Activation ............................................................................................ 3-10 Reach/Retract Activation .................................................................................................................... 3-10 Side Shift Activation............................................................................................................................ 3-10

TABLE OF CONTENTS 3.

THEORY OF OPERATIONS (continued) Solenoid/Valve Activation Chart ......................................................................................................... 3-11 Lift Pressure Adjustment .................................................................................................................... 3-12 Maximum Lowering Speed Adjustment (Mechanical) ........................................................................ 3-12 Emergency Lowering .......................................................................................................................... 3-12 Electrical Lowering Speed Adjustment............................................................................................... 3-13

OPERATOR DISPLAY Operator Display ..................................................................................................................................... Self Test .................................................................................................................................................. Operating Hours...................................................................................................................................... Battery State-of-Charge .......................................................................................................................... Normal Conditions .................................................................................................................................. Fault Conditions ...................................................................................................................................... Travel Speed Indicator ............................................................................................................................ Access to Parameter Values ...................................................................................................................

4-1 4-2 4-2 4-2 4-2 4-3 4-3 4-3

BPK PROGRAMMING AND SETTINGS Section Overview .................................................................................................................................... 5-1 General Information ................................................................................................................................ 5-1 Up & Down Buttons ................................................................................................................................ 5-1 Left & Right Buttons................................................................................................................................ 5-2 Teach-In Procedure for Hall Effect Sensors............................................................................................ 5-2 Extended Menus ..................................................................................................................................... 5-3 Default Settings for Pump Controller ...................................................................................................... 5-4 Pump Controller Parameters................................................................................................................... 5-5 Pump Controller Fault Codes.................................................................................................................. 5-10 Default Settings for Traction Controller ................................................................................................... 5-12 Traction Controller Parameters ............................................................................................................... 5-13 Traction Controller Fault Codes .............................................................................................................. 5-17 Default Settings for Steering Controller .................................................................................................. 5-20 Steering Controller Parameters .............................................................................................................. 5-21 Steering Controller Fault Codes.............................................................................................................. 5-23

SETUP USING THE BPS SOFTWARE Section Overview .................................................................................................................................... General Information ................................................................................................................................ Parameter Changes ................................................................................................................................ Fault Conditions ......................................................................................................................................

6-1 6-1 6-2 6-4

SETUP AND OPTION INSTALLATION Speed Hall Effect Sensors Adjustment Overview................................................................................... Speed Hall Effect Sensors Calibration Procedure—Teach-In Method .................................................. Travel Alarm Option ................................................................................................................................ Cold Storage Option ............................................................................................................................... Reverse Light Option .............................................................................................................................. Height Display Option ............................................................................................................................. Lift Limit Cutout with Bypass Option....................................................................................................... Perform Height Calibration...................................................................................................................... Program the Lift Limit Height .................................................................................................................. Program the Half Speed Height.............................................................................................................. Program the Deceleration Ramp for Half Speed Lift .............................................................................. Weight Function Option .......................................................................................................................... Calibrate Weight Display .........................................................................................................................

iii

7-1 7-1 7-2 7-3 7-5 7-5 7-6 7-6 7-7 7-7 7-7 7-8 7-8

TABLE OF CONTENTS 7.

SETUP AND OPTION INSTALLATION (continued) Minimum Load Adjustment ..................................................................................................................... Maximum Load Adjustment .................................................................................................................... Reverse Steering Option.........................................................................................................................

7-8 7-9 7-9

MAST Contents.................................................................................................................................................. 8-1 Periodic Inspection.................................................................................................................................. 8-1 Inspection................................................................................................................................................ 8-1 500 Hour Inspection................................................................................................................................ 8-1 Troubleshooting....................................................................................................................................... 8-3 Mast Removal ......................................................................................................................................... 8-5 Cylinders Main Lift Cylinder................................................................................................................................ 8-4 Free Lift Cylinder ................................................................................................................................ 8-6 Cylinder Operation.............................................................................................................................. 8-9 Main Lift Cylinder Service................................................................................................................... 8-11 Free Lift Cylinder Service ................................................................................................................... 8-15 Mast Uprights Upright Description ............................................................................................................................. 8-17 Upright Chain Inspection .................................................................................................................... 8-18 Cracked Plates ................................................................................................................................... 8-19 Ultimate Strength Failure .................................................................................................................... 8-19 Tight Joints ......................................................................................................................................... 8-19 Chain Length Adjustments Periodic Inspection—Triple-Stage Upright (TSU) Chain Length Adjustments.................................... 8-20 Periodic Inspection—Chain Lubrication.............................................................................................. 8-22 General Guidelines ............................................................................................................................. 8-22 Chain Removal and Replacement...................................................................................................... 8-23 Lift Chains (Standard & TSU) ............................................................................................................. 8-23 Primary Cylinder/Carriage Chains (TSUs) ......................................................................................... 8-23 Other Chain Service Notes................................................................................................................. 8-23 Periodic inspection—Upright & Lift Bracket Removal & Replace Roller Shim Adjustments Lift Bracket Removal Preparation ....................................................................................................... 8-24 Removal & Replace Roller Shim ........................................................................................................ 8-25 Upright & Lift Bracket Removal .......................................................................................................... 8-26 Upright Removal ................................................................................................................................. 8-31 Upright Disassembly Rail Cylinders—Rollers and Shims .................................................................................................... 8-31 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

TABLE OF CONTENTS MAST (continued) 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 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 v

TABLE OF CONTENTS MAST (continued) 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

ELECTRICAL General Overview ................................................................................................................................... 9-1 Diagram of Controllers ............................................................................................................................ 9-2 Connector Numbering............................................................................................................................. 9-3 Pump Controller Wiring Diagram ............................................................................................................ 9-4 Pump Controller—Key Switch and Analog and Digital Outputs ............................................................. 9-5 Pump Controller—Valve 46—Tilt and Sideshift Selection ...................................................................... 9-5 Pump Controller—Valves Y41, Y43, Y44 and Y45 .................................................................................. 9-5 Pump Controller—Connection for Thermistor, Encoder and Fans.......................................................... 9-5 Pump Controller—Height Measurement, Pressure Sensor, and Top Limit Override.............................. 9-6 Pump Controller—Set Value for Speed Pump and Digital Inputs ........................................................... 9-6 Pump Controller—RS485 Interface ........................................................................................................ 9-7 Traction Controller Wiring Diagram ......................................................................................................... 9-8 Traction Controller—Key Switch, Analog Output and Digital Output for K12.......................................... 9-9 Traction Controller—Main Contactor and Additional Inputs .................................................................... 9-9 Traction Controller—Connections for the Motor (Brake, Thermistor & Encoder).................................... 9-9 Traction Controller—Buzzer and Additional Inputs X5............................................................................ 9-10 Traction Controller—Set Value for Traction Speed and Digital Inputs..................................................... 9-10 Traction Controller—RS485 Interface ..................................................................................................... 9-11 Steering Controller Wiring Diagram ........................................................................................................ 9-12 Steering Controller—Key Switch and Position Sensors.......................................................................... 9-13 Steering Controller—Safety Circuit ......................................................................................................... 9-13 Steering Controller—Digital Inputs, Digital Outputs................................................................................ 9-13 Steering Controller—Connections for the Motor (Thermistor and Encoder) .......................................... 9-13 Steering Controller—Input for the Stepper Motor at the Steering Wheel ............................................... 9-14 Steering Controller—RS485 Interface .................................................................................................... 9-14

10. ELECTRICAL SCHEMATICS How to Use the Schematic ..................................................................................................................... 10-1 Schematic (1/12)—Power Supply—24 Volt............................................................................................. 10-2 Schematic (2/12)—Main Power Circuits ................................................................................................. 10-3 Schematic (3/12)—Drive Circuit.............................................................................................................. 10-4 Schematic (4/12)—Steering Circuits....................................................................................................... 10-5 Schematic (5/12)—Hydraulic Schematic Circuits ................................................................................... 10-6 Schematic (6/12)—Hydraulic Control Output Circuits............................................................................. 10-7 Schematic (7/12)—Hydraulic Sensing Circuits ....................................................................................... 10-8 Schematic (8/12)—Pump and Traction Encoders/Temp Sensing Circuit................................................ 10-9 Schematic (9/12)—Horns, Light, and Travel Alarms ...............................................................................10-10 Schematic (10/12)—Fans .......................................................................................................................10-11 Schematic (11/12)—Communication Connections .................................................................................10-12 Schematic (12/12)—Cold Storage Use—Option ....................................................................................10-13 Location of Components on Schematic ..................................................................................................10-14

TABLE OF CONTENTS 11. HYDRAULIC SCHEMATICS Hydraulic Schematic / Diagram............................................................................................................... 11-1

12. TROUBLESHOOTING & PIN BY PIN VOLTAGES Fault Condition or Status Report Display Information Example ............................................................. 12-1 Traction Controller Fault Codes .............................................................................................................. 12-2 Steering Controller Fault Codes.............................................................................................................. 12-5 Pump Controller Fault Codes.................................................................................................................. 12-9 Pin-by-Pin Voltages Worksheet ...............................................................................................................12-11

13. PLANNED MAINTENANCE Maintenance Locations ........................................................................................................................... 13-1 Maintenance Intervals............................................................................................................................. 13-2 Recommended Oils ................................................................................................................................ 13-3 Fluid Capacities ...................................................................................................................................... 13-3

vii

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

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

INSTALLATION INSTRUCTIONS This section of the manual provides the installation instructions.

• There should be no distractions during setup of this truck.

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

• Do not allow observers to stand nearby.

Items Needed

• The Mast/Tractor Assembly is laid down on a skid (this is known as cradling). Usually if the Overall Lowered Height (OAL) is above 107 in. (2717 mm), 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 page 1-1.

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.

• The carriage is strapped to the truck’s base legs (for cradled trucks).

Option 1:Uprighting with Two Chain Hoists

In the battery compartment: • Two battery doors are strapped in place.

Use this procedure when two chain hoists of suitable weight capacities are available.

Uprighting a Cradled Truck

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.

This section includes instructions for uprighting a cradled truck. Generally, when the OAL (Overall Lowered Height) of a truck is above 107 in. (2717 mm), it will be secured to a cradle and shipped lying down (with the mast horizontal).

2. Position the cradled truck so it is lying directly beneath and parallel to the chain hoist rail.

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

3. Attach the first chain hoist to the upper cross piece of the cradled truck’s mast.

CAUTION

4. Attach the second chain hoist to the base legs of the cradled truck.

Two technicians are required for erecting and assembling the unit.

5. Slowly raise each chain until all slack is gone.

! WARNING

CAUTION

While performing the next step, be sure that the chain on the base legs 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.

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.

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 base legs.

1-1

INSTALLATION INSTRUCTIONS 8. Once the weight has shifted, continue to lower the truck with the base leg 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.

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

11. Remove the bolts from the bottom cradle cross piece that secures the cradle to the truck’s front bumper.

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 base legs 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

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.

4. Attach the chain hoist to the base legs of the cradled truck. 5. Slowly raise the chain hoist until all slack is gone.

1-2

INSTALLATION INSTRUCTIONS INSTALLATION INSTRUCTIONS

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”.

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. See page 13-3 for oils required for non-standard application.

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 No. 2 grade multipurpose (lithium base) grease. See page 13-3.

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 8-22 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

Tension 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.

Shim

Cylinder Alignment Pin Tab

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

MA0980.eps

Alignment Pin

Chains are adjusted at the chain anchors (see Section 8, page 8-20 through 8-23). To determine equal tension, extend the unloaded mast to put

Figure 1.1 Shimming ML Cylinders 1-3

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

INSTALLATION INSTRUCTIONS Overhead Guard Mounting Bolts and Torque Specifications

Figure 1.3 Bolt type M20 x 40 DIN 933 10.9 Washer, Lock 20

Torque [Nm]

Quantity [pcs]

400 (292.0244 ft. lbs.)

Only jack 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.

1-5

INSTALLATION INSTRUCTIONS Hydraulic Fluid Level

Hydraulic Functions

Refer to Service Data on page 13-3 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 point 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 pump intake coupling, labeled A, which is 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

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.

1-6

GENERAL INFORMATION & FEATURES 2.

GENERAL INFORMATION & FEATURES Glossary Activate A word used with a component or circuit. To change from the normal condition to the “activated” 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 for a supply of electric current.

Continuity Having the ability to allow current flow.

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

Control Circuits The 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 to which 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 go 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 continuity.

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.

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

Conductor A material that provides a path for current flow. Connector Part if 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 Glossary (continued) 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. RS485 Bi-directional Serial Communication line that allows the connection and communication of the controllers.

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

2-2

GENERAL INFORMATION & FEATURES Glossary (continued) Stator That part of an AC induction motor’s magnetic structure, which does not rotate. It usually contains the primary winding.

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.

Steering The method in which the reach truck turns the vehicle while transporting product within the warehouse

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).

Terminal An electrical connection point on an electrical component.

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

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

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

Varistor An electrical filter that is usually terminated across the horn connections of a mechanical horn to eliminate voltage spikes when the horn is activated.

Mitsubishi Forklift Trucks Reach Truck Serial Number Definition 2 NR 3 3 11 7 01

Serial Number Character

Definition

Defines Mast/Chassis Combination

Chassis Type

Voltage

Chassis MFG Year

mm Chassis Planned MFG Week

Chassis Family Indicator

Chassis Sequence Within MFG Week

NR • Single Reach 2 • 24V

3 • 2003

11 • Week 11

7 • Orion

01 • 1st Build

2 • 3K Standard

ND • Deep Reach

4 • 2004

3 • 3K Performance

SS • Straddle

Range 1 • 2.5K Standard

3 • 36V

5 • 2005

4 • 3.5K Standard

6 • 2006

5 • 4K Standard

7 • 2007

6 • 4.5K Standard

2-3

(01–99)

GENERAL INFORMATION & FEATURES General Overview

The pump controller is the interface between the control handle and the controllers responsible for carrying out the request (See Figure 2.1). The pump controller analyzes the information from the control handle along with information from the traction controller about 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

2-4

GENERAL INFORMATION & FEATURES increase or decrease depending on the feedback of the traction 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 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 slow or “plug” the motion of the motor. The brake is applied once the traction controller senses no movement from the traction speed encoder.

Communications: The vehicle has three “intelligent modules.” The modules communicate and share data with one another via the RS485 Bus. The communications for the vehicle will be referred to as the “RS485 Bus” system. Several messages may travel over the RS485 Bus system at any given moment. The vehicle’s internal software will determine the message priority and respond accordingly. The pump controller manages the communications between the controllers. At power on, the pump controller searches for the display on the Bus. If the display answers, the pump controller knows the system is complete and begins to play the role as master. The pump controller is the Bus master as long as it is connected to the display. If the display is not connected to the pump controller at power on, the pump controller goes into slave status until reconnected to the display, hand held console or a computer. The vehicle’s internal software will determine the message priority and respond accordingly.

Note: The operational characteristics of the traction system can be modified. Refer to “programming through the handset” or “programming through the computer” sections of this manual for additional informational. Lift: A lift 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)

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 prior to requesting travel from the control handle. (See Figure 2.1)

The pump 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 pump controller will then determine if there are constraints put on the vehicle such as lift cut out or lift interrupt. If there are lift constraints, the gauge will indicate why the lift request is being ignored. If there are no lift constraints, then the pump controller will send the lift request along with a percentage of the maximum lift speed via the RS485 Bus to the valve controller to request lift/lower solenoid to be put in the lift position.

Note: If the control handle is engaged prior to the operator presence pedal being engaged the display gauge will indicate to the operator—incorrect start. If the sequence is correct, the pump controller will send a message over the RS485 Bus to the traction controller for travel including direction and desired speed. Once the traction controller receives the message from the pump controller indicating direction and speed it will also verify 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

Note: The RS485 Bus is a bidirectional serial communication line that allows the connection and communication of the controllers. Note: The lift/lower solenoid is located on the tractor manifold (See Figure 2.1)

2-5

GENERAL INFORMATION & FEATURES 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 feed back 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.

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. 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. Note: The operational characteristics of the steer system can be modified. Refer to “programming through the handset” or “programming through the computer” sections of this manual for additional information. Auxiliary Function: The request for an auxiliary function originates from the control handle. The information is gathered from the pump controller and is distributed via the RS484 Bus to both the valve and pump controller.

Note: The RS485 Bus is a bidirectional serial communication line that allows the connection and the communication of the controllers. 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)

Depressing the operator presence switch is not required for auxiliary functions. Auxiliary functions consisting of reaching, retracting, tilt up, tilt down, side shift left, and side shift right require the displacement of the 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 cylinder. Carriage hydraulic manifold #2 directs the hydraulic fluid to either the tilt or side shift cylinders. The direction of the fluid used to tilt up or down, side shift left or right, reach or retract is determined by the directional solenoids located on the tractor hydraulic manifold. A message from the pump controller indicating an auxiliary request will engage the lift motor along with the required solenoids associated with the auxiliary function. This system utilizes the lift motor and pump assembly to control lift and auxiliary requirements.

The pump controller will require the lift/lower potentiometer to be in the neutral position upon key up or an alarm will occur. The pump 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 operational characteristics of the lift and lower system can be modified. Refer to “programming through the handset” or “programming through the computer” sections of this manual for additional information.

Note: The operational characteristics of the auxiliary system can be modified. Refer to “programming through the handset” or “programming through the computer” sections of this manual for additional information.

Steering: 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 pump controller has not sent a message to the

2-6

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.

2-7

GENERAL INFORMATION & FEATURES 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.

Installation:

M12 Front Bolt

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

2. Insert one more washer on each shaft.

Closed (Straddle) Front Load Wheel Plates

3. Slide the plate and joint onto the shafts. 4. Insert the 2 spring pins.

Washer

5. Slide the wheel plate mounting bolts through one side of the plates, and insert them into the baseleg assemblies.

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

2-8

GENERAL INFORMATION & FEATURES Load Wheel Replacement Procedure for 10.5" Diameter Wheels (See figures 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

•

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

•

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

Seal

Shaft

Spring Load Setting

Bearing Ring Screw

Retainer

Figure 2.6 10.5" Diameter Wheel Assembly

Caster Adjustment Note: 1/2"

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.

•

2-9

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 disc thickness E, (see figure 2.7) 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

Coil Resistance

8.0mm

0.3-0.4mm

23.0 (Nm)

31.4 ohms

5/16 inch

(.012–.016) inches

17 ft. lbs.

2.) Air gap should be 0.3-0.4mm (.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) 3.) Tighten screws (10) 23.0 (Nm) 17 ft. lbs.

Figure 2.8

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.

2-10

GENERAL INFORMATION & FEATURES NOTES

2-11

GENERAL INFORMATION & FEATURES Drive Assembly

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 3.

THEORY OF OPERATIONS Additional Safety Circuit (Emergency Power Off)

THEORY OF OPERATIONS Use the 24 volt schematic starting on page 10-2 of the Electrical Section.

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 K1 (K1-1).

Every connection will not be addressed in the theory of operation. To trouble shoot a particular component you will need to locate the component on the associated page number at the top of each schematic, and check the circuitry associated with it. You will need to have the schematic handy as a reference while reading text.

Should the operator need to remove the power from the system for any reason, the emergency power off switch can be depressed. With the switch depressed (down), the normally closed switch will open and remove B+ from the main contactor coil (K1).

Plugging In the Battery

With the switch in the vehicle operational (up) position, B+ will be present at the following points.

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.

B+ Feed to Page

Zone

Component(s)

10-2

1F1 Fuse

10-2

2F1 Fuse

10-2

K1 Contactor

10-9

K11 Relay Pin 4

10-3

10-2

1F2

10-2

2F2

10-2

Connection (Reference Feed To Controllers)

10-2

Connection

10-2

Connection

10-2

12F2 Fuse

10-4

Upon turning on the key switch (S2) B+ will flow to the traction motor controller and to the B+ terminal of the K1 coil. This will cause the energizing of the K1 contactor. B+ will now feed to the K2 contactor tip. The individual controllers; pump controller, steering controller and traction controller will begin their internal checks to verify that all internal hardware is functioning properly. After all internal checks have passed, the controllers will engage their respective safety circuits.

B- Feed to Component(s)

10-4

Refer to Schematic in Electrical Section starting on page 10-2.

B- will connect to several fuses, several motor controllers, the horn, the strobe light (option), the steering feedback sensor, and to optional features such as the fan:

Zone

Turning Key Switch (S2) ON

12 S1 Emergency Disconnect

Page

The RS485 Bus will now be operational and the controllers will communicate status and fault conditions. If everything checks out okay, the traction controller will activate the K2 contactor coil and the contactor tips will provide B+ to the power fuses for the motor controllers. Should an error occur causing K2 contactor to become de-energized, power to all three AC motors (pump motor, traction motor and electric steer motor) will be removed.

3-1

THEORY OF OPERATIONS B+ will also go from the traction motor controller into the electric steer controller at connector XA32 pin 1 (See Page 10-4 Zone 18). The electric steer controller will allow B+ to exit the controller at connector XA3-2 pin 2 to feed B+ to the brake pedal switch (S11) The internal switch has been designed to remove or supply power to the electric brake coil depending on the system status.

Stepping on the Operator Presence Pedal

RS485 Bus Communication

S12 (Page 10-4, Zone 20) will apply B+ to the traction motor controller which is used to determine the status of the operator presence switch. It will also supply B+ to the steering motor controller connector XA3-3pins 5 and 6 (Page 10-5, Zone 27).

Upon stepping on the operator presence pedal, two switches located underneath the pedal will be activated. S11 (Page 10-4, Zone 18) will apply B+ to the electric brake coil. The brake coil activation will now be controlled by the traction motor controller via connector XA1-4 pin 5.

RS485 is the bi-directional serial communication Bus. All controllers or “nodes” connected to the Bus have the ability of communicating with each other. The communication connections are shown on Page 10-12 of the schematic.

3-2

THEORY OF OPERATIONS Steer Request

the traction motor controller will send a message on the RS485 Bus notifying all controllers that the operator presence switch has been depressed. The steer motor controller will then gather information from the steer wheel sensor. Electrical Schematic (Page 10-5, Zone 14-17). 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 XA3-6 pins 1, 2, 3, 4, 5 and 6. The amplitude and frequency of these signals will increase, the faster the steering wheel is turned. See Figure 2.0 below.

Refer to 24 Volt Schematic in Section 10 of the Electrical Section. Prior to a steer 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. Refer to the schematic in the electrical section (Page 10-4, Zone 18). The contacts will exit the steer motor controller on connector XA3-2 pins 1and 2. The internal relay is in series with the operator presence switch and will break power to the electric brake if an internal error occurs. Once the operator presence switch is depressed

Steering Motor

Figure 3.0 Sinusoidal Output from Steering Wheel Motor

3-3

THEORY OF OPERATIONS The steer motor controller will also determine position of the drive unit at all times though the two proximity switches connected to XA3-1 pins 2 and 3 on the controller. Refer to Electrical Schematic (Page 10-5, Zone 19 and 21). With both proximity switches engaged the drive tire is centered. B+ and B- are the supply for these proximity switches. The signal that enters the steer motor controller at XA3-1 pins 2 and 3 will be B+ when the LED on the proximity switch is illuminated. The signal will be zero volts when the proximity switch leaves the metal surface and the LED are turned off.

STEER MOTOR CONTROLLER The steer motor controller determines which direction the operator wishes to steer by comparing the signals from the steering wheel motor. The channels from the steering wheel 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 coming from the steering wheel motor. After the request for steering has been accepted, the steer motor 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 motor. (See Figure 3.2) The outputs (U, V, W) from the steer motor controller are pulsed with both a positive and negative voltage. Figure 3.2 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 extreme left or right of the drive unit is monitored through the use of a proximity switch (S34) at XA3-1 pin 2. When the movement of the drive unit has activated the switch, the steer motor controller will stop pulsing the steer motor. Position of the drive tire is indicated to the operator through the display. The information is not displayed until travel is requested.

Note: The characteristics of the steering can be adjusted using the handset (BPK) or the computer PC software tool (BPS).

/ / / / / /

Left

-- -- --

Straight Ahead

\ \ \ \ \ \

Right

Figure 3.1 Steer Indicator

3-4

THEORY OF OPERATIONS Before engaging the drive motor, the traction motor controller will need to release the electric brake. The traction motor controller through the electric steer controller and operator presence switch #2 powers 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 reach 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.

Travel Request 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 the traction potentiometer R12 (Page 10-4, Zone 28) within the control handle. The 5v supply for the traction potentiometer comes from traction motor controller at connector XA1-6 pin 11. The ground will be supplied through the traction motor controller at connector XA1-6 pin 7. The wiper or varying voltage will be input to the traction motor controller at connector XA1-6 pin 6. In the neutral position, the voltage at the wiper will be nominally 2.5v. As the control handle is moved in the tractor forward direction, the voltage on the traction potentiometer should gradually increase to nominal value of 4.5v. As the control handle is moved in the forks first direction, the voltage on the traction potentiometer should gradually decrease to a nominal value of 0.5v.

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 (BM1). 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 alarm occurs forcing the traction motor controller too 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: If the traction potentiometer requires replacement, the values of the potentiometer must be learned through the handset using the Teach-In procedure. Refer to the Set Up and Options Installation of Section 7 of this manual for additional information. The traction motor controller will gather the information from the wiper of the traction potentiometer many times per second. As the voltage from the wiper of the traction potentiometer increases or decreases in voltage above the nominal neutral value of 2.5v, the traction motor controller will distribute this information over the RS485 Bus. All controllers attached to the bus decode the message. When the traction motor controller receives a travel request, it will first check the operator presence input at connector XA1-6 pin 2 for B+. If B+ is present at this input and there are no internal errors with the traction motor controller, the request will be accepted.

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 controller can vary the speed of the drive motor. (See Figure 3.4) The outputs (U, V, W) from the traction motor controller are pulsed with both a positive and negative voltage. Figure 2.2 shows the varying duty

3-5

THEORY OF OPERATIONS The traction motor controller determines speed of the motor by counting the number of pulses from a single channel over a certain period of time. 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 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 3.3, 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.

cycle along with the positive and negative values. The actual current passing through the motor will be more sinusoidal then pulsed due to the characteristics of an inductor.

Figure 3.2 Width Modulation of the AC Motor

The traction motor encoder determines the speed and direction of the motor through the pulses sent from the traction speed encoder (BM1) mounted within the motor.

A temperature sensor is located in the drive motor. The sensor for the drive motor enters the traction motor controller on connector XA1-4 at pins 2 and 6. The temperature sensor is nominally 600 ohms at 25 degrees C.

Note: The handset allows for adjusting the vehicles top travel speeds.

Plugging 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 the process of plugging. 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 slow the motion until the vehicle comes to a rest. If the request continues after the vehicle comes to rest, the motor will begin to turn in the opposite direction.

The encoder plugs into the traction motor controller at connector XA1-4 pins 3, 4, 7 and 8. Refer to Electrical Schematic (Page 10-9, Zone 12). Pin 7 is the 15v supply. Pin 8 is the ground. Pin 3 is channel A. Pin 4 is channel B. Figure 3.3 shows the pulse from channel A and B and their phase orientation to each other.

Figure 3.3 Traction Encoder Pulses (Channel A and B)

3-6

THEORY OF OPERATIONS Note: The handset allows for adjusting of the plugging characteristics. Refer to the settings section of the manual for additional information.

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 of 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 the battery voltage, the charging procedure continues.

Figure 3.4 Regenerative Braking

3-7

THEORY OF OPERATIONS Lift\Lower Request

Lift Activation

Refer to Schematic Section 10 of the Electrical Section.

Refer to the Schematic in Section 10 of the Electrical Section and Section 11 of the Hydraulic Section.

The request for lift or lower originates from the potentiometer module (R13) within the control handle. Within the potentiometer 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 connector X14A pin 8. and will be an input to the pump controller at connector XA2-6 pin 2. The potentiometer will exit the control handle at connector at X14A pins 4, 5 and 6. The 5v supply for the lift potentiometer comes from the pump controller at connector XA2-6 pin 11. The ground will be supplied through the pump controller at connector XA2-6 pin 12. The wiper or varying voltage will be an input to the pump controller at connector XA2-6 pin 6. In the neutral position, the voltage of 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 speed lower 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.

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 lift request, it will first check for internal errors. If there are no internal errors or other liming factors, like lift cut out due to a low battery the lift request will be accepted. The pump controller will control the solenoids used for the hydraulic functions. 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. The outputs (U, V, W) from the pump controller are pulsed with both a positive and negative voltage. Figure 3.2 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. At the same time the lift motor is pulsed the m2 solenoid will be activated by the pump controller at connector XA2-3 pin 5 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. (Refer to Section 10 Hydraulic Schematic). See mast section regarding the lift cylinder operation.

Note: If the lift potentiometer requires replacement, the values of the potentiometer must be learned. The pump controller will gather the information form 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 pump controller will distribute this information as a message over the RS485 Bus which would include request for lift or lower and the velocity associated with it. All controllers attached to the bus decode the message.

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

Lower Activation Refer to Electrical Schematic in Section 10 and Hydraulic Schematic in Section 11. The request and rate of lowering will be internally processed by the pump controller. The pump controller will activate the lowering proportional valve (m2) at connector XA2-3 pin 12 and cause the lift/lower spool to be moved to the lower position. The amount of time that the valve is on will

3-8

THEORY OF OPERATIONS the pump controller. When any of the micro switches is depressed the voltage on the pump controller pin for the function requested should increase to a nominal value of B+.

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 detailed further in this section. There is an electrical adjustment of the lowering function that is described in detail in the Electric Lowering Speed Adjustment on page 3-14.

Tilt Activation Refer to Electrical Schematic in Section 10 and Hydraulic Schematic in Section 11. After the request for 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 3.2 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.

See mast section regarding the lift cylinder operation.

Auxiliary Functions: The pump controller 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 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 3.5, is a chart that will show the various solenoids activated for a particular function.

The directional valve in the main hydraulic manifold is used to determine whether a tilt up or tilt down will occur. The control for these solenoids at the pump controller are at connector XA2-3 pin 10 (Tilt Down) and connector XA2-3 pin 9 (Tilt Up).

Reach/Retract Request Refer to Electrical Schematic in Section 10. The reach/retract request comes from the micro switch (S14) within the control handle. The reach switch (S14) signal will exit the control handle at connector X14B pin 4. As the reach micro switch is depressed the voltage on connector XA2-6 pin 5 on the pump controller should increase to a nominal value of B+. The retract request comes from micro switch (S15) within the control handle. The retract switch (S15) signal will exit the control handle at connector X14B pin 5. As the retract micro switch is depressed the voltage on connector XA2-6 pin 10 of the pump controller should increase to a nominal value of B+.

The pump controller is used to activate the solenoids to properly route the hydraulic fluid. As the request from the handle enters the pump controller, the pump controller will first check for internal errors. If there are no internal errors or other limiting factors then the request will be accepted.

Tilt Request Refer to Electrical Schematic in Section 9: 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 pin 6 and go to connector XA2-6 pin 4 of the pump controller. The tilt down (S17) micro switch will exit the control handle at connector X14B pin 7 and go to connector XA2-6 pin 9 of

Side Shift Request The side shift request comes from the micro switches within the control handle. The side shift left (S18) micro switch signal will exit the control handle at connector X14B pin 9 and go to connector XA2-6 pin 3 on the pump controller. The side

3-9

THEORY OF OPERATIONS shift right (S19) micro switch signal will exit the control handle at connector X14B pin 8 and go to connector XA2-6 pin 8 of the pump controller.

When any of the micro switches are depressed the voltage on the pump controller for the function requested should increase to a nominal value of B+.

Reach/Retract and Side Shift Activation Refer to Electrical Schematic in Section 10 and Hydraulic Schematic in Section 11. After the request for the reach/retract or side 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 speed of the lift motor. The outputs (U,V, W) from the pump controller are pulsed with both a positive and negative voltage. Figure 3.2 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 side shift left/right will occur. The control for

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 3.5

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

Figure 3.5

3-11

THEORY OF OPERATIONS Lift Pressure Adjustment

3. Measure the lowering time (in seconds) starting from the top until forks are in down position with maximum lowering speed. (Let’s call this measurement one).

CAUTION

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

4. Loosen the lowering speed valve locknut and back out screw two full turns.

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

5. Repeat step 3 action. 6. Compare the lowering time with the original one. If the new lowering time is longer, go to step 7. If the lowering time isn’t longer, repeat steps 4 and 5 until the result is longer than the original time.

1. Install a calibrated pressure gauge (5000 psi [34,470 KPa] in the lift pressure test port (AS). 2. Loosen the relief valve locknut and back out the high pressure relief valve screw.

7. Now tighten the lowering speed valve screw two full turns, repeat step 3 action.

3. Place a rated load on the forks.

Compare the lowering time with the original one, if the new lowering time is longer repeat step 8 action. If the new lowering time is equal to the original one, you are close to the final result and only need to tighten the lowering valve screw. Turn and lock the nut.

4. Reconnect the battery connector and turn the key switch ON. 5. Start the lift system and turn the pressure relief valve screw clockwise until the carriage starts to lift. Note the pressure required when the carriage elevates above the free lift stage. (carriage and telescopics elevated).

8. Check the lowering system for proper operation.

6. Adjust the pressure relief valve to a pressure 100 to 300 psi (689.5 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.

This adjustment has been carried out to make sure that the electrical and hydraulic functions are in balance with each other and the system is working properly.

Emergency Lowering

7. After the adjustment is complete, tighten the relief valve lockout.

1. Slowly rotate the emergency lowering valve screw clockwise until the forks lower.

8. Check the pressure again. If the value has changed, repeat this procedure until the correct pressure is obtained.

Once the forks start lowering, don’t attempt to increase the lowering speed by turning the valve screw further.

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 system for proper operation.

Maximum Lowering Speed Adjustment (Mechanical)

If the valve 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.

1. Make sure the parameters for the lowering speeds are set OK! 2. Lift the forks to the top maximum position without load.

3-12

THEORY OF OPERATIONS Lift Pressure Setting Notes: Turn OFF the key switch and disconnect the battery connector before working on lift system hydraulic connections. Battery must be fully charged and connected to the truck without jumper cables. Battery must be fully charged before performance testing. ESR15N

ESR18N

ESR20N

EDR13N

ESS15N

ESS20N

Test Load [lbs]

3000

3500

4000

2500

3000

4000

Lift Speed Loaded [fpm]

Lift Speed Empty [fpm]

Lower Speed Loaded [fpm]

110

Lower Speed Empty [fpm]

Lowering speed adjustment A

Hydraulic pressure adjustment B

Lifting capability decrease --

Lifting capability

Slower ---

increase + + Faster +

Manual, lowering

emergency

1. Lifting hydraulic pressure can be adjusted by bolt labeled B. 2. Lifting capability increases when the bolt is adjusted in the positive (+) direction. 3. Lifting capability decreases when the bolt is adjusted in the negative (-) direction.

3-13

THEORY OF OPERATIONS Parameter name

MAX LOWER

Parameter location

PUMP CONTROLLER

Electrical Lowering Speed Adjustment

4. Adjust MAX LOWER parameter upward 1 to 2 steps per attempt to find out the exact Parameter value that changes the maximum lowering speed.

Handset (BPK) operation is required. Refer to Section 5 Settings and Program. 1. Connect the handset to the pump controller and find the MAX LOWER parameter. Adjust this parameter as high as possible (above 200) in order not to disturb mechanical adjustment of 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.

2. Take the maximum load on the forks; adjust the maximum lowering speed with adjustment bolt A (see picture above). Write down speed value (1).

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.

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).

3-14

OPERATOR DISPLAY 4.

4-1 4-2 4-2 4-2 4-2 4-3 4-3 4-3

OPERATOR DISPLAY Operator Display The operator display is the control systems method of communicating to the operator. The display for the 24 volt truck is a simple display gauge. When the power is switched on, the background lights and the display is lit. Below is a picture of the operator display with a description of the individual component icons listed below.

Figure 4.1 Operator Display

Operator Display 1. Alphanumeric field for text and steering angle indicator.

2. Clock symbol flashes if the hour-meter counts; otherwise, it is off. The hour meter starts counting when either the pump motor or the steering motor has voltage. 3. Battery symbol, normally on, flashes if BDI is only at 1.

4. Snail symbol, if one of the speed reductions is active or if the BDI is below the value of parameter 175. 5. Indicates battery state-of-charge.

6. Tool Symbol—not in use in actual software. 4-1

OPERATOR DISPLAY Self Test: Self test occurs for the first two seconds after power ON. All icon symbols will be shown in the display. Self test checks all electrical components and circuits. If a problem is detected, a fault code is displayed. During self test, you will here the truck’s contactors clicking.

Battery State-of-Charge Battery state-of-charge shows the energy level which remains in the battery, based on voltage readings. The value displayed is the percentage of usable energy. When battery level drops below a predetermined level a flashing battery symbol is shown on the display. Normal Conditions: As long as there are no faults or alarms indicated, the text field shows the angle of the steered wheel. Straight Ahead

Operating Hours: After self test, the operating hours of the truck are shown for 5 seconds in the text field. The hour meter records the total hours that the pump, traction motor, and steering motor has operated.

Left

Right

4-2

OPERATOR DISPLAY Access to Parameter Values

Fault conditions: Fault code and the address of the unit where the problem exist is presented as alphanumeric characters on the display. AL xyy

Alarm

WR xyy

Warning

The operator can not access parameter values; parameter settings are set at the factory and must be set by factory trained or authorized service personnel. Parameter changes and diagnostics are made by accessing the RS485 port (serial interface) on the pump inverter, either by using the hand held operating terminal (BPK) or the Windows based PC software (BPS).

x = Address (1= traction, 2= steering, 3= pump) yy = number of fault or warning

By using the BPK or BPS, single parameters can be altered, internal values monitored, complete parameters sets loaded or saved and the fault register checked. Because there is no communication between the inverters during this time, system functionality is not completely available.

Example:

Parameters not accessible to the operator are parameters related to the adoption of the inverter to the motor (voltage, frequency, motor encoder pulses etc.) and parameters related to the safety of the system (temperature limits, frequencies etc.)

Fault codes will disable the system until the problem is corrected. If a fault code appears, contact a qualified factory trained service technician to correct the problem.

4-3

BPK PROGRAMMING AND SETTINGS 5.

BPK PROGRAMMING AND SETTINGS SECTION OVERVIEW

The handset is used for: • Setting Parameters

This section of the manual will provide an explanation and the correct settings for the controllers used on the vehicle. It will contain information of how to setup and use the handset (BPK).

• Checking Parameters • Monitoring of the Actual Drive Condition • Fault Display • Monitoring of Inputs and Outputs • Time Counter Display • Load Total Parameter Sets • Save Total Parameter Sets Every controller connected to the RS485 Bus has the above menus available to the technician to make adjustments or complete a maintenance test. Further detail will be provided for each individual controller located within this chapter. First Display The handset will display its software version and then look for any attached controllers. If a controller is found, the terminal will display the serial number and software version of the controller. Example:

SN: Version:

256704785 10000

GENERAL INFORMATION

UP & DOWN BUTTONS

Important: To connect or disconnect a BPK, PC or display to the controllers, the system must be turned off.

By pressing either the UP or DOWN button the service technician is able to scroll up or down through the parameters list. Only released parameters can be displayed and changed. Information parameters can only be displayed.

Adjustment of parameters and testing of each individual controller can be accomplished through the handset. The handset (BPK) connects to any of the controllers at X7 via the RS485 BUS. The handset is designed for the service technician to adjust certain characteristics of the vehicle. Alarms will also be visible through the use of the handset.

First Activation of the

DOWN button:

By pressing the DOWN button, the technician will see the message “Searching next parameter” displayed. During this time the unit will search for the next released parameter on the list.

5-1

BPK PROGRAMMING AND SETTINGS When the first parameter is found—the display will show the parameter text on the first line and the parameter number on the second line.

By pressing the UP button once the digit is changed from 5 to 6, setting the value to 2260 rpm.

Displayed Parameter Number: serial number 7

Change of the max Max.speed FWD speed forward

In a few seconds, the parameter number shown in the display will be replaced by the parameter value number.

6.00 Mph

If the UP button is not pressed after one second, the new value is active. As long as the digit is flashing, it is not activated and it can be reset by the Esc key.

Display of Serial Number: serial number 256704785

By pressing the Enter button all changes will be made active and the parameter will be saved.

By pressing the Esc key the parameter number will again be shown for a short period of time.

Teach-In procedure for hall effect sensors (go to parameter 251):

LEFT & RIGHT BUTTONS

Teach-in speed

Before a parameter can be changed, either the LEFT button or the RIGHT button must be pressed. The last (right) digit of the parameter value will flash. The flashing parameter value can be changed by pressing the UP button or the DOWN button.

0 By pressing either the LEFT button RIGHT button the digit zero is

or the

underlined and begins to flash. Teach-in speed

Press the LEFT button to select digits to the right that need to be changed. Continue using this method until the complete parameter has been changed.

0 Now the digit is changed to 1 by pressing the UP button Teach-in speed

Example: The right end digit is underlined and flashing: Change of the max speed forward

1 By pressing the ENTER button

Max.speed FWD

Teach-in procedure is started.

5.00 Mph

Within 15 seconds of pressing the ENTER button , the control handle must be slowly

By pressing key LEFT button five times the digit 5 is flashing: Change of the max Max.speed FWD speed forward

the

moved to the maximum forward position. The control handle is held in this position for about one second and then is pulled back to the max-

5.00 Mph

5-2

BPK PROGRAMMING AND SETTINGS List of Errors (Fault History)

imum backward position, and then back to the neutral position. After 15 seconds the digit will change from one, then back to zero indicating that the Teach-in procedure has been successfully completed.

• Displays in order the faults that have occurred in the system. • A total of 8 different controller faults can be displayed. • Repeating failures of the same kind will only be shown once.

Note: During Teach-in the output from the controller is blocked, so the motor will not turn.

daCi) (Load parameters from the Write (BPK hand held terminal (BPK) to the controller) Extended Menus

BPK) (Retrieve parameters from Read (daCi the controller to the hand held terminal (BPK)) The “Read” function will store a copy of the actual parameters within the connected controller on the hand held terminal (BPK). 8 memories, for this purpose, are available on the BPK and can be selected using the arrow keys. By using the “Write” function, it is possible to select from 8 stored parameter sets in the BPK to be downloaded to the connected controller.

By pressing the LEFT button and the RIGHT button simultaneously, the display on the handset will show the extended menus: List of Errors

(Fault history)

Write (BPK daCi)

(Load parameters from the hand held terminal (BPK) to the controller)

Read (dACi BPK)

(Retrieve parameters from the controller to the hand held terminal (BPK))

Search Device

(Search for controller addresses)

Select Address

(Select an inverter address)

Select Language

(Select language for the hand held terminal BPK)

Back to Main Menu

Search Device (Search for inverter addresses) The hand held terminal (BPK) can communicate with the all of the controllers on the same communication bus, so the actual address for each controller must be known. If the address is not known, it is possible to make a search to obtain the addresses of the connected controllers. The controllers have the following addresses: • 1 = Traction Controller (TA)

(Return to parameter setting menu)

• 2 = Steering Controller (EL) • 3 = Pump Controller (H) Note: If only one controller is connected to the hand held terminal, the search function is not used.

The menus can be selected by pressing the RIGHT button

or the

DOWN button to

Select Address (Select an inverter address) If more than one controller is connected to the BPK, the address of the controller to be addressed is selected in this menu.

go down the list, or by pressing the LEFT button

or the

UP button to go up the list.

The function is activated by pressing the ENTER button

Select Language (Select language for the hand held terminal (BPK) Two languages are available, English and German. 5-3

BPK PROGRAMMING AND SETTINGS Default Settings for Pump Controller

5-4

BPK PROGRAMMING AND SETTINGS Pump Controller Parameters List of parameters for pump controller, displayable in BPK: Text

Par. No.

Software Version Password Service Operating Hours Serial Number

Read / Write R W R/W R

Actual Speed Speed Set Value Set value PV1

R R R

10 11 16

Temp. controller Mast encoder Temperature Motor Operating State

R R R R

17 18 19 25

Lift Pot Value

Pressure Sensor

Battery Voltage

Digital Inputs 1

Digital Inputs 2

Encoder Signals

0 2 4 7

Range

0…65535 (h)

(rpm) (rpm)

Remarks

System software version for the controller. Used to adjust operating hours manually. Operating hours of the truck. Serial number of the controller, part of the complete number on the nameplate. Actual speed of the pump motor. Speed set value of the pump motor. Set value for the proportional valve measured in mA. Temperature of the pump controller in °F. Counts the pulses of the mast height encoder. Temperature of the pump motor in °F. 0= fault 1= ready 2= motor voltage on Analog value from lift/lower hall effect sensor in digits (0…1023). Voltage coming from pressure sensor.

0…1023 (*5V / 1023) 0…1023 Shows the actual battery voltage. (*100% / 512) Nominal Value = 512. Bit 0: X6.2 center switch Bit 1: X6.3 side shift left Bit 2: X6.4 tilt up Bit 3: X6.5 reach out Bit 4: X6.7 lift height reference sensor Bit 5: X6.8 side shift right Bit 6: X6.9 tilt down Bit 7: X6.10 reach in Bit 0: internal signal Bit 1: internal signal Bit 2: internal signal Bit 3: internal signal Bit 4: X5.6 top limit override Bit 5: X5.2 height encoder signal A Bit 6: X5.3 height encoder signal B Bit 7: internal signal Bit 0: X4.4 speed sensor signal B Bit 1: X4.3 speed sensor signal A Bit 2: 0 Bit 3: 0 Bit 4: A XOR B speed sensor Bit 5: A XOR B height encoder Bit 6: 0 Bit 7: 0 5-5

BPK PROGRAMMING AND SETTINGS Text

Par. No.

Digital Outputs 1

Read / Write R

Digital Outputs 2

Connector X1 Connector X2 Connector X3 Connector X4 Connector X5 Connector X6 Lift Cut-off

R R R R R R R/W

46 47 48 49 50 51 61

Minimum Current PV1 Maximum Current PV1 Falling Ramp PV1 Rising Ramp PV1 Dither PV1 Motor Off delay

R/W

Warning Temperature Controller Warning Temperature Motor Acceleration

R/W

107 122…158 (°F)

R/W R/W

Deceleration

R/W

Smoothing Curve

R/W

109 150…266 (°F) 133 500…30000 (rpm/s) 134 500…30000 (rpm/s) 137 0…9

R/W R/W R/W R/W R/W

Range

Remarks

Bit 0: X4.5 1= fan full speed Bit 1: X2.2 1= valve Y46 on Bit 2: 0 Bit 3: 0 Bit 4: LED 1= LED on Bit 5: 0 Bit 6: 0 Bit 7: 0 Bit 0: X3.6/12 1= valve Y41.1 on Bit 1: X3.5/11 1= valve Y41.2 on Bit 2: X3.7 1= valve Y45 on Bit 3: X3.8 1= valve Y44 on Bit 4: X3.9 1= valve 43.2 on Bit 5: X3.10 1 = valve 43.1 on Bit 6: X1.3 Bit 7: X1.6 Shows logic levels at inputs and outputs.

0…1

10…2000 (mA) 85 10…2000 (mA) 88 100…4000 (mA/s) 89 100…4000 (mA/s) 92 30…70 (mA) 100 0…3 (s)

0= lifting always possible. 1= lifting only possible if battery is not low (see level low battery at traction controller) or during 30 seconds after power on. Minimum current for proportional valve. Maximum current for proportional valve. Ramp for falling proportional valve current. Ramp for rising proportional valve current. Amplitude of proportional valve dither current. After deceleration to zero speed, the controller holds the motor in stand still for the adjusted time. After that time, motor current will be switched off. Controller near the maximum allowed temperature. Motor near the maximum allowed temperature. It is recommended that a KTY84-130 is used. Due to increasing set value, measured in rpm/s. Due to decreasing set value, measured in rpm/s. Smoothing the edges of acceleration. and deceleration curves. 0= no smoothing, 9 = maximum smoothing

5-6

BPK PROGRAMMING AND SETTINGS Text

Par. No.

Progression Curve

Read / Write R/W

Minimum Speed Lift

R/W

221 200…3600 (rpm) 222 200…3600 (rpm) 225 200…3600 (rpm) 226 200…3600 (rpm) 227 200…3600 (rpm) 228 200…3600 (rpm) 229 200…3600 (rpm) 230 200…3600 (rpm) 233 0…1

Maximum Speed Lift R / W

Range

138 0…100

Speed Sideshift

R/W

Speed Tilt

R/W

Speed Reachout_1

R/W

Speed Reachout_2

R/W

Speed Retract_1

R/W

Speed Retract_2

R/W

Height Display

R/W

Offset Height

R/W

Lift Limit Function

R/W

Lift Limit Height

R/W

237 0…40 (ft)

Halfspeed Height

R/W

Deceleration Lift Limit Weight display

R/W R/W

238 0…40 (ft) 239 50…32000 (rpm/s) 241 0…1

Calib weight T.in forks empty

R/W R/W

244 245

T.in cali weight

R/W

246

Teach-in Lift

R/W

251

234 0…20 (ft) 236 0…1

Remarks

Influence of the gradient of increasing set value on the acceleration ramp. 0= no progression, 100= maximum progression Minimum pump speed. Maximum pump speed. Pump speed for side shift functions, same speed for left and right. Pump speed for tilt functions, same speed for up and down. Pump speed if only reach gets activated. (X6.5) Pump speed if first reach (X6.5) and then retract (X6.10) gets activated. Pump speed if only retract gets activated (X6.10). Pump speed if first reach (X6.10) and then retract (X6.5) gets activated. 0= do not show lift height in display. 1= show lift height in display. The lift height will be displayed if mast is above definite limit (X6.7 = low). Has to be set to the height where the lift height reference sensor is mounted. 0= no lift limitation 1 = lift limitation Height at which lifting gets stopped. Lifting can then be started again by activating input X5.6 (top limit override). Height at which lifting speed gets reduced to 50%.

Deceleration ramp for speed reduction above halfspeed height. 0= do not show weight in display. 1= show weight in display. The weight will be displayed if the mast is below a definite limit (X6.7 = high) and does not move. The weight will be shown for 5 seconds. 100…5000 (lb) Actual weight of the calibration load. 0…1 Must be set to 1 to start the process, resets itself after value is read in. 100…5000 (lb) The input of a valid number activates the process. Resets itself after the value is read in. 0…1 Must be set to 1 to start the process, then the control handle must be turned slowly to the maximum and then to the minimum limits. Resets itself after 15 seconds.

5-7

BPK PROGRAMMING AND SETTINGS Parameter changes allow certain characteristics of the vehicle to become modified. Below is a list of pump controller parameters that can be changed: Lift Cut-Off

When set at 0 lifting is always possible. When set at 1 lifting is only possible if battery is not drained or during 30 seconds after power up.

Minimum Current PV1

Minimum current for proportional valve.

Maximum Current PV1

Maximum current for proportional valve.

Falling Ramp PV1

Ramp for falling proportional valve current.

Rising Ramp PV1

Ramp for rising proportional valve current.

Dither PV1

Amplitude of proportional valve dither current.

Motor Off Delay

After deceleration to zero speed the controller holds the motor still for the adjusted time.

Warning ºF Control

Controller is near the maximum allowed temperature.

Warning ºF Motor

Motor is near the maximum allowed temperature.

Acceleration

Due to increasing set value, measured in rpm/s.

Deceleration

Due to decreasing set value, measured in rpm/s.

Smoothing Curve

Smoothing of the edges of the acceleration and deceleration curves. Where 0 = no smoothing and 9 = maximum smoothing.

Progression Curve

Influence of the gradient of increasing set value. Where 0 = no progression and 100 = maximum progression.

Minimum Speed

Minimum Pump Speed Lift

Maximum Speed Lift

Maximum Pump Speed Lift

Speed Side Shift

Pump speed for side shift function, speed will be the same for left and right function.

Speed Tilt

Pump speed for tilt functions, speed will be the same for up and down function.

Speed Reachout_1

Pump speed only if reach (X6.5) is activated.

Speed Reachout_2

Pump speed, if first reach (x6.5) is activated and then retract (X6.10) is activated.

Speed Retract_1

Pump speed, if reach (X6.10) is activated.

Speed Retract_2

Pump speed, if first reach (X6.10) is activated and then retract (X6.5) is activated. 5-8

BPK PROGRAMMING AND SETTINGS Height Display

When set at 0 does not show lift height in display. When set at 1 shows lift height in display. The lift height will be displayed if the mast is above the defined limit. (X6.7) = low.

Offset Height

Set to the height where the lift height reference sensor is mounted.

Lift Limit Function

When set at 0 there is no lift limitation. When set at 1 there is lift limitation.

Lift Limit Height

Height at which lifting is stopped. Lifting can then be started again by activating input X5.6 (top limit override).

Halfspeed Height

Height where lifting speed is reduced to 50%.

Deceleration Lift Limit

Deceleration ramp for speed reduction above half speed height.

Weight Display

When set at 0 it does not show weight in display. When set at 1 it does show the weight in the display. The weight will be displayed if the mast is below a defined limit (X6.7 = high) and does not move. The weight will be shown for five seconds.

Calibrate Weight

Actual weight of the calibration load.

Teach in Forks Empty

Must be set to 1 to start the process, resets itself after value is read.

Teach in Calibrate Weight

The input of a valid number activates the process. Resets itself after the value is read in.

Teach In Lift

Must be set to 1 to start the process, then the control handle must be pulled to the right for the maximum position and then pushed downward to the minimum position before being released to the neutral position. Resets itself after 15 seconds.

5-9

BPK PROGRAMMING AND SETTINGS Pump Controller Fault Codes Below is list of fault codes for the pump controller Watchdog

This fault occurs when the internal watch dog timer times out. If there is a permanent alarm present, replace the controller.

RAM Fault

This fault occurs when there is a Random Access Memory failure. Replace the controller.

Flash Fault New Software Version

This fault occurs when new software is downloaded. Power stage and brake won’t be turned on. Reset with parameter 150.

Over Current Power Stage

This fault occurs when the battery current is too high. Motor current and brake will be switched off.

Low Voltage

This fault occurs when the voltage has fallen below a defined limit. Motor current and brake will be switched off.

Over Voltage

This fault occurs when the voltage rises above a defined limit. Motor current and brake will be switched brake will be switched off.

High Temperature Motor

This fault occurs when the motor temperature becomes too high. Motor current and brake will be switched off.

High Temperature Controller

This fault occurs when the motor controller temperature becomes too high. Motor current and brake will be switched off.

Parameter Set Value Lift

This fault occurs when the lift set value is out of range. Make a new Teach-In process

Supervision Lift Hall Effect Sensor

This fault occurs when the supervisory voltage is out of range. Value has to be has to be between 0.25 volts and 4.75 volts.

Hydraulic Inputs at Power On

This fault occurs when inputs at self test are out of range. All self test inputs should be low at power on.

Warning Temperature Motor

This fault occurs when the motor temperature comes close to the maximum allowed value.

Warning Temperature Controller

This fault occurs when the controller temperature comes close to the maximum allowed value.

Digital Outputs

If this fault occurs, all of the digital outputs will be disabled. Only the lower valve can be switched on. A short circuit, overload or a broken wire has occurred at one of the digital outputs.

EEROM

This fault occurs when there is an error with the memory. Power stage and brake won’t be switched on. Replace the controller. 5-10

BPK PROGRAMMING AND SETTINGS RS485 Communication Steering

This fault occurs when there is no communication with the steering inverter. Check the wiring and the steering controller.

RS485 Communication Drive

This fault occurs when there is no communication with the traction controller. Check the wiring and the traction controller.

RS485 Communication Display

This fault occurs when there is no communication with the display. Check the wiring and the display.

UL—check short circuit LOW

This fault occurs when there is a failure in the power stage. Power stage and brake will not be switched on.

UL—check short circuit HIGH

This fault occurs when there is a failure in the power stage. Power stage and brake will not be switched on.

UL—check phase U LOW—switches This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on. UL—check phase U HIGH—switch

This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on.

UL—check phase V LOW—switches

This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on.

UL—check phase V HIGH—switch

This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on.

UL—check phase W LOW—switches This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on. UL—check phase W High—switch

This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on.

UL—check no battery voltage

This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on.

Wrong V/F Adjustment

This fault occurs when the voltage/frequency ratio for the motor are not within parameters. Replace parameter set.

5-11

BPK PROGRAMMING AND SETTINGS Default Settings for Traction Controller

5-12

BPK PROGRAMMING AND SETTINGS Traction Controller Parameters List of parameters for traction controller, displayable in BPK: Text

Read / Write R R

Par. No.

Actual Speed Speed Set value Temperature Motor Temperature Controller BDI-Level Operating State

R R R R

10 11 16 17

R R

18 25

Throttle Value

Battery Voltage

Digital Inputs 1

Digital Inputs 2

Encoder Signals

Digital Outputs 1

Software Version Serial Number

Range

0 7 (*0.01mph) (*0.01mph)

Remarks

System software version of the controller. Serial number of the controller, part of the complete number of the nameplate. Actual speed. Set speed. Temperature of the traction motor in °F. Temperature of the traction controller in °F. Battery State-of-Charge, 1 = empty, 10 = full 0= fault 1= ready 2= motor voltage on Analog value from speed hall effect sensor in digits (0…1023). Measured in digits (0…1023), 100% = 512. Bit 0: X6.2 1= pedal full pressed Bit 1: X6.3 1= pedal half pressed Bit 2: X6.4 1= input high (lift height below ref.) Bit 3: X6.5 1= input high (no speed reduction) Bit 4: X5.3 not in use Bit 5: X5.6 not in use Bit 6: X3.6 not in use Bit 7: X3.7 not in use Bit 0: internal signal Bit 1: 0 Bit 2: internal signal Bit 3: internal signal Bit 4: X6.12 1= driver present, battery locked Bit 5: 0 Bit 6: internal signal Bit 7: X6.8 not in use Bit 0: X4.4 speed sensor signal B Bit 1: X4.3 speed sensor signal A Bit 2: 0 Bit 3: 0 Bit 4: A XOR B speed sensor Bit 5: 0 Bit 6: 0 Bit 7: 0 Bit 0: X4.5 1= brake voltage on Bit 1: X3.10 1= transistor on Bit 2: X5.4 1= buzzer on Bit 3: X1.2 1= K12 (reverse travel horn) on Bit 4: LED 1= LED on 5-13

BPK PROGRAMMING AND SETTINGS Text

Read / Write

Par. No.

Range

Remarks

Bit 5: X2.4 1= main contactor on Bit 6: 0 Bit 7: 0 Shows logic levels at inputs and outputs.

Connector X1 Connector X2 Connector X3 Connector X4 Connector X5 Connector X6 Wheel Diameter

R R R R R R R/W

46 47 48 49 50 51 60

BDI Curve

R/W

BDI-Reset BDI-Timer

R/W R/W

68 69

Warning Output

R/W

Time Brake Off

R/W

101 0…2 (s)

Warning Temperature Controller Warning Temperature Motor Acceleration

R/W

107 122…158 (°F)

R/W R/W

Motor near the maximum allowed temperature It is recommended that a KTY84-130 is used. Due to increasing set value.

Coast Distance

R/W

109 150…266 (°F) 133 1…10 (mph/s) 134 1…10 (mph/s)

Pedal Braking

R/W

Deceleration if foot pedal gets is partially released.

Smoothing Curve

R/W

135 1…10 (mph/s) 137 0…9

Progressive Curve

R/W

138 0…100

12.5…14.5 (inch) 0…10 (V) 0…655 (s) 0…7

Measured in inches. Discharge characteristic of the battery. 0 = fully discharged, 10 = fully charged. Voltage level to reset BDI to 100% after charging. Timer for discharge characteristic of the battery. 0 = not active 1 = forward 2 = backward 3 = forward or backward 4 = lift 5 = lower 6 = lift or lower 7 = forward or backward or lift or lower After deceleration to zero speed the controller holds the motor in stand still for an adjusted amount of time. After that period, the brake voltage and motor current will be switched off. Controller near the maximum allowed temperature.

Due to decreasing set value.

Smoothing the edges of acceleration and deceleration curves. 0= no smoothing, 9 = max. smoothing Influence of the gradient of increasing set value on the acceleration ramp. 0= no progression, 100= max. progression

5-14

BPK PROGRAMMING AND SETTINGS Text

Inverse Braking

Read / Write R/W

Level Low Battery Low Battery Speed

R/W R/W

Maximum Speed Forward Potentiometer Forward Y%

R/W R/W

Par. No.

Range

139 1…10 (mph/s) 175 1…5 176 10…100 (%) 211 0.2…6.3 (mph) 212 10…30 (%)

Remarks

Deceleration if control handle is moved in the opposite direction. Voltage level for speed reduction if battery is low. Value for speed reduction if battery is low. Maximum speed forward. backward

speed

Pot BWD Y%

forward

Pot FWD Y%

30% 0

Analog in 1023

10% 100%

50%

100%

adjusted in adjusted by by teach teach-in

Maximum Speed Back Potentiometer Backward Y% Slow Speed_1 Forward Slow Speed_1 Backward Slow Speed_2

R/W

Teach-In Speed

R/W

R/W R/W

216 0.2…6.3 (mph) 217 10…30 (%) 221 10…100 (%) 222 10…100 (%) 223 10…100 (%) 251 0…1

Maximum possible speed backward.

see parameter 212. Measured in % of maximum speed forward. Measured in % of maximum speed backward. Measured in %. Must be set to 1 to start the process, then joystick must be turned slowly to the forward and then to the backward limits. Resets itself after 15 seconds.

5-15

BPK PROGRAMMING AND SETTINGS Parameter changes allow certain characteristics of the vehicle to become modified Below is a list of traction controller parameters that can be changed: Wheel Diameter BDI Curve

Discharge characteristic of the battery

BDI Reset

Voltage level to reset BDI to 100% after charging battery.

BDI Timer

Timer for discharge characteristic of the battery.

Warning Output

0 = Not Active 1 = Forward 2 = Backward 3 = Forward and Backward 4 = Lift 5 = Lower 6 = Lift or Lower 7 = Forward or Backward or Lift or Lower

Time Brake Off

After deceleration to zero speed the controller holds the motor still for the adjusted time. After that, the brake voltage and motor current will be switched off.

Warning Temperature Control

Controller temperature is near the maximum allowed temperature.

Warning Temperature Motor

The motor is near the maximum allowed temperature.

Acceleration

Due to increasing set value

Coast Distance

Due to decreasing set value

Pedal Braking

Deceleration if pedal gets lifted half way.

Smoothing Curve

Smoothing the edges of acceleration and deceleration curves. Where 0 = no smoothing and 9 = maximum smoothing.

Progression Curve

Influence of the gradient of increasing set value on the acceleration ramp. Where 0 = no progression and 100 = maximum progression.

Inverse Braking

Deceleration if control handle is moved to the opposite direction.

Level Low Battery

Voltage level for speed reduction when battery voltage declines.

Low Battery Speed

Value for speed reduction when battery voltage declines.

Maximum Speed Forward

Maximum possible speed forward.

5-16

BPK PROGRAMMING AND SETTINGS Potentiometer Forward Y%

Adjusted by Teach-in

Maximum Speed Backward

Maximum possible speed backward.

Potentiometer Backward Y%

Adjusted by Teach-in

Slow Speed_1 FWD

Measured in percentage of maximum speed forward

Slow Speed_2 BWD

Measured in percentage of maximum speed backward

Slow Speed_2

Measured in percentage.

Teach-in Speed

Must be set to 1 to start the process, then the control must be pushed forward to the maximum position and then pulled backward to the minimum position before being released to the neutral position. Resets itself after 15 seconds.

Traction Controller Fault Codes Below is list of fault codes for the Traction controller: Watchdog

This fault occurs when the internal watch dog timer times out. If there is a permanent alarm present, replace the controller.

RAM Fault

This fault occurs when there is a Random Access Memory failure. Replace the controller.

Flash Fault New Software Version

This fault occurs when new software is downloaded. Power stage and brake won’t be turned on. Reset with parameter 150.

Over Current Power Stage

This fault occurs when the battery current is too high. Motor current and brake will be switched off.

Low Voltage

This fault occurs when the voltage has fallen below a defined limit. Motor current and brake will be switched off.

Over Voltage

This fault occurs when the voltage rises above a defined limit. Motor current and brake will be switched brake will be switched off.

High Temperature Motor

This fault occurs when the motor temperature becomes too high. Motor current and brake will be switched off.

5-17

BPK PROGRAMMING AND SETTINGS High Temperature Controller

This fault occurs when the motor controller temperature becomes too high. Motor current and brake will be switched off.

Pedal Level_2

This fault occurs during self test the operator presence pedal should not be depressed. Power stage will not switch on. Reset by lifting the pedal.

Encoder Supervision

This fault occurs when there is a big difference in actual speed measured and set speed. Possible fault in the sensor bearing or wiring.

High Temperature Motor

This fault occurs when the motor temperature becomes too high. Motor current and brake will be switched off.

High Temperature Controller

This fault occurs when the motor controller temperature becomes too high. Motor current and brake will be switched off.

Set Value Supervision

This fault occurs when the control handle is not in the neutral position at power on. If control handle is not in neutral position at power on, the power stage will not turn on. Reset by moving control handle into the neutral position.

Analog Input Supervision

This fault occurs when the supervisory voltage is out of range. Value has to be has to be between 0.25 volts between 0.25 volts and 4.75 volts.

Wrong V/f Adjustment

This fault occurs when the voltage/frequency ratio for the motor are not within parameters. Replace parameter set.

Wrong Set Value Characteristics

This fault occurs when parameters of the set value curve are not realistic. Create a new Teach-in process.

Wrong Slip Parameters

This fault occurs when the parameters of the slip curve are not realistic. Adjustments of parameter 62 through 65.

Digital Outputs

If this fault occurs, all of the digital outputs will be disabled. Only the lower valve can be switched on. A short circuit, overload or a broken wire has occurred at one of the digital outputs.

UL—check short circuit LOW

This fault occurs when there is a failure in the power stage. Power stage and brake will not be switched on.

UL—check short circuit HIGH

This fault occurs when there is a failure in the power stage. Power stage and brake will not be switched on.

5-18

BPK PROGRAMMING AND SETTINGS UL—check phase U LOW—switches

This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on.

UL—check phase U HIGH—switch

This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on.

UL—check phase V LOW—switches

This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on.

UL—check phase V HIGH—switch

This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on.

UL—check phase W LOW—switches

This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on.

UL—check phase W High—switch

This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on.

UL—check no battery voltage

This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on.

5-19

BPK PROGRAMMING AND SETTINGS Default Settings for Steering Controller

5-20

BPK PROGRAMMING AND SETTINGS Steering Controller Parameters List of parameters for steering inverter, displayable in BPK: Text

Read / Write R R

Par. No.

Operating Hours Actual Speed Speed Set Value Actual Set Speed Temperature Controller Operating State

R R R R R R

9 10 11 18 24 25

(h) (rpm) (rpm) (rpm)

Wheel Angle Battery Voltage

R R

26 34

(*0.1°)

Digital Inputs 1

Digital Inputs 2

Digital Outputs

Software Version Serial Number

Range

0 7

Remarks

System software version of the controller. Serial number of the controller, part of the complete number of the nameplate. Operating hours of the steering unit. Actual speed of the shaft of the steering motor. Set speed of the shaft of the steering motor. Actual speed of the steering wheel. Temperature of the steering controller in °F. 0= fault 1= ready 2= motor voltage on Actual angle of the wheel. Measured in digits (0…1023), 100% = 512 Bit 0: X3.3 Bit 1: X3.4 Bit 2: X3.5/6 Bit 3: safety circuit 0= on Bit 4: safety circuit 0= input voltage (X2.1) ok Bit 5: internal signal Bit 6: safety circuit 0= over current Bit 7: 0 Bit 0: X3.1 Bit 1: X3.2 Bit 2: X1.2 sensor A Bit 3: X1.3 sensor B Bit 4: X1.4 sensor C Bit 5: 0 Bit 6: 0 Bit 7: 0 Bit 0: internal value for X3.9 Bit 1: internal value for X3.10 Bit 2: internal value for X3.11 Bit 3: internal value for X3.12 Bit 4: 0 Bit 5: 0 Bit 6: 0 Bit 7: 0 Bit 8: X3.9 1= transistor on (low) Bit 9: X3.10 1= transistor on (low) Bit 10: X3.11 1= transistor on (low) Bit 11: X3.12 1= transistor on (low) Bit 12: 0 Bit 13: 0 Bit 14: 0 Bit 15: 0 5-21

BPK PROGRAMMING AND SETTINGS Text

Connector X1 Connector X3 Connector X5 Warning Temperature Controller Warning Temperature Motor Gear Steer/Wheel

Read / Write R R R R/W

Par. No.

R/W

43 44 45 107

Range

Remarks

Shows logic levels at inputs and outputs.

0…174 (°F)

Controller near the maximum allowed temperature.

109

0…311 (°F)

Motor near the maximum allowed temperature. It is recommended that a KTY84-130 is used.

R/W

142

0.1…0.3

R/W

145

0.1…0.3

R/W

146

0.1…0.3

Total ratio between shaft of the steering motor and steered wheel. Ratio between driving wheel and steering wheel at low speeds. Ratio between driving wheel and steering wheel at high speeds.

R/W

147

0…100 (%)

Maximum traction speed for full ratio (par. 145).

R/W

148

0…100 (%)

Forward_Reverse

R/W

164

Minimum traction speed for reduced ratio (par. 146). Phase sequence of steering wheel encoder (step per motor). 0= normal, 1= inverted

ratio ratio driving drivingwheel/ wheel/ steering steeringwheel wheel Pa 145

Pa 146

Pa 147

Pa 148

Figure 5.1

5-22

100%

traction speed traction speed

BPK PROGRAMMING AND SETTINGS Parameter changes allow certain characteristics of the vehicle to become modified. Below is a list of traction controller parameters that can be changed. Warning Temperature Control

Controller is near the maximum allowed temperature.

Warning Temperature Motor

Motor is near the maximum allowed temperature.

Gear Steer/Wheel

Total ratio between shaft of the steering motor and steering wheel.

Ratio between driving wheel and steering wheel at low speeds.

Ratio between driving wheel and steering wheel at high speeds.

Maximum traction speed for full ration (parameter 145)

Minimum traction speed for reduced ratio (parameter 146)

Forward_Reverse

Phase sequence of steering wheel encoder (stepper motor)

Steering Controller Fault Codes Watchdog

This fault occurs when the internal watch dog timer times out. If there is a permanent alarm present, replace the controller.

RAM Fault

This fault occurs when there is a Random Access Memory failure. Replace the controller.

Flash Fault New Software Version

This fault occurs when new software is downloaded. Power stage and brake won’t be turned on. Reset with parameter 150.

Signal Motor Encoder or Motor Blocked This fault occurs when no signals are received from the motor’s incremental encoder although the motor is supplied with current. Check the encoder and wiring. Excess Temperature Controller

This fault occurs when the controller temperature becomes too high. Motor current and brake will be will be switched off.

Excess Temperature Motor

This fault occurs when the motor temperature becomes too high. Motor current and brake will be switched off.

Low Voltage

This fault occurs when the voltage has fallen below a defined limit. Motor current and brake will be switched off. 5-23

BPK PROGRAMMING AND SETTINGS Over Voltage

This fault occurs when the voltage rises above a defined limit. Motor current and brake will be switched brake will be switched off.

Plausibility Error

This fault occurs when the supervision between the calculated steering angle and signals from the proximity switches has detected an unacceptable combination. Check the mechanical connections and the switches.

Inductive Switch

This fault occurs when the there is an unacceptable combination between the three proximity switches.

Over Current Power Stage

This fault occurs when the battery current is too high. Motor current and brake will be switched off.

Safety Circuit (internal)

This fault occurs when the self test has detected a fault inside the safety circuit, replace the inverter.

Voltage Supervision UZK

This fault occurs when the battery voltage is above a defined limit, motor current and brake will be switched off.

Redundant Digital Inputs

This fault occurs when fault code 13 shows that either X1.1 was different to X1.3 or X1.2 was different to X1.4 for more than 50 milliseconds. For safety reasons these digital signals have to come in at two inputs at the same time: X1.1 with X1.3 and X1.2 with X1.4.

Supervision Incremental Encoder

This fault occurs when there is a problem detected with the stepper motor inside the steering wheel or the wiring.

Wrong u/f Adjustment

This fault occurs when the current/frequency ratio for the motor are not within parameters. Replace the parameter set.

Low Pass Filter—Steering Encoder

This fault occurs when the self test of the stepper motor has detected an internal fault. Replace the inverter.

Current Consumption Motor Encoder

This fault occurs when the current of the incremental encoder in the motor (sensor bearing) is too high or too low. Check the encoder and the wiring.

Faulty EEPROM

This fault occurs when there is an error with the memory. Power stage and brake won’t be switched on. Replace the controller.

Wrong Steering Ratio Parameter

This fault occurs when the steering ratio parameters are out of parameters. Reference Figure 5.1.

Overcurrent Safety Circuit

This fault occurs when the current in the safety circuit is too high. System has switched off the safety circuit, but steering is still possible.

5-24

BPK PROGRAMMING AND SETTINGS Breakage of Safety Circuit

This fault occurs when there is no input voltage for the safety circuits, but steering is still possible.

UL—check short circuit LOW

This fault occurs when there is a failure in the power stage. Power stage and brake will not be switched on.

UL—check short circuit HIGH

This fault occurs when there is a failure in the power stage. Power stage and brake will not be switched on.

UL—check phase U LOW—switches

This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on.

UL—check phase U HIGH—switch

This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on.

UL—check phase V LOW—switches

This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on.

UL—check phase V HIGH—switch

This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on.

UL—check phase W LOW—switches

This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on.

UL—check phase W High—switch

This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on.

UL – check no battery voltage

This fault occurs when there is a failure in the power stage during power on. Power stage and brake will not be switched on.

Break Safety Circuit at Power-Up

This fault occurs when no input voltage is found for the safety circuit at power up. Self test is not possible.

Warning Temperature Motor

This fault occurs when the temperature of the motor comes close to the maximum allowed value.

Warning Temperature Inverter

This fault occurs when the temperature of the controller comes close to the maximum allowed value.

5-25

SETUP USING THE BPS SOFTWARE 6.

6-1 6-1 6-2 6-4

SETUP USING THE BPS SOFTWARE Section Overview

The controllers are connected to each other via the RS485 Bus connection. Individual controllers can be addressed from the software by choosing the correct address. • 1 = Traction Controller (TA) • 2 = Steering Controller (EL) • 3 = Pump Controller (H)

This section of the manual will provide an explanation of how to use the BPS for the set up of the controllers.

GENERAL INFORMATION Important: To connect or disconnect a BPK, PC or display to the controllers, the system must be turned off.

Extended Functions: • Load and retrieve total parameter sets to and from the controller. • Load new software down to the controller. • Compare parameter sets.

The software communicates to the controllers through the COM-port of the PC. To connect to the RS485 on the controller, a converter box RS232 to RS485 must be used.

For complete functionality of the software setup tool, a set of data for each controller software and language must be available. The data should contain the following information. • Parameters that can be changed and the matching limitations. • Parameters that can be displayed online and the matching format. • Text to be used for default description.

The converter from RS232 to RS485 to be used between the RS232 (COM-port) and the RS485 on the controller is available as an accessory. On the RS232 side, the connection to the PC can be done with a 1:1 extension cable (Sub-D9 pole). The converter is supplied from the controller.

6-1

SETUP USING THE BPS SOFTWARE

Parameter Changes:

Software version of the connected inverter

Changeable parameters

DiagnosticParameters (Read)

Actual Fault

Fault History

Inverter

When started the setup tool will search for a connected controller on the COM-port. The search will start at address 1. If more then one controller is connected, the one with the lowest address will be shown.

6-2

SETUP USING THE BPS SOFTWARE If connection to another controller is desired, a double click on the “controller address” field will open a dialog box where other connected controllers can be selected.

In the upper window of the setup tool the changeable parameters can be addressed. By double clicking on a parameter, a dialog box will appear.

If a new value is entered and acknowledged by pressing the OK button, the value is immediately transferred to the controller and stored in the controllers EEPROM.

6-3

SETUP USING THE BPS SOFTWARE Fault Conditions A fault in the controller will be immediately indicated. The field “Actual Fault” in the BPS program will change to red and flash the fault code. By double clicking on the fault code field, the information box will show the fault code description.

A fault code or a warning is displayed here

The fault code description is shown, and can be reset, when the cause has been found.

6-4

SETUP USING THE BPS SOFTWARE In the fault history memory, the last eight different faults are stored with a time stamp. If the same fault keeps reoccurring, the fault will only be shown once with the latest time stamp. This is to avoid filling up the memory with reoccurring faults.

6-5

SETUP AND OPTION INSTALLATION 7.

7-1 7-1 7-2 7-3 7-5 7-5 7-6 7-6 7-7 7-7 7-7 7-8 7-8 7-8 7-9 7-9

SETUP AND OPTION INSTALLATION This section of the manual will provide instructions regarding calibration of the traction and the lift lower speed hall effect sensors, and how to set up a vehicle that is already functional. In the unlikely event that a controller has to be replaced, see Section 9 for replacement of the controller. Reference section 5 to obtain information to program the controllers.

To calibrate the speed hall effect sensor module: 1. Verify that the handle assembly has no mechanical binding. 2. With the key switch off connect the handset or PC to X7 the pump controller. 3. Go to (Parameter 251) Teach-In procedure for the hall effect sensors.

Speed Hall Effect Sensors Adjustment Overview:

Teach-In procedure for Hall effect sensors (go to Parameter 251):

Whenever a speed reference hall effect module R12 (Traction Speed and Direction Sensor Potentiometer) or R13 (Lift/Lower Potentiometer) has been changed, it is necessary to calibrate the control system. The neutral position is preset but the minimum and maximum activation values must be calibrated.

Teach-in speed 0 By pressing either the LEFT button RIGHT button the digit zero is

or the

The calibration will determine the amount of the handle movement that is needed to occur prior to the pump controller requesting a lift or lower request function from itself, or a traction speed and direction function from the traction controller.

underlined and begins to flash.

Speed Hall Effect Sensors Calibration Procedure—Teach-In Method

Change the digit from 0 to 1 by pressing the UP button .

Teach-in speed 0

When calibrating the speed hall effect sensors to the minimum values the position of the handle should be in the position where there is a slight tension on the spring. When properly adjusted the handle will return to the neutral position and a request for a function should not occur. When calibrating the handle for the maximum values the position of the handle should be to the full range of movement for the corresponding item selected. Excessive force should not be applied to the handle.

Teach-in speed 1 By pressing the ENTER button In procedure is started.

the Teach-

R12 Set Up Within 15 seconds the control handle must be slowly moved to the maximum forward position. Hold the control handle in the maximum forward position for about one second, and then pull the handle to the maximum backward position before returning to the neutral position. After 15 seconds the digit will return back to zero, indicating that the Teach-In procedure is completed.

The controllers work together with two speed hall effect sensor elements, one for pump speed (pump controller) and one for traction speed (traction controller). The sensor is connected to three pins: Positive – X6.11, Negative – X6.7 with the reference on X6.6. A rough mechanical adjustment of the speed hall effect sensor is sufficient. The final adjustment of the maximum and minimum position of the speed hall effect sensor is completed by the Teach-In function system setup (Parameter 251).

R13 Set Up Within 15 seconds the control handle must be slowly moved to the maximum position (left). Hold the control handle in the maximum posi7-1

SETUP AND OPTION INSTALLATION Hardware For Travel Alarm

tion for about one second, and then pull the handle to the (right) minimum position before returning to the neutral position. After 15 seconds the digit will return back to zero, indicating that the Teach-In procedure is completed. Note: The output of the controller is blocked during Teach-in, so the motor will not turn. 4. Test for correct operation of lift and travel after calibration is completed.

Bolt Type

Torque (Nm)

Quantity (pcs)

M6 x 16, DIN 912

Washer 6, DIN 9021

Nut, M6, DIN 985

Parameter Name

Warning Output

Parameter Location

Traction Controller

Available Values

0, 1, 2, 3, 4, 5, 6, and 7

Parameter 72

Travel Alarm Alarm option requires mounting box. Travel alarm is connected to the wire harness (connector XE55). Handset operation is required. Refer to Section 5 Settings.

Select the desired function for the audible travel alarm: 0 = OFF (default) 1 = ON in Forward Traction 2 = ON in Backward Traction 3 = ON in Traction Forward and Backward 4 = ON in Lifting 5 = ON in Lowering 6 = ON in Lifting and Lowering 7 = ON in Forward / Backward / Lifting / Lowering

7-2

SETUP AND OPTION INSTALLATION Cold Storage Option 7

Uninstall panels

Tie cold storage wire harness to existing wire harness with 10 cable ties. Connect 9F1:2 to fusebox Connect X2:-to insulation support Disconnect X12:3 from key switch Connect XS2.1:44.2 to key switch Connect XS2.1:44.1 to X12:3

Disconnect battery

23 Connect battery

21 Install panels

Uninstall display

19 Install display, torque 10 NM

Uninstall pedal

18 Install pedal, torque 25 NM

Open doors or uninstall sideplates

22 Close doors or 4

install sideplates

Uninstall floor plate

20 Install floor plate

12 Connect wires, connectors X342

11 Install Thermostat with 2 screws

9 M3x6 DIN 7985 torque 1 Nm

Connect wires, connectors X343

M3x6 DIN 7985 torque 1 Nm

13 Connect wires, connectors S342

Install 120 R Resistor with 2 screws

7-3

Install resistor 120 R with two screws

SETUP AND OPTION INSTALLATION

• 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

M3x35 DIN 7985 bolts and M3 DIN 985 nuts, torque 1 Nm

14 Install resistor 120 R to plate with 2 pcs M3x6 DIN 7985, torque 1 Nm Connect wires, connectors X344

17 15 Uninstall micro switches. 16 Install micro switches and resistor plate with 2 screws and 2 nuts

7-4

SETUP AND OPTION INSTALLATION Reverse Light Option

Reverse light option requires mounting box.

The reverse warning light is connected to the wire harness (connector XE55). Handset operation is required. Refer to BPK Program and Settings. Parameter name

Warning output

Parameter number

72 (traction inverter)

Available values

0, 1, 2, 3, 4, 5, 6 and 7

Height Display Option To activate the height display, pulse encoder B41 must be assembled to the mast and connected to the wire harness (connector XB41). Handset operation is required. Refer to BPK Program and Settings. Parameter name

Height display

Parameter number

233 (pump inverter)

Available values

0 and 1

Select the status of the height display: 0 = no height is shown on the display (default). 1 = height is shown on the display.

7-5

SETUP AND OPTION INSTALLATION

Perform height display calibration using handset. Parameter name

Offset height

Parameter number

234 (pump inverter)

Available values

0…20 ft

1. 2. 3. 4. 5. 6. 7.

Lift forks until the red LED of the free lift sensor (S43) turns off. Turn off the key switch. Measure the distance between floor level and upper face of the forks. Turn on the key switch. Select parameter “Offset height”. Insert offset value (the measured value in step 3). Recycle key switch and verify the height display reading.

Lift Limit Cutout with Bypass Option To activate the lift limit cutout, pulse encoder B41 must be assembled to the mast and connected to the wire harness (connector XB41). Lift limit is activated through handset: Parameter name

Lift limit function

Parameter number

236 (pump inverter)

Available values

0 and 1

Select the status of the lift limit: 0 = no lift limit (default). 1 = lift limit.

Perform Height Calibration: Parameter name

Offset height

Parameter number

234 (pump inverter)

Available values

0…20 ft

1. 2. 3. 4. 5. 6.

SETUP AND OPTION INSTALLATION

Program the Lift Limit Height: Parameter name

Lift limit height

Parameter number

237 (pump inverter)

Available values

0…40 ft

1. 2. 3. 4. 5. 6. 7.

Lift forks to the desired limit height. Turn off the key switch. Measure the distance between floor level and upper face of the forks. Turn on the key switch. Select parameter “Lift limit height”. Insert limit height value (the measured value in step 3). Test lift limit cutoff and bypass: • Lift forks until they stop at the desired height. • Press blue bypass button on the panel. • Continue lifting.

Program the Half Lift Speed Height: Parameter name

Half speed height

Parameter number

238 (pump inverter)

Available values

0…40 ft

1. Select parameter “Half speed height”. 2. Set height value 1 ft below lift limit height (measured value in step 3 above). 3. Test lift limit cutoff and bypass: • Lift forks until they stop at the desired height. • Press blue bypass button on the panel. • Continue lifting.

Program the Deceleration Ramp for Half Lift Speed: Parameter name

Dec. lift limit

Parameter number

239 (pump inverter)

Available values

50…32000 rpm/s

1. Select parameter “Dec. lift limit”. 2. Set proper value. 3. Test lift limit cutoff and bypass: • Lift forks until they stop at the desired height. • Press blue bypass button on the panel. • Continue lifting.

7-7

SETUP AND OPTION INSTALLATION

Weight Function Option To activate the weight function, pressure sensor B42 must be assembled to the hydraulic system and connected to the wire harness (connector XB42). Handset operation is required. Refer to BPK Program and Settings. Parameter name

Weight display

Parameter number

241 (pump inverter)

Available values

0 and 1

Select the status of the weight function 0 = do not show weight in display (default). 1 = show weight in display. Weight will be displayed when the mast is below lift limit height.

Calibrate Weight Display Handset operation is required. Refer to BPK Program and Settings. Parameter name

Calib. Weight

Parameter number

244 (pump inverter)

Available values

100…5000 lbs.

Set the actual weight of the calibration load 100…5000 lbs.

Minimum Load Adjustment Handset operation is required. Refer to BPK Program and Settings. Parameter name

Teach in forks empty

Parameter number

245 (pump inverter)

Available values

0 and 1

Select the status of the “teach in” function 0 = no “teach in” (default). 1 = start “teach in” process. 1. Enter parameter value “1” to start “teach in” process. 2. Parameter resets itself after the value has been read in.

SETUP AND OPTION INSTALLATION

Maximum Load Adjustment Handset operation is required. Refer to BPK Program and Settings. Parameter name

Teach in calib. weight

Parameter number

246 (pump inverter)

Available values

100…5000 lbs.

1. Enter a valid number (100…5000), which activates “teach in” process. 2. Parameter resets itself after the value has been read in.

Reverse Steering Option Handset operation is required. Refer to BPK Program and Settings. Parameter name

Forward_reverse

Parameter number

164 (steering inverter)

Available values

0 and 1

Select the status of the steering direction 0 = normal (default). 1 = inverted.

7-9

MAST 8.

MAST 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 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

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.

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

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.

PERIODIC MAINTENANCE 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 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,

3. Lubricate the full length of each mast upright rail. 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-to-side clearance should be 0.020 in. (.5 mm) max. across the tightest point throughout the travel of the upright. If shimming is required.

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

Inspection

5. Check chains for wear and stretch.

Perform the following at the beginning of each work shift:

6. Check the backrest capscrews for tightness. Tighten capscrews to 145 ft.-lbs. (195 Nm).

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.

8-1

MAST NOTES ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________

8-2

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

a) Unplug hose or replace.

b) Insufficient oil.

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) Bent or jammed plunger.

c) Repair or replace as necessary.

a) Plugged piston check valve.

a) Unplug check valve or replace.

b) Truck relief valve setting low.

b) Raise truck relief setting to specified level

c) Over capacity.

c) Reduce load to specified capacity.

d) Mechanical bind due to bent plunger or bad rollers

d) Remove mechanical bind by replacing/freeing plunger and rollers.

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

Loaded

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.

a) Tighten or replace as necessary.

b) Truck valve defective-cycle to full lift height to verify.

b) Repair or replace truck valve.

c) External leaks at retainer.

c) Replace all cylinder seals.

d) Piston check valve leaking.

d) Replace check valve.

a) Sticky or defective truck relief 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.

8-3

MAST Main Lift Cylinder

Old Style

New Style

Retainer

Retainer Retainer Seals

Retainer Seals

O-Ring Wear Ring

Back-Up O-Ring Back-Up O-Ring

Shell

Rod

Spacer

Piston Seal Wear Ring Split Piston Spring

Retainer

Plug

Retainer

Ball

MA2974.eps MA2213.eps

Bleed Screw

Washer

Figure 8.1 8-4

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 8.1) 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. 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. 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.

8-5

Old Style

Free Lift Cylinder

New Style

Retainer Retainer

Retainer Seals Retainer Seals

O-Ring Back-Up

Back-Up

O-Ring

O-Ring Rod Shell

Rod Shell

Set Screw Nylon Plug Piston Back-Up

Back-Up O-Ring

Set Screw

Piston Seal W/O-Ring

Ball

Wear Ring

Seal W/O-Ring Piston

Retainer

Wear Ring Retainer

Plug Plug

MA2975.eps

MA2212.eps

Figure 8.2 8-6

MAST Free Lift Cylinder Description The free lift cylinder (see Figure 8.2) 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. 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 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. 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.

8-7

8-8

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 hydraulic fluid out through the hydraulic fuse/cushion valves.

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: 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.

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.

2. Hydraulic fluid flows to the lowering control valve where it is restricted at a controlled speed determined by the load being handled.

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.

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.

8-9

MAST Main Lift Cylinder

Old Style

New Style

Retainer

Retainer Retainer Seals

Retainer Seals

O-Ring Wear Ring

Back-Up O-Ring

Shell

Rod

Shell Rod

Spacer

Piston Seal Wear Ring Split Piston Spring

Retainer

Plug

Retainer

Ball

MA2974.eps

MA2213.eps

Bleed Screw

Washer

Figure 8.3 8-10

MAST Main Lift Cylinder Service

Cleaning and Inspection

Main Lift Cylinder Disassembly

1. Discard old seals, o-rings, back-up rings, wiper and lock washer.

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.

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

2. Wash remaining parts in a stoddard type cleaning solvent and dry with a clean shop rag. 3. Inspection threaded parts for damage. 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.

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.

4. Pull piston rod from barrel assembly. •

Remove spacer and split piston from piston rod.

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

8-11

8-12

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 8.3.

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 8.3. 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.

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

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 backup ring into the outer groove on the retainer. Install lock washer on outside of retainer.

8-13

MAST Old Style

Free Lift Cylinder

New Style

Retainer Retainer

Retainer Seals Retainer Seals

O-Ring Back-Up

Back-Up

O-Ring

O-Ring Rod Shell

Rod Shell

Set Screw Nylon Plug Piston Back-Up

Back-Up O-Ring

Set Screw

Piston Seal W/O-Ring

Ball

Wear Ring

Seal W/O-Ring Piston

Retainer

Wear Ring Retainer

Plug Plug

MA2975.eps

MA2212.eps

Figure 8.4 8-14

MAST Free Lift Cylinder Service

Cleaning and Inspection

Free Lift Cylinder Disassembly

1. Discard old seals, o-rings, back-up rings, wiper and lock washer

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

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

2. Wash remaining parts in a Stoddard type cleaning solvent and dry with a clean shop rag. 3. Inspect threaded parts for damage. 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.

3. Using a spanner wrench or a bronze (brass) drift, remove retainer assembly from cylinder barrel. 4. Remove and discard lock washer, back-up ring and o-ring located inside cylinder retainer. 5. Remove and discard both o-rings and backup 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 8.4.

8-15

MAST Free Lift Cylinder Reassembly

Note:

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 8.4. 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.

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.

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. 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. 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.

8-16

MAST MAST UPRIGHTS Upright Description Outer Upright Assembly

Pantograph Rollers

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 8.5

8-17

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:

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 8.6.

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 8.6. 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 8.6. 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 integrity between outside plates and pins has been altered, it cannot

Figure 8.6 8-18

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.

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).

MA1002.eps

Figure 8.7 Arc-like cracks in plate are a sign of stress corrosion.

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.

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.

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 arch-like pattern between the holes on the plate.

Corrosion fatigue is the combined action of an aggressive environment and a cyclic stress (not a static stress alone, as in stress corrosion).

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.

Corrosion fatigue is not the same as stress corrosion.

Ultimate Strength Failure This type of failure is caused by overloads far in excess of the design load. See Figure 8.8.

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 8.8

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 8.13, Page 826. 8-19

MAST Chain Length Adjustment

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. • Do not reach through open areas of the upright. • Never attempt to move or align the rails by hand. Use a prybar.

Periodic Inspection Triple-Stage Upright (TSU) Chain Length Adjustments 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: •

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.

•

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

•

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

Failure to follow these warning could result in serious injury.

IMPORTANT •

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

•

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

To adjust the cylinder lift chains on a TSU use the following illustration and procedures: 1. Set the upright in the vertical position.

•

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

2. Break the jam nuts loose on the chain anchors.

•

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

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.

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

8-20

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.

1. Fork-to-ground clearance:

•

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

b. Break the jam nuts loose on the chain anchors.

•

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

c. Turn the chain adjustment nuts until clearance between forks and ground is 10-20 mm (0.40–0.80 in.).

•

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

a. Set the upright to vertical position.

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.

To inner rail

MA1004.eps

3. Carriage Stop-to-Upright: Adjust chain length here

a. Lift upright to its full height and check for clearance on the carriage safety stop.

Figure 8.9

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. 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 8.10 8-21

MAST Periodic Inspection

General Guidelines

Chain Lubrication

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

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: •

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.

Lubrication—Assure that the chain is well lubricated with the heaviest oil that will penetrate the void between the link plate apertures and the pins. Paint—Make sure the chain does not get painted over at any time. 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.

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.

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.

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.

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.

8-22

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. • Do not reach through open areas of the upright. Failure to follow these warnings can result in serious injury.

Lift Chains (Standard & TSU)

Primary Cylinder/Carriage Chains (TSUs) 1. Tilt the upright forward, lower it and completely collapse the primary cylinder to create slack in the chains. The carriage may also be lifted and blocked in position and the primary cylinder completely collapsed to create slack in the chains. 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. 3. Remove the chain anchor pins from the back of the carriage. 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 •

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

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

•

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.

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

8-23

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 8-11. 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 8.11 8-24

MAST Periodic Inspection Upright & Lift Bracket Removal & Replace Roller Shim (continued)

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

6. Remove two bolt from cable retainers. 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 8.12

8-25

MAST Lift Bracket Removal Upright & Lift Bracket Removal Note:

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 8.13 8-26

MAST Lift Bracket Removal (continued) Upright & Lift Bracket Removal 13. Using a 5-ton chain hoist, attach hoist to the inner and intermediate rail assemblies, See Figure 8.14 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 8.14 8-27

MAST Lift Bracket Removal (continued)

Note:

Upright & Lift Bracket Removal 15. Move truck away from lift bracket just far enough to allow the intermediate and inner rails to clear the lift bracket.

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.

16. Completely lower the intermediate and inner rail assemblies. 17. Disconnect hoist and move truck away from lift bracket.

Figure 8.15 8-28

MAST Lift Bracket Removal (continued) 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.

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 8.17. 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.

2. Disconnect truck battery at the battery disconnect.

WARNING

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

3. Remove battery from truck. Note: The lift bracket must be removed before attempting to remove the upright.

WARNING

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

Disconnect Battery 4. Remove any overhead guards and/or screen guards. 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 8.16

Figure 8.17 8-29

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 8.18

8-30

Hardwood (Oak) Blocking

MAST Upright Removal 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 8.19

Cylinder Base

Snap Ring

MA1040.eps

Figure 8.20 Outrigger(s)

Inner Rail Assembly

Top

Bottom MA1038.eps

Intermediate Rail Assembly

Truck Side Outer Rail Assembly Figure 8.21 8-31

Hardwood (Oak) Blocking

MAST Upright & Lift Bracket Removal

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

WARNING

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 8.22

8-32

MAST Upright Disassembly (Continued)

Upright & Lift Bracket Removal

WARNING

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

Cable, Hose and Chain Sheaves •

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. Installation is the reverse of removal.

15 5

6 13

Free Lift Cylinder

•

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

•

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

•

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

7 9 10 11 12

Free Lift Cylinder

Installation is reverse of removal.

Note: The free lift cylinder may be removed with upright attached to truck. 13 14 MA1041.eps

Figure 8.23

Outrigger(s)

Inner Rail Assembly

Top

Bottom MA1038.eps

Intermediate Rail Assembly

Truck Side Outer Rail Assembly

Figure 8.24 8-33

Hardwood (Oak) Blocking

MAST Upright & Lift Bracket Removal 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 8.25

Upright & Lift Bracket Removal 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 8.26 Figure 8.27 8-34

MAST Upright & Lift Bracket Removal

Shimming

Figure 8.28

Figure 8.29

Shimming Load Roller Adjustment Shims

Carriage

Scissors

Lift Fork Carriage Allen Head Screw

MA2190.eps

Figure 8.30 8-35

MAST Lift Bracket Assembly Shimming

Outrigger(s)

Inner Rail Assembly

Top

Bottom MA1038.eps

Intermediate Rail Assembly

Truck Side Outer Rail Assembly

Hardwood (Oak) Blocking

Figure 8.31

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

Checks and Adjustments

Shimming

Note:

2. Set outside spanning tool to match the adjusted inside spanning tool.

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

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 8.33

Figure 8.32

8-36

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 8.34

Figure 8.36

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.

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.

6. Install upper carriage rollers and securely tighten the Allen head retaining capscrews. Load Roller Adjustment Shims

Carriage

Scissors

Allen Head Screw

MA1052.eps

Figure 8.35 8-37

•

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.

MAST 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.

Shimming

Figure 8.37

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 8.39

Figure 8.38 8-38

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

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). •

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

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.

Carriage

Scissors

Carriage 1/32" Shim

MA1058.eps

Figure 8.41

Scissors

MA1057.eps

Figure 8.40 8-39

1/32" Shim

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 8.43

Outer Rail MA1060.eps

Point of Roller Contact Figure 8.42 8-40

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 clearance when extending upright.

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

When using a pry bar:

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.

Shimming •

Insert the pry bar between the outer and intermediate upright rail on the right side ( as shown in Figure 8.42. 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 the chart on this page.

•

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.

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.

8-41

MAST Shimming “C” Clamp Method: • Install “C” clamp at the location shown in Figure 8.44. 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 8.44.

•

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 8-34.

•

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 8.44

8-42

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 8.45 8-43

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 8.46

8-44

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 8.47 8-45

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 8.48 8-46

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 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.

# of 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

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 8.49 8-47

MA1067.eps

Rail extended to within 6 - 10" of full extension.

MAST Shim Adjustment With the upright laying horizontal on blocking. • •

•

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.

Shimming Lift Bracket & Fork Carriage Assembly 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. 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 8.51

MA2189.eps

Figure 8.50

Figure 8.52 8-48

MAST FORK REMOVAL

LIFT BRACKET SERVICE

Refer to Figure 8.53.

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.

WARNING

Forks are heavy. Care must be taken to avoid personal injury.

Models Equipped with Side Shift Only 1. Remove hose hold down cap. 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 8.54 MA2201.eps

Figure 8.53

MA2207.eps

Figure 8.55 8-49

MAST Fork Carriage Removal

To Remove Arm Roller “B” (or “C”):

Models Equipped with Tilt Only

Slowly move Arm “A” (up as required) while rotating Arm “B” (as shown) to move arm roller upward and out of the carriage channel.

1. Remove both cable and hose covers (4), See below. 2. Disconnect hydraulic connection (a) from tilt cylinders.

Be extremely careful that you do not “pinch” your hands or fingers.

All Models 3. Install lifting straps as shown to chain hoist equipped with safety hook. 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 8.57

2 1

MA2218.eps

Figure 8.56 8-50

MAST Lift Bracket Service 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 8.56. 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 8.57. 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 8.58. 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.

Figure 8.58

8-51

MAST Lift Bracket Service 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 8.59

Important: Prepack bearing cup and cone assemblies prior to installation. 5. Disassemble the outer arm assembly.

Note:

6. Replace seals with new ones.

If the Inner Arm Pivot Bearings need to be replaced, the lift bracket carriage must be removed from the upright.

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.

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.

8-52

MAST Lift Bracket Service Figure 8.60

Tilt Cylinder Overhaul Cylinder Removal Remove forks. Refer to Figure 8.60 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 Side Shifter 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 8.61 8-53

MAST ITA Lift Bracket without Side Shifter Carriage Frame Assembly

Dowel Pin

Capscrew Shim Lockwasher Hose Clamp Snap Ring

Capscrew

Shim

Carrier Assembly

Cap Shaft Bushing

Clip Ring

MA2219.eps

Figure 8.62

Cylinder removal:

7. Disconnect the hydraulic hoses from the tilt cylinder.

Remove the fork carriage by removing the lower claws and lifting the carriage bars off the carriage frame. Refer to Figure 8.61 and 8.62.

8. Remove the capscrews holding the tilt cylinder pivot caps in place. 9. Remove the tilt cylinder.

1. Extend the tilt cylinder completely. 2. Secure the carriage frame using an overhead hoist and a lifting strap.

Preparation Cleaning and Inspection

3. Remove snap rings from the tilt pin. See Figure 8.61 and 8.62.

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 Figure 8.61 and 8.62. 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.

8-54

MAST Disassembly

Retainer Assembly

(Refer to Illustration Below)

1. Remove wiper ring.

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.

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.

1. Place cylinder in a vise equipped with soft jaws. Do not overtighten—distortion of the shell will result.

4. Discard seals, wiper and backup rings.

2. Push piston rod all the way into cylinder.

Piston Rod and Piston

3. Using a narrow blade screwdriver, remove the capscrew securing the pull wire / retaining ring.

1. Separate the inner shell from the rod assembly. 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. 4. Remove piston seal with o-ring from piston and discard.

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

Retaining Ring Back-Up O-Ring

Rod

Base Retaining Ring O-ring Piston

Rod Seal Wiper Fitting

Outer Shell Pivot Shaft MA2209.eps

Figure 8.63

8-55

MAST

1. Discard old seals, wiper and shear ring.

4. Lubricate and install a new backup ring into the outer groove on the retainer.

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

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 8.63.

3. Inspect cylinder mounting bushings for damage. If the bushings show signs of wear and/or damage, they should be replaced with new bushings.

6. Push retainer as far as it will go into the housing.

Cleaning and Inspection

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.

4. 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.

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.

REACH CYLINDER OVERHAUL Cylinder Removal

Reassembly

Remove forks.

1. Using only new seals and o-rings, lubricate all parts with clean hydraulic fluid.

Refer to Figure 8.63. 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. Lubricate and install the energizer o-ring into the groove in the piston. Refer to Figure 8.63. 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.

WARNING

Support forks as forkbar is removed so they cannot fall.

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. 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.

MA2201.eps

3. Install a new wiper into retainer. Figure 8.64 8-56

MAST Cylinder removal: Remove the fork carriage Refer to Figure 8.65. 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.

Preparation, Cleaning and Inspection

5. Remove the reach cylinder and place on a clean work bench.

1. The exterior surface of a cylinder should be thoroughly washed before disassembly.

Figure 8.66

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 8.65

8-57

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 8.67 8-58

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 8.67)

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.

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. Place cylinder in a vise equipped with soft jaws. Do not overtighten—distort shell.

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.

2. Push piston rod all the way into cylinder. 3. Using snap ring pliers, remove the snap ring from the cylinder retainer.

5. Discard o-ring, sealing ring and energizer. Always install new seals.

4. Remove o-ring. 5. Using a bronze drift, gently tap retainer assembly into cylinder housing clear of the shear ring.

Cleaning and Inspection 1. Discard old seals, wiper and 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. 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.

8-59

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 8.67. 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. Figure 8.68

6. Install nut onto piston rod finger tight against the piston. 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.

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. 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.

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.

Retainer Assembly

11. Lubricate a new backup ring and place it over the o-ring just installed.

1. Lubricate new seals, wiper ring and retainer assembly with clean hydraulic fluid.

12. Install the washer over the retainer and next to the backup ring previously installed.

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.

13. Install a new split retainer into it’s groove in the retainer assembly. Be sure it is completely seated in it’s groove.

3. Install a new wiper into retainer.

14. Install jam nut and rod end to the same location it was when removed from the piston rod.

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.

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.

8-60

MAST SIDE SHIFT CYLINDER OVERHAUL

Preparation Cleaning and Inspection

Cylinder Removal / Lift Bracket Service

1. The exterior surface of a cylinder should be thoroughly washed before disassembly.

Remove forks. 1. Refer to Figure 8.69. 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 side shifter cylinder, catching any oil that may escape. 3. Using a pry bar, push the side shifter 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.

Disassembly (Refer to Figure 8.70) Wash exterior of the side shift 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.

WARNING

Support forks as forkbar is removed so they cannot fall.

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 8.69 8-61

MAST LIFT BRACKET SERVICE

Figure 8.70

8-62

MAST Cleaning and Inspection

Preparation

1. Discard old seals and wiper.

Reach and Side Shift Selector Valve

2. Wash all rods and retainers in a Stoddard type cleaning solvent and dry with a clean lint free shop rag.

1. Move the truck to a service area. • Move truck to a flat level surface.

3. Inspect surfaces of the rod to be sure they are clean, smooth and free of damage.

Reassembly

•

Extend lift bracket.

•

Fully lower lift bracket.

•

Tilt (if so equipped) forks forward until the fork tips touch the ground.

2. Turn key switch off.

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.

•

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 8.71 8-63

MAST Figure 8.72

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 8.73

8-64

MAST Hydraulic Schematic For Mast Model S/N 40HR-MT-001 through 40HR-MT-111 For Mast Model S/N 45HR-MT-001 through 45HR-MT-102 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

Hydraulic Schematic Figure 8.74

8-65

SIDESHIFT CYLINDER

MAST Hydraulic Schematic For Mast Model S/N 40HR-MT-112 through Present For Mast Model S/N 45HR-MT-103 through Present Secondary Cylinders

MAIN LIFT HOSE

Primary Cylinder

Sideshift Cylinder (optional)

Lift S9

C2 C1

V1 A1

S7 V1

C5 C2

AUX Reach Cylinders S6

C4 C6

V2 S8

V2 S10

C4 ORION Hyd.eps

Hydraulic Schematic Figure 8.75

8-66

Tilt Cylinder

MAST 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 • Figure 8.76

Reach and Tilt Selector Valve

WARNING

Hydraulic lines may have trapped pressure. “Crack” the fittings to bleed pressure before disconnecting.

Note: The valve body and valves are not serviceable. If the unit is not functioning properly, it must be replaced.

WARNING

Be sure the lift bracket is blocked.

Remove nuts, coils and solenoid valves (S5) and (S6) from the valve body.

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.

8-67

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.

2. Turn key switch off. •

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. a. Remove guard lockwashers and capscrews.

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.

CAUTION

The system must be purged of air before putting truck back into service or damage to the hydraulic system may occur.

10. Install and tighten clamp bolts (#4).

Lift Bracket Service Side Shifter Solenoid Control 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.

Figure 8.77 8-68

MAST (continue with Removal—Figure 8.77 )

Installation

• • •

Mount Selector Valve

•

Unplug Connectors from (S7) coil. Label each hose with it’s location. Disconnect hydraulic connections (V1, V2, C6, C5, C2, and C4) from the side shifter selector valve. Cap each hose when disconnected.

•

Install Hoses • Wipe hose ends and connectors clean. Remove hose caps just prior to installation. Be certain all connections are tight.

WARNING

Hydraulic lines may have trapped pressure. “Crack” the fittings to bleed pressure before disconnecting.

Line up mounting holes in selector valve with those in the mounting bracket. Install mounting bolts finger tight.

Connect Coils •

Plug connectors to (S7) and (S8) 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.

Figure 8.79 3

•

Tighten all mounting fasteners.

•

Install guard.

MA2207.eps

Figure 8.78 8-69

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 8.80 8-70

MAST Double Reach Without Sideshifter Hose routing.

Figure 8.81

Figure 8.82

8-71

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 8.83

8-72

MAST Reach and Tilt Selector Valve Service Disassembly

Note:

1. Remove nuts, coils, and solenoid valves (S5) and (S6) 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.

2. Remove both counter balance valves from the valve body.

Typical Counterbalance Valve

MA2580.eps

Typical Solenoid Valves

Figure 8.84

8-73

MAST Reach and Tilt Selector Valve Service

Cleaning 1. Wash all parts except the coils in a Stoddard type cleaning solution. Wipe the coils with a clean cloth.

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.

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 8.85

8-74

MAST Reach and Tilt Selector Valve Service Reassembly—Solenoid Valves

Leads

1. Lubricate all parts in clean hydraulic fluid prior to installation. Nut Torque to 5 lb.ft. (6.8 Nm) Max.

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).

Coil MA1073.eps

Figure 8.86

4. Install the coil over the solenoid valve. 5. Install the coil retainer nut and torque to 25 ftlbs (33.9 Nm) maximum. This allows the coil to be correctly positioned during installation to the truck.

8-75

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 8.87

CAUTION

8-76

MAST Reach and Tilt Selector Valve Service

Side Shift Selector Valve Service

Reassembly—Counterbalance Valves Valve Body

1. Lubricate all parts in clean hydraulic fluid prior to installation. Use only new seals. 2. f 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 ft-lbs. (47 Nm) maximum.

MA2582.eps

Installation

Check Valve

IMPORTANT Inspect hoses, hydraulic connections and their seals for damage.

Solenoid Stem Valve

Wipe hose ends and connections clean, prior to installing them to the solenoid valve. Remove hose caps prior to installation.

Solenoid Coil

Figure 8.88

8-77

MAST Side Shift Selector Valve Service O-Ring(s)

Typical Cartridge Kit

Back-Up Ring(s)

Solenoid Valve

Typical Illustration

Figure 8.89

Disassembly

Cleaning

1. Remove nut and coil from each solenoid valve.

1. Wash all parts except the coils in a Stoddard type cleaning solution. Wipe the coils with a clean cloth.

2. Remove both solenoid valves from the valve body.

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.

8-78

MAST Side Shift Selector Valve Service

Leads

Reassembly 1. Lubricate all parts in clean hydraulic fluid prior to installation.

Nut Torque to 5 lb.ft. (6.8 Nm) Max.

2. Install the solenoid valves back into their respective ports on the valve body.

Coil MA1073.eps

Be certain the solenoid valve is torqued correctly to the body. Torque 8–10 ft-lbs. (11–14Nm).

Figure 8.90

3. Install the cover over the solenoid valve. 4. Install the coil retainer nut and torque to 25 ftlbs. (33.9 Nm) maximum. This allows the coil to be correctly positioned during installation to the truck. Cause is broken wire in aux circuit. Turn parameter “Open Valve Diag” Off in SICOS, troubleshoot resistances using page 11-18. Once wire has been repaired, turn parameter back to ON.

8-79

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 8.91

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 8.92 8-80

MAST Field Replacement of Mast Triline Harness

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.

1. Remove mast guard (plexiglass) in order to access the backside of the mast from the chassis.

12. Disconnect freelift triline hose from the “U” tubes. 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. 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.

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.

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.

15. Unplug mast harness from pantograph harness. 16. Remove the clips and brackets securing mast harness and end plug.

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.

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.

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.

18. Disconnect pull wire through old harness.

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.

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.

8-81

MAST 22. Reinstall clips and brackets to secure new harness near plug end. 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.

8-82

MAST Step 2

Mast “Auxiliary” Hydraulic Flushing Procedure 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 side shift and tilt cylinders.

•

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.

Step 3 •

If the mast is equipped with a side shifter, loosen and remove the side shift cylinder head retainers. If the unit does not have a side shifter, 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 side shifter hoses at the fitting near the side shifter. 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 side shifter hoses, pump oil into the open end of the side shift 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 side shift 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.

•

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.

8-83

MAST Step 4

Step 6

•

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.

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 5 •

•

Remove the solenoid assemblies with electrical wires still connected. (If the unit does not have a side shifter, 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 side shifter has been repeatedly malfunctioning, replace the solenoid stems with new stems.

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.

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.

8-84

MAST Step 8

Step 10

•

Install the tilt cylinder and reconnect and tighten the hydraulic lines.

•

Attach and tighten the side shift 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 side shift 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.

•

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.

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.

8-85

ELECTRICAL 9.

ELECTRICAL

Forward

Reverse

ELECTRICAL GENERAL OVERVIEW

Digital Inputs All digital inputs are high-active inputs, where high = battery position

Note: When disconnecting the power cables from a controller, the negative power cable should be the last cable disconnected.

Digital Outputs Most of the digital outputs are protected against overload and short circuits. Broken wires can be detected.

Note: When reconnecting the power cables to a controller, the negative power cable should always be the first one connected.

Acceleration and Deceleration Ramps The setting of the acceleration ramp is done by Parameter 133 in traction and pump software.

Terminals U, V, W

Deceleration can be performed in different ways.

The motor are connected to these terminals. The motors have to be connected to the controllers as U motor to U controller, V motor to V controller and W motor to W controller.

• By reducing the speed set value, the traction and pump controllers will always use the deceleration ramp set by parameter 134.

With a positive set value, the traction motor should drive the vehicle forward. If it doesn’t, Parameter 180 of the traction controller’s software can change the sequence of the motor output and the encoder input.

• In the traction drive, a steeper deceleration ramp can be set by reversing the control handle to the opposite direction. The deceleration will follow parameter 139.

With a positive set value, the pump motor should drive the pump in the right direction. If it doesn’t, Parameter 180 of the pump controllers software can change the phase sequence of the motor output and the encoder input.

• If the brake pedal is lifted a little bit (X6.2 = low), a separate brake ramp will take place—defined by Parameter 133. If the brake pedal gets pushed down again (before the vehicle comes to a stop), the vehicle will accelerate again with the ramp defined in Parameter 133.

Hall Elements The traction and pump controller work with two hall elements (potentiometers), one for traction speed and one for pump speed. The adoption of the hall element signal to the maximum and minimum position on the control handle is done by the Teach-In procedure.

• If the brake pedal is completely lifted, a fast deceleration will happen. Together with the mechanical brake the vehicle will be decelerated in a very short time, Under normal condition the mechanical brake will dominate the deceleration process.

Encoders

Electromagnetic Brake in Motor

All three motor drives are speed controlled, so every motor has an encoder (sensor bearing) to measure the speed. For correct function, it is important that the direction of rotation and the phase sequence of the encoders signals fit together. If they don’t, the drives will run at relatively low speeds that are independent from the set values. A special control algorithm avoids acceleration to a dangerous high speed.

The traction controller is able to control the electromagnetic brake in the motor. The control of the brake is linked to the actual speed of the motor. This means that when the brake is released (active voltage signal) before the motor turns. Brake is deactivated when zero speed is reached. The controller is able to control the motor at zero speed enabling jerk free starts and stops. The brake is only activated at zero speed, thus minimum brake wear.

The pump works together with a second encoder for measuring lift height.

9-1

ELECTRICAL Action by Faults

duction to the mounting plate. The Traction and Pump Controllers have cooling fins where an external fan blows across.

The controllers are constantly monitoring fault situations. The type of fault can be observed either from the integrated LED located on the display, through the hand held terminal (BPK) or the PC service software (BPS).

BUS-Master The pump controller is the BUS-master, as long as it is connected to the display. If the display is not connected to the pump controller at power on, the pump controller goes into the slave status as well as the traction controller and the steering controller.

Installation of the Controller The controllers have to be mounted on a flat base plate to provide for sufficient cooling. The steering controller dissipates the heat by con-

DIAGRAM OF CONTROLLERS

Pump and Motor Controller

Steering Controller

9-2

ELECTRICAL Display

Connector Numbering The following is an example of the numbering of a 6 and 10 pin connector on a controller.

Rear View M6

8-pole 8-pole Molex Molex Mini MiniFit Fitplug plugconnector connector

PIN No. 1 2 3 4 5 6 7 8

Connection RS485 A-Signal RS485 B-Signal ----+15 V 0V

123 4 567 8

9-3

ELECTRICAL

Pump Controller Wiring Diagram 9-4

ELECTRICAL PUMP CONTROLLER X1: KEY SWITCH, ANALOG OUTPUTS AND DIGITAL OUTPUTS

PUMP CONTROLLER X2: VALVES Y46, TILT AND SIDESHIFT SELECTION

X1.1 Key-switch

X2.1 Positive Pin for Valves

Battery voltage has to be supplied to this input in order to power on the controller. The controller does not work without the key switch being connected to the supply voltage. At that moment, the current consumption on the main terminals is less than 10mA.

The pin is supplied through the key switch input and protected with the internal fuse. X2.2 Negative Pin for Valves The pin is switched to a negative pole via a transistor.

A 10 amp fuse, that is located outside the controller housing, protects this input. This input provides the supply voltage for other connections like contactors and valves.

PUMP CONTROLLER X3: VALVES Y41, Y43, Y44 AND Y45 X3.1 – X3.6 Positive Pins for The Valves

X1.3, X1.6 Optional Digital Outputs

X3.7 Negative Pin for Valve Y45 Sideshift

Open drain outputs, transistors switch to 0 Volts, free wheeling diodes are connected to X1.1 (key switch input). The configuration of the digital outputs can be set by parameters 70 and 71. Actual Setting: Parameter 70 :5 , Parameter 71: 8

Reach

X3.9 Negative Pin for Valve Y43.2 for Reach, Tilt, Sideshift

BW/R

X3.10 Negative Pin for Valve Y43.1 FW/L for Reach, Tilt, Sideshift

Parameter 70 (X1.3) and 71 (X1.6) 0 1 2 3 4 5 6 7 8

X3.8 Negative Pin for Valve Y44

output not active inverter ready (no fault) output not active start release slip > parameter 120 same as state LED temperature warning for inverter temperature warning for motor power state active

X3.11 Negative Pin for Valve Y41.2 Lift X3.12 Negative Pin for Valve Y41.1 Lower The valves are always connected to the battery plus through the key switch input and are turned on and off by a transistor.

PUMP CONTROLLER X4: CONNECTIONS FOR THERMISTOR, ENCODER AND FANS

X1.4 Gnd

X4.1 Protected Key Switch Voltage

Same as battery negative.

The pin is supplied through the key switch input and protected with the internal fuse.

X1.2, X1.5

X4.5 Negative Pins for Fans

Not in Use

This pin is switched to the negative pole via a transistor if the heatsink of the traction or pump controller has a higher temperature than 104º F. As long as the transistor is off, the fans run with a series resistor in the negative line. Above a definite temperature for the traction or pump controller the transistor switches on and provides full voltage for the fans. After the first 5 seconds of power on, the fans are running 9-5

ELECTRICAL PUMP CONTROLLER X5: HEIGHT MEASUREMENT, PRESSURE SENSOR AND TOP LIMIT OVERRIDE.

full speed. X4.2, X4.6 Temperature Sensor (Motor) A temperature sensor (PTC) can be connected to this input. For the actual software, it is assumed that a KTY84-130 is used.

X5.1 Protected Key Switch Voltage At this pin, the fuse protected key switch voltage is available for the top limit override switch.

X4.3 Encoder Signal A The actual software calculates with an encoder the 64 pulses per revolution.

X5.5 Ground

X4.4 Encoder Signal B X4.7 +15V Power Supply for Encoder

X5.7 +15V Output for the Sensor Bearing and the Pressure Sensor

X4.8 0V Connection for Encoder

X5.2 Encoder Signal A

The speed of the traction motor is monitored and controlled. An Incremental encoder suitable for the 15 volt supply voltage must be connected at the terminals mentioned above.

X5.3 Encoder Signal B

The encoder must deliver two 90º phase shifted signals (A and B). At the clockwise rotation of the motor flux from U, V and W, signal A must come before signal B at the encoder.

X5.4 Input for Pressure Signal

Phase Sequence of Encoder Signals:

X5.6 Input for Top Limit Override Switch

Phase sequence of encoder signals and phase sequences of motor currents have to fit together.

It is recommended that lifting shall be stopped above a definite height. To lift higher in special situations it is necessary to provide an extra signal to this input. It is not possible to push this button to avoid stopping of the lifting.

Same as battery negative.

By counting the pulses of the sensor bearing at the mast, the height will be monitored.

By measuring the pressure in the main cylinder the load on the forks can be monitored. Range: between 0 to 5 volts.

When the shaft of the motor turns right (right sequence U,V,W), the controller expects signal A before signal B. Signal A before signal B is calculated as a positive speed.

Parameter

Parameter 180 = 0 Parameter 180 = 1

PUMP CONTROLLER X6: SET VALUE FOR PUMP SPEED AND DIGITAL INPUTS

Pump Drive Motor Current Sequence

Encoder Signal Sequence

U, V, W

A before B

W, V, U

B before A

At power on, inputs X6.2, X6.3, X6.4, X6.5, X6.8, X6.9 and X6.10 will be low, otherwise error 10 will occur. Combination of Hydraulic Functions Together with lift or lower, one additional function can be activated; tilt, reach or sideshift. The first additional function chosen disables the other additional functions. The pump will run with the maximum speed of the chosen function. X6.1 Protected Key Switch Voltage On this pin, the fuse protected key switch voltage is available for supply to other components in the system.

9-6

ELECTRICAL

Low, If control handle in the neutral position.

PUMP CONTROLLER X7: RS485 INTERFACE

X6.3 Side Shift Left

X7.1 +15V

X6.2 Center Switch of Control Handle

X6.4 Tilt Up

A 15 volt supply is available for an external interface converter or for the Setup terminal (BPK).

X6.9 Tilt Down

X7.2 0V

X6.5 Reach

The RS485 does not necessarily need a 0 volt connection. To avoid a floating potential, it is recommended that this pin be used for the RS485 ground.

X6.8 Side Shift Right

If reach and retract are pressed at the same time, the first one defines the function and the second one will define the speed.

X7.3 RS485, A Signal

X6.10 Retract

X7.4 RS485, B Signal

X6.7 Mast Height Switch Must be connected to X6.4 of the controller. X6.6, X6.11 and X6.12 Speed Reference Hall Element The speed reference Hall element is connected to the following three pins; X6.11- positive, X6.12—negative and the reference on X6.6 where lower voltages equal lift and higher voltages equal lower. A rough mechanical adjustment of the Hall element is sufficient. The final adjustment of the maximum and minimum position of the Hall element is done by the Teach-In function during setup (Parameter 251). Valves Y41.1

Y41.2

Y43.1

Y43.2

Y44

Y45

Y46

S5/S6

S9/S10

S7/S8

LOWER

LIFT

DIRA

DIRB

REACH

TILT/SS

X3-6/12

X3-5/11

X3-10

X3-9

X3-8

X3-7

X2-2

Functions Lower Pot. Lift Pot. Retract

ANALOG ON ON

Reach Tilt Down

ON ON

Tilt Up Side Shift Left

ON ON

Side Shift Right

ON 9-7

ON ON

ELECTRICAL

Traction Controller Wiring Diagram 9-8

ELECTRICAL X2.4 Negative Pin for the Main Contactor

TRACTION CONTROLLER X1: KEY SWITCH, ANALOG OUTPUT AND DIGITAL OUTPUT FOR K12

The pin is switched to the negative pole via a transistor. To operate the main contactor, Pin X2.4 is connected to the negative pole for approximately 1 second. After that, the transistor will reduce the voltage to the main contactor by PWM switching with a duty cycle of 60%; supplying 60% of the battery voltage. This is enough time to keep the main contactor switched on and at the same time reduce thermal stress.

X1.1 Key Switch Battery voltage has to be supplied to this input in order to power on the controller. The controller does not work without the key switch being connected to the supply voltage. At that moment, the current consumption on the main terminals is less than 10mA. A 10 amp fuse, that is located outside the controller housing, protects this input. This input provides the supply voltage for other connections like contactors and valves.

X2.3, X2.6 Additional Inputs

X1.2 Digital Output for K12

Same as battery negative.

Open drain output, transistor switches to 0 volts, freewheeling diode connected to X1.1 (key switch input). The function depends on Parameter 72.

TRACTION CONTROLLER X3: NOT IN USE

Currently have no function designated. X2.5 Ground

TRACTION CONTROLLER X4: CONNECTIONS FOR THE MOTOR (BRAKE, THERMISTOR & ENCODER)

Parameter 72 0 1 2 3 4 5 6 7

output not active forward backward forward or backward lift lower lift or lower forward or backward or lift or lower

X4.1 Positive Pin for the Electro Magnetic Brake The pin is supplied through the key switch input and protected with the internal fuse. X4.5 Negative Pin for the Electro Magnetic Brake The pin is switched to a negative pole via a transistor. To operate the brake, the pin X4.5 is connected to the negative pole for approximately 1 second. After that, the transistor will reduce the voltage to the main contactor by PWM switching with a duty cycle of 60%, supplying 60% of the battery voltage. This is enough voltage to keep the main contactor switched on and at the same time reduce thermal stress.

X1.4 Analog Output (Positive Pin) 0 thru 10 volts Not in use in actual software. X1.3 Analog Output (Negative Pin) Same as battery negative.

TRACTION CONTROLLER X2: MAIN CONTACTOR AND ADDITIONAL INPUTS

X4.2, X4.6 Temperature Sensor (Motor) A temperature sensor (PTC) can be connected to this input. For the actual software it is assumed that a KTY84-130 is used.

X2.1, X2.2 Positive Pin for the Main Contactor The pin is supplied though the key switch input.

9-9

ELECTRICAL X4.3 Encoder Signal A

X5.4 Buzzer Negative

The actual software calculates with an encoder the 64 pulses per revolution.

Buzzer will be switched on three times (beep, beep, beep) after a new alarm or warning has appeared in the display.

X4.4 Encoder Signal B

X5.3, X5.6 Additional Inputs

X4.7 +15V Power Supply for the Encoder

Currently has no function designated.

X4.8 0V Connection for the Encoder The speed of the traction motor is monitored and controlled. An incremental encoder suitable for 15V supply must be connected to pins X4.7 and X4.8. The encoder must deliver two 90º phase shifted signals (A and B). At the clockwise rotation of the motor flux from U, V and W, the signal A must come before signal B at the encoder.

TRACTION CONTROLLER X6: SET VALUE FOR TRACTION SPEED AND DIGITAL INPUTS

Phase Sequence of Encoder Signals

X6.2 Traction Enable 2

Phase sequence of encoder signals and phase sequence of motor currents have to fit together. When the shaft of the motor turns right (right sequence U, V, W), the controller expects signal A before signal B. Signal A before signal B is calculated as positive speed.

Connected to the pedal switch; high, if pedal is completely depressed.

Parameter

Parameter 180 = 0 Parameter 180 = 1

X6.1 Protected Key Switch Voltage On this pin, the fuse protected key switch voltage is available to other components in the system.

X6.3 Traction Enable 1 Connected to the pedal switch; high if pedal is

Traction Drive

Pedal

X6.3

X6.2

Motor Current Sequence

Encoder Signal Sequence

U, V, W

A before B

depressed half way or completely.

W, V, U

B before A

X6.4 Speed Reduction 1 (Mast Above Definite Limit) High = Full Speed, Low = Reduction Must be connected to input X6.7 at pump controller.

TRACTION CONTROLLER X5: BUZZER AND ADDITIONAL INPUTS

X6.5 Speed Reduction 2

X5.1, X5.2 Protected Key Switch Voltage

High = Full Speed, Low = Reduction

On this pin, the fuse protected key switch voltage is available for supply to other components in the system.

X6.7 Ground Same as battery negative X6.8, X6.9, X6.10 Additional Inputs

X5.5 Ground

Currently not in use

Same as battery negative

X6.12 Driver Present/ Battery Locked Not in Use

9-10

ELECTRICAL X6.8, X6.9, X6.10 Speed Reference Hall Element The speed reference Hall effect sensor is connected to the following three pins; X6.11—positive, X6.7—negative and the reference on X6.6. A rough mechanical adjustment of the Hall effect sensor is sufficient. The final adjustment of the maximum and minimum position of the speed Hall effect sensor is done by the TeachIn function during system setup (Parameter 251).

TRACTION CONTROLLER X7: RS485 INTERFACE X7.1 +15 Volts A 15V supply is available for an external interface converter or for the setup terminal (BPK). X7.1 0 Volts The RS485 does not necessarily need a 0 volt connection. To avoid a floating potential, it is recommended that this pin be used for the RS485 ground. X7.3 RS485, A Signal X7.4 RS485, B Signal

9-11

ELECTRICAL

Steering Controller Wiring Diagram 9-12

ELECTRICAL STEERING CONTROLLER X1: KEY SWITCH AND POSITION SENSORS

STEERING CONTROLLER X3: DIGITAL INPUTS, DIGITAL OUTPUTS

X1.1 Key Switch

X3.1 Digital Input 1, not used.

Battery voltage has to be supplied to this input in order to power on inverter. The inverter does not work without the key switch being connected to the supply voltage. At that moment, the current consumption on the main terminals is less than 10ma.

X3.2 Digital Input 2, not used.

X1.2, X1.3, X1.4 Position Sensors for Steering

X3.6 Digital Input 5/6, not used

Sensors A and B are necessary to detect the neutral position of the wheel. Sensor C is the end stop. If the wheel is in neutral position, sensor A is active and sensor B is inactive.

X3.7, X3.8 Output state for LED

X3.3 Digital Input 3, not used. X3.4 Digital Input 4, not used. X3.5 Digital Input 5/6, not used.

An OR relationship exist between X3.5 and X3.6.

Anode at pin 8, Cathode at pin 7.

X1.2: Sensor A

STEERING CONTROLLER X5: CONNECTIONS FOR THE MOTOR (THERMISTOR AND ENCODER)

X1.3 Sensor B X1.4 Sensor C

X5.4, X5.6 Temperature Sensor A temperature sensor (PTC) can be connected to this input. For the actual software, it is assumed that a KTY84-130 is used. X5.3 Encoder Signal A The actual software calculates with an encoder the 64 pulses per revolution. X5.5 Encoder Signal B X5.1 +15 Volt Power Supply for the Encoder X5.2 0V Connection for the Encoder The speed of the steering motor is always monitored and controlled. An incremental encoder suitable for the 15 volt supply must be connected at terminals X5.1 and X5.2. The encoder must deliver two 90º phase shifted signals (A and B). At a right turning motor flux from U, V and W, the signal A must come before the signal B at the encoder.

STEERING CONTROLLER X2: SAFETY CIRCUIT X2.1 Safety Circuit Input Needs to be supplied with battery positive X2.2 Safety Circuit Output As long as everything in the steering circuit is correct, the voltage of X2.1 is lead through X2.2. In the case of a fault, the connection will be interrupted. An overcurrent protection switches off, if the current exceeds 4.5A.

9-13

ELECTRICAL TRACTION CONTROLLER X7: RS485 INTERFACE

Phase Sequence of Encoder Signals Phase sequence of encoder signals and phase sequence of motor currents have to fit together. When the shaft of the motor turns right (right sequence U, V, W), the controller expects signal A before signal B. Signal A before signal B is calculated as positive speed.

A 15V supply is available for an external interface converter or for the setup terminal (BPK). X7.2 0 Volts

Motor Current Sequence

Encoder Signal Sequence

The RS485 does not necessarily need a 0 volt connection. To avoid a floating potential, it is recommended that this pin be used for the RS485 ground.

U, V, W

A before B

X7.3 RS485, A Signal

W, V, U

A before B

X7.4 RS485, B Signal

Parameter

Parameter 171 = 0 Parameter 171 = 1

X7.1 +15 Volts

Steering Motor

Bus Connection and Display

Contrary to the traction and pump controllers , this parameter only inverts the sequence of the motor phases, not the sequence of the encoder signals.

Four components are connected via a RS485 Bus: • Traction Controller • Pump Controller

STEERING CONTROLLER X6: INPUT FOR THE STEPPER MOTOR AT THE STEERING WHEEL

• Steering Controller • Gauge for Controllers The gauge is supplied with 15 volts from the traction controller which switches the main contactor. Basically, any one of the controllers could provide the 15 volts. The other three lines (A, B and Ground) from the controllers have to be connected to the Bus.

X6.1 Stepper Motor Terminal A0 X6.2 Stepper motor Terminal B+ X6.3 Stepper motor Terminal BX6.4 Stepper motor Terminal A+ X6.5 Stepper motor Terminal AX6.6 Stepper motor Terminal B0 It is recommended that 6 wire stepper motors be used for the steering set value. The inputs are monitored, so broken wires and short circuits can be detected.

9-14

ELECTRICAL SCHEMATICS 10. ELECTRICAL SCHEMATICS How to Use the Schematic ..................................................................................................................... 10-1 Schematic (1/12)—Power Supply—24 Volt............................................................................................. 10-2 Schematic (2/12)—Main Power Circuits ................................................................................................. 10-3 Schematic (3/12)—Drive Circuit.............................................................................................................. 10-4 Schematic (4/12)—Steering Circuits....................................................................................................... 10-5 Schematic (5/12)—Hydraulic Schematic Circuits ................................................................................... 10-6 Schematic (6/12)—Hydraulic Control Output Circuits............................................................................. 10-7 Schematic (7/12)—Hydraulic Sensing Circuits ....................................................................................... 10-8 Schematic (8/12)—Pump and Traction Encoders/Temp Sensing Circuit................................................ 10-9 Schematic (9/12)—Horns, Light, and Travel Alarms ...............................................................................10-10 Schematic (10/12)—Fans .......................................................................................................................10-11 Schematic (11/12)—Communication Connections .................................................................................10-12 Schematic (12/12)—Cold Storage Use—Option ....................................................................................10-13 Location of Components on Schematic ..................................................................................................10-14

ELECTRICAL SCHEMATICS SCHEMATIC How to Use the Schematic

Page (1/12) Locator Box: 23

The electrical (schematics) are multiple pages that give reference points to indicate common connections and information relating to the wire number(s) and component identifiers.

This section of the schematic depicts a 10A fuse which is labeled 9F1. The fuse has two locations referenced 1 and 2. The side labeled 2 is connected to a wire that is labeled 9L1.

There are page numbers and sections referenced. The schematics for this vehicle are very similar to using a road map. There are numbered zones shown on the topside of the page to aid in locating specific area (See Figure 9-1).

Note the numbers 12/16 below the wire identifier (9L1). The first number will direct you to page 12 of the schematic. The second number will direct you too locator box 16 where the wire is connected. The same procedure is used for all the circuits throughout the schematic. Note: Single numbers without the (/) indicate that the connection is on the same page. The schematics do not differentiate between power cables and control wires. There are no bold lines to indicate power cables, nor is there a particular location used exclusively for the power circuitry.

Figure 9-1

10-1

Power Supply 24 Volt

Schematic (1 / 12)

ELECTRICAL SCHEMATICS

10-2

Main Power Circuits

Schematic (2 / 12)

ELECTRICAL SCHEMATICS

10-3

Drive Circuits

Schematic (3 / 12)

ELECTRICAL SCHEMATICS

10-4

Steering Circuits

Schematic (4 / 12)

ELECTRICAL SCHEMATICS

10-5

Hydraulic Control Circuits

Schematic (5 / 12)

ELECTRICAL SCHEMATICS

10-6

Hydraulic Control Output Circuits

Schematic (6 / 12)

ELECTRICAL SCHEMATICS

10-7

Hydraulic Sensing Circuits

Schematic (7 / 12)

ELECTRICAL SCHEMATICS

10-8

Pump & Traction Encoders / Temp Sensing Circuit

Schematic (8 / 12)

ELECTRICAL SCHEMATICS

10-9

Horns, Lights and Travel Alarms

Schematic (9 / 12)

ELECTRICAL SCHEMATICS

10-10

Fans

Schematic (10 / 12)

ELECTRICAL SCHEMATICS

10-11

Communication Connections

Schematic (11 / 12)

ELECTRICAL SCHEMATICS

10-12

Cold Storage Use—Option

Schematic (1 2 / 12)

ELECTRICAL SCHEMATICS

10-13

ELECTRICAL SCHEMATICS Location of Components on Schematic The schematics do not differentiate between power cables and control wires. There are no bold lines to indicate power cables, nor is there a particular location used exclusively for the power circuitry. Page

Description of information included.

Power Supply

Main Power Circuits

Drive Circuits

Steering Circuits

Hydraulic Control Circuits

Hydraulic Control Output Circuits

Sensing Circuits

Pump & Traction Encoders/Temp Sensing Circuits

Fans, Lights and Travel Alarms

Fans

Communication Connections

Cold Storage Use Optional

Identifier

Description

Sheet No. Box

1F1

B+ (10A) Fuse to Key Switch

1/13

1F2

B - (10A) Fuse to Key Switch

1/13

2F1

B+ (10A) Fuse to Auxiliary Devices

1/14

2F2

B - (10A) Fuse to Auxiliary Devices

1/14

3F1

B + K2 (325A) Fuse to Drive Motor Controller

1/17

4F1

B + K2 (325A) Fuse to Pump Motor Controller

1/18

5F1

B + K2 (50A) Fuse to Steer Motor Controller

1/19

8F1

B + K2 (10A) Fuse (Spare)

1/22

9F1

B + K1 (10A) Fuse to Cold Storage Option

1/23

10F1

B + K1 (10A) Fuse to Drive Circuit

1/24

11F1

B + K1 (10A) Fuse (Spare)

1/25

12F1

B + K1 (10A) Fuse to Auxiliary Devices

1/26

12F2

B – K1 (10A) Fuse to Auxiliary Devices

1/26

Traction Motor Controller

2,3,8,9,11

Pump Motor Controller

2,5,6,7,8,11

Steer Motor Controller

2,4,8,11

B11

Steering Wheel Sensor

4/14

B41

Pulse Encoder Level Sensor (Option)

7/16

B42

Pressure Sensor (Option)

7/21

BM1

Speed and Direction Encoder (Drive Motor)

8/11

BM2

Speed Encoder (Hydraulic Pump Motor)

8/16

BM3

Speed Encoder (Steering motor)

8/22 10-14

ELECTRICAL SCHEMATICS Identifier

Description

Sheet No. Box

E51

Cabin Light (Option)

9/21

E52

Working Light (Option)

9/23

E53

Working Light (Option)

9/25

E54

Warning Light (Option)

9/27

E55

Reverse Travel/Horn (Option)

9/28

F101

Suppressor on K1 Coil

3/11

F103

Fly Back Diode on Brake Coil

3/17

F104

Suppressor on Horn Coil

9/13

F105

Suppressor on Alarm Coil

9/29

G1 24V

Battery 24 Volt

1/12

Horn

9/14

Traction Controller Buzzer

9/17

H55

Reverse Travel/Horn (Option)

9/29

K1 Contactor Tips (B+) to 9F1, 10F1, 11F1, 12F1

1/15

K1 Coil

3/12

K2 Contactor Tips (B+) to 3F1, 4F1, 5F1, 8F1

1/16

K2 Coil

3/14

K11

Horn B+ Tips in K11 Relay

9/14

K12

Warning Light B+ Tips in K12 Relay

9/29

K12 Coil

9/20

Traction Motor

2/11

Hydraulic Pump Motor

2/15

Steer Motor

2/19

Controller Fan

10/18

Controller Fan

10/16

M51

Driver Fan

10/23

22R/25W Resistor (Controller Fan)

10/16

R12

Traction Speed and Direction Sensor Potentiometer

3/29

R13

Lift/Lower Potentiometer (Includes Center Switch)

5/13

R342

120R/25W Heater (Display) Cold Storage

12/20

R343

120R/25W Heater (Steering Wheel) Cold Storage

12/22

R344

120R/25W Heater (Brake Pedal)

12/24

RM1

Temperature Sensor (Traction Motor)

8/15

RM2

Temperature Sensor (Pump Motor)

8/20

RM3

Temperature Sensor (Steer Motor)

8/25

Emergency Stop Switch

3/12

Key Switch

3/12

S11

Brake Pedal Switch

3/18

S12

Operator Presence Switch

3/20

S13

Horn Button

9/12

K1 (24V in Box) K2 K2 (24V in Box)

K12 (Box)

10-15

ELECTRICAL SCHEMATICS Identifier

Description

Sheet No. Box

S14

Reach (Out) Switch

5/19

S15

Reach (In) Switch

5/20

S16

Tilt (Up) Switch

5/22

S17

Tilt (Down) Switch

5/21

S18

Sideshift (Left) Switch

5/24

S19

Sideshift (Right) Switch

5/23

S25

Top Limit Override Switch

7/13

S32

Steering Feedback Sensor (Sensor A)

4/18

S33

Steering Feedback Sensor (Sensor B)

4/21

S34

Steering Feedback Sensor (Sensor C)

4/23

S36

Battery Lock Switch (Option)

3/22

S37

Slow Speed 2 (Option)

3/24

S43

Slow Speed 1

3/26

S51

Cabin Light Switch (Option)

9/21

S52

Working Light Switch (Option)

9/23

S53

Undefined Switch (Option)

9/25

S54

Driver Fan Switch

10/23

S342

Switch Cold Storage Heater Circuits

12/20

SR345

+10º C N/O Thermostat

12/14

X1: -

Battery SB Connector (Negative)

1/12

X1: +

Battery SB Connector (Positive)

1/12

X2: -

Battery Negative (Panel Ground)

1/25

Service Brake Coil

3/18

Y41

Lift/Lower Solenoid Coil (M1-M2 Coil)

6/13

Y43

Direction of Sideshift, Tilt, Reach

6/17

Y44

Reach/Retract Solenoid (S5-S6)

6/20

Y45

Sideshift Solenoid (S9-S10)

6/23

Y46

Tilt/Sideshift Selection (S7-S8)

6/26

Y31 (24V in Box)

10-16

HYDRAULIC SCHEMATICS 11. HYDRAULIC SCHEMATICS Hydraulic Schematic / Diagram............................................................................................................... 11-1

HYDRAULIC SCHEMATICS

11-1

TROUBLESHOOTING & PIN BY PIN VOLTAGES 12. TROUBLESHOOTING & PIN BY PIN VOLTAGES Fault Condition or Status Report Display Information Example ............................................................. 12-1 Traction Controller Fault Codes .............................................................................................................. 12-2 Steering Controller Fault Codes.............................................................................................................. 12-5 Pump Controller Fault Codes.................................................................................................................. 12-9 Pin-by-Pin Voltages Worksheet ...............................................................................................................12-11

TROUBLESHOOTING & PIN BY PIN VOLTAGES FAULT CONDITION OR STATUS REPORT In case of a fault or warning, the display shows the address of the unit where the problem exist and the number of fault or warning. AL xyy

Alarm

WR xyy Warning x = Address (1= traction, 2= steering, 3= pump) yy = Number of fault or warning Example: AL 108 where 1 = Traction controller and 08 indicates that the brake pedal was depressed at power on during Selftest. WR 110 where 1 = Traction controller and 10 indicates that the traction motor temperature is close to the maximum allowed variable.

12-1

New software version

Overcurrent in power stage Low voltage

Overvoltage

High temperature motor

High temperature controller

Pedal level_2 (power-on)

Incremental encoder

Warning temperature motor Warning temperature controller

Overcurrent powerstage

Low voltage

Overvoltage

High temperature motor

12-2

High temperature controller

Pedal level_2

Encoder supervision

Warning temperature motor

Warning temperature controller

111

110

109

108

107

106

105

104

103

102

(FLASH—Fault)

New software version

(RAM—Fault)

Fault No. -

Text in BPS

(Watchdog)

Text in BPK

Traction Controller Blinkcode of LED

Remarks

11 pulses…pause

10 pulses…pause

9 pulses…pause

8 pulses…pause

7 pulses…pause

6 pulses…pause

5 pulses…pause

4 pulses…pause

3 pulses…pause

2 Pulses…pause

Duty cycle 3:1 (f = 2.1 HZ)

Duty cycle 1:3 (f = 2.1 HZ)

Controller temperature comes close to the maximum allowed value.

Motor temperature comes close to the maximum allowed value.

Large difference between the actual speed measured and the set speed. May be due to a fault in the sensor bearing or wiring.

During Selftest, the brake pedal should not be depressed at power on (reset by lifting pedal).

Traction controller temperature is too high for too long. Motor current and brake will be switched off

Traction motor temperature is too high for too long. Motor current and brake will be switched off

Battery voltage above a definite limit for too long. Motor current and brake will be switched off.

Battery voltage below a definite limit for too long. Motor current and brake will be switched off.

High current, motor current and brake will be switched off.

Power stage and brake won’t be switched on (Reset with parameter 150).

Power stage and brake won’t be switched on. Replace the controller.

Duty cycle 1:1 (f = 1.25 HZ) Power stage and brake won’t be switched on. Replace the controller.

TROUBLESHOOTING & PIN BY PIN VOLTAGES

Text in BPS Set value too high (power-on)

Supervision of analog input

EEPROM Parameters of V/f-ratio not realistic Parameter of set value curve not realistic Parameters of slip curve not realistic Digital outputs UL-check, short-circuit LOW-side or intermediate direct current link UL-check, short-circuit HIGH-side

UL-check, LOW-side phase U, high resistance UL-check, HIGH-side phase U, high resistance UL-check, LOW-side phase V, high resistance UL-check, HIGH-side phase V, high resistance UL-check, LOW-side phase W, high resistance

Text in BPK

Set value supervision

Analog input supervision

EEPROM

Wrong V/f adjustment

Wrong set value characteristic

Wrong slip parameters

Digital outputs

UL-check short-circuit LOW

UL-check short-circuit HIGH

UL-check phase U LOW-switches

UL-check phase U HIGH-switch

UL-check phase V LOW-switches

UL-check phase V HIGH-switch

UL-check phase W LOW-switches

Traction Controller (continued)

12-3 128

127

126

125

124

123

122

118

117

116

115

114

113

112

Fault No.

28 pulses…pause

27 pulses…pause

26 pulses…pause

25 pulses…pause

24 pulses…pause

23 pulses…pause

22 pulses…pause

18 pulses…pause

17 pulses…pause

16 pulses…pause

15 pulses…pause

14 pulses…pause

13 pulses…pause

12 pulses…pause

Blinkcode of LED

Failure in power stage detected during power on. Power stage and brake won’t be switched on.

Short circuit, overload or broken wire at one of the digital outputs,

Adjustment of parameters 62 through 65 make no sense.

Create a new Teach-In Process

Making motor adjustments—makes no sense. Replace parameter set.

Power stage and brake won’t be turned on. Replace the controller.

Supervision of control handle and wiring. Value has to be between 0.25v and 4.75V.

For selftest the Hall effect sensor (control handle) has to be in neutral position at power on, otherwise: power stage won’t be switched on (Reset by moving the control handle to the neutral position).

Remarks

TROUBLESHOOTING & PIN BY PIN VOLTAGES

Text in BPS UL-check, HIGH-side phase W, high resistance UL-check, battery voltage low

Text in BPK

UL-check phase W HIGH-switch

UL-check no battery voltage

Traction Controller (continued)

130

129

Fault No.

30 pulses…pause

29 pulses…pause

Blinkcode of LED

Remarks

Failure in power stage detected during power on. Power stage and brake won’t be switched on.

TROUBLESHOOTING & PIN BY PIN VOLTAGES

12-4

Undervoltage

Overvoltage

Plausibility supervisory

Fault at inductive proximity switches Overcurrent in power stage Safety circuit (internal error)

Low voltage

Over voltage

Plausibility error

Inductive switch

Over current power stage

Safety circuit (internal)

Excessive temperature of controller

Excess temperature controller

Excessive temperature of motor

break encoder signal motor or motor blocked

Signal motor enc., mot.block.

Excess temperature motor

New software version

12-5 211

210

208

207

206

205

204

203

202

(FLASH—Fault)

New software version

(RAM—Fault)

Fault No. -

Text in BPS

(Watchdog)

Text in BPK

Steering Controller Remarks

11 pulses…pause

10 pulses…pause

9 pulses…pause

8 pulses…pause

7 pulses…pause

6 pulses…pause

5 pulses…pause

4 pulses…pause

3 pulses…pause

2 pulses…pause

Duty cycle 3:1 (f = 2.1 HZ)

The selftest had detected a fault inside the safety circuit. Replace the controller.

High current—motor current will be off.

Unacceptable combination between the three proximity switches.

Supervision between calculated steering angle and signals from proximity switches has detected an unacceptable combination. Check the mechanical and the switches.

Battery voltage is above a defined limit for too long. Motor current and brake will be switched off.

Battery voltage is below a definite limit for too long. Motor current and brake will be switched off.

Steering motor temperature is too high for too long. Motor current and brake will be switched off.

Steering controller temperature is too high for too long. Motor current and and brake will be switched off.

No signals from incremental encoders although the motor is supplied with current and should run. Check the encoder and the wiring.

Power stage and brake won’t be switched on (Reset with parameter 150).

Power stage and brake won’t be switched on. Replace the controller.

Duty cycle 1:3 (f = 2.1 HZ) Power stage and brake won’t be switched on. Replace the controller.

Duty cycle 1:1 (f = 1.25 HZ) Power stage and brake won’t be switched on. Replace the controller.

Blinkcode of LED

TROUBLESHOOTING & PIN BY PIN VOLTAGES

Text in BPS Battery overvoltage signal

Redundant digital inputs

Supervision steering encoder

Parameter of U/f characteristic is unrealistic Fault at Low Pass filter for the steering encoder Current of motor encoder is too high/too low

Damaged EEPROM Parameter reduction characteristic steering ratio unrealistic. Overcurrent of safety circuit (external error) Missing input voltage for safety circuit UL-check, short-circuit LOW-side or intermediate direct current link UL-check, short-circuit HIGH-side

Text in BPK

Voltage supervision UZK

Redundant digital inputs

Supervision increment. Encod.

Wrong U/f adjustment

Low pass filter steering enc.

Current consumption mot. enc.

Faulty EEPROM

Wrong steering ratio parameter

Overcurrent safety ratio

Breakage of safety circuit

UL-check short-circuit LOW

UL-check short-circuit HIGH

Steering Controller (continued)

12-6 223

222

221

220

219

218

217

216

215

214

213

212

Fault No.

23 pulses…pause

22 pulses…pause

21 pulses…pause

20 pulses…pause

19 pulses…pause

18 pulses…pause

17 pulses…pause

16 pulses…pause

15 pulses…pause

14 pulses…pause

13 pulses…pause

12 pulses…pause

Blinkcode of LED

Failure in power stage detected during power on. Power stage and brake won’t be switched on.

No input voltage for the safety circuit, steering is still possible.

Current in safety circuit was too high, system has switched off the safety circuit. Steering is still possible.

Settings make no sense. See figure below this chart.

Power stage and brake won’t be switched on. Replace the controller.

The current of the incremental encoder in the motor (sensor bearing) is too high or two low. Check the encoder and the wiring.

Selftest of supervision of the stepper motor has detected an internal fault. Replace the controller.

Motor adjustments make no sense. Replace parameter sense.

Fault detection of the stepper motor inside the steering wheel or fault in the wiring.

If needed: For safety reasons some digital signals have to come in at two inputs at the same time: X1.1 with X1.3 and X1.2 with X1.4. Error 13 would indicate that either X1.1 was different to X1.3 or X1.2 was different X1.4 for more than 50 milliseconds.

Battery voltage is above a defined limit for too long. Motor current and brake will be switched off.

Remarks

TROUBLESHOOTING & PIN BY PIN VOLTAGES

Text in BPS UL-check, LOW-side phase U, high resistance UL-check, HIGH-side phase U, high resistance UL-check, LOW-side phase V, high resistance UL-check, HIGH-side phase V, high resistance UL-check, LOW-side phase W, high resistance UL-check, HIGH-side phase W, high resistance UL-check, battery voltage low

Safety circuit , missing input voltage at Power-Up warning limit temperature motor warning limit temperature controller

Text in BPK

UL-check phase U LOW-switches

UL-check phase U HIGH-switch

UL-check phase V LOW-switches

UL-check phase V HIGH-switch

UL-check phase W LOW-switches

UL-check phase W HIGH-switch

UL-check no battery voltage

Break safety circ, at Power Up

Warning temperature motor

Warning temperature controller

Steering Controller (continued)

12-7 233

232

231

230

229

228

226

225

224

Fault No.

33 pulses…pause

32 pulses…pause

31 pulses…pause

30 pulses…pause

29 pulses…pause

28 pulses…pause

27 pulses…pause

26 pulses…pause

25 pulses…pause

24 pulses…pause

Blinkcode of LED

Steering controller temperature comes close to the maximum allowed value.

Steer motor temperature comes close to the maximum allowed value.

No input voltage for the safety circuit at power up, selftest is not possible.

Failure in power stage detected during power on. Power stage and brake won’t be switched on.

Remarks

TROUBLESHOOTING & PIN BY PIN VOLTAGES

TROUBLESHOOTING & PIN BY PIN VOLTAGES ratio ratio driving wheel/ wheel/ driving steering wheel wheel steering Pa 145

Pa 146

Pa 147

Pa 148

12-8

100%

traction tractionspeed speed

High temperature controller

Parameter of set value curve lift not realistic Supervision lift Hall effect sensor

Hydraulic inputs (at power on) Warning temperature motor Warning temperature controller Digital Outputs

Parameter set value lift

Supervision lift Hall effect sensor

Hydraulic inputs at power-on

Warning temperature motor

Warning temperature controller

Digital Outputs

Overvoltage

High temperature controller

Low voltage

High temperature motor

Overcurrent in power stage

Overcurrent powerstage

High temperature motor

New software version

12-9 313

312

311

310

309

308

307

306

305

304

303

302

(FLASH—Fault)

New software version

(RAM—Fault)

Fault No. -

Text in BPS

(Watchdog)

Text in BPK

Pump Controller Remarks

Power stage and brake won’t be switched on. Replace the controller.

13 pulses…pause

12 pulses…pause

11 pulses…pause

10 pulses…pause

9 pulses…pause

8 pulses…pause

7 pulses…pause

6 pulses…pause

5 pulses…pause

4 pulses…pause

3 pulses…pause

2 Pulses…pause

Short circuit, overload or broken wire at one of the digital outputs. If this fault occurs, all the outputs will be disabled. Only the lower valve can be switched on.

Pump controller temperature comes close to the maximum allowed value.

Pump motor temperatures comes close to the maximum allowed value.

For Selftest, all inputs have to be low at power on.

Supervision of control handle and wiring, value has to be between 0.25V and 4.75V

Create a new Teach-In process.

Pump controller temperature is too high for too long. Motor current and brake will be switched off.

Pump motor temperature is too high for too long. Motor current and brake will be switched off.

Battery voltage above a definite limit for too long. Motor current and brake will be switched off.

Battery voltage below a definite limit for too long. Motor current and brake will be switched off.

High current, motor current and brake will be switched off.

Power stage and brake won’t be switched on (Reset with parameter 150).

Duty cycle 3:1 (f = 2.1 HZ) Power stage and brake won’t be switched on. Replace the controller.

Duty cycle 1:3 (f = 2.1 HZ)

Duty cycle 1:1 (f = 1.25 HZ) Power stage and brake won’t be switched on. Replace the controller.

Blinkcode of LED

TROUBLESHOOTING & PIN BY PIN VOLTAGES

UL-check, HIGH-side phase V, high resistance UL-check, LOW-side phase W, high resistance UL-check, HIGH-side phase W, high resistance UL-check, battery voltage low

UL-check phase W LOW-switches

UL-check phase W HIGH-switch

UL-check no battery voltage

UL-check, short-circuit HIGH-side

UL-check short-circuit HIGH

UL-check phase V HIGH-switch

UL-check, short-circuit LOW-side or intermediate direct current link

UL-check short-circuit LOW

UL-check, LOW-side phase V, high resistance

RS485 communication with SGI

UL-check phase V LOW-switches

RS485 communication drive controller

RS485 communication drive

UL-check, HIGH-side phase U, high resistance

RS485 communication steering controller

RS485 communication steering

UL-check phase U HIGH-switch

Parameters of V/f-ratio not realistic

Wrong V/f adjustment

UL-check, LOW-side phase U, high resistance

EEPROM

UL-check phase U LOW-switches

Text in BPS

Text in BPK

Pump Controller (continued)

12-10 330

329

328

327

326

325

324

323

322

318

317

316

315

314

Fault No.

30 pulses…pause

29 pulses…pause

28 pulses…pause

27 pulses…pause

26 pulses…pause

25 pulses…pause

24 pulses…pause

23 pulses…pause

22 pulses…pause

18 pulses…pause

17 pulses…pause

16 pulses…pause

15 pulses…pause

14 pulses…pause

Blinkcode of LED

Remarks

Failure in power stage detected during power on. Power stage and brake won’t be switched on.

No communication with display possible, check wiring and display.

Communication failure with traction controller, check wiring and traction controller.

Communication failure with steering controller, check wiring and steering controller.

Motor adjustments make no sense. Replace the parameter set.

Power stage and brake won’t be switched on. Replace the controller.

TROUBLESHOOTING & PIN BY PIN VOLTAGES

12-11 3

XA1-6:1

24V

XA1-6:5

XA1-6:12

XA1-6:7

XA1-6:5

XA1-6:11

XA1-6:6

XA1-6:2

XA1-6:3

XA1-6:6

Page

XA1-6:3

Brake Pedal

Brake Control

XA1-4:5

X13:4

Brake Control

XA1-4:5

Brake Pedal

Safety B+ into Steer

XA3-2:1

Brake Pedal

XA3-2:2

X13:4

XA3-2:2

X13:3

Key

24V (Brake Feed)

Main Cont Control

XA1-2:4

XA1-4:1

Main Cont

XA1-2:4

XA1:1

Main Cont Control

XA1-2:1

Name

Main Cont Control

XA1-2:1

Label

Zone

Traction

S11

Traction

Steer Motor

Traction

Controller

All Voltages in Reference to battery Negtive.

Pin By Pin Voltages Worksheet

Currently jumper between this pin and XA1-6:4

Key On

Key On/Vehicle Speed Limited to 1 MPH when Switch Opens or Jumper Removed

Key On/Vehicle Not Speed Limited to Due to Limited Switch Status

Key On

Key On/Forks Trailing Direction Request

Key On/Forks First Direction Request

Key On

Key On/Operator Presence Switch (S12) Activated

Key On/Operator Presence Switch (S12) Not Activated

Key On/No Steering Faults/ Brake Pedal Switch Activated

Key On/No Steering Faults/ Brake Pedal Switch Not Activated

Key On/No Steering Faults/ Brake Pedal Switch Activated

Key On/No Steering Faults/ Brake Pedal Switch Not Activated

Key On/No Steering Faults

Key On/ No Steering Faults/Brake Pedal Switch Activated

Key On/ No Steering Faults/Brake Pedal Switch Not Activated

Key On

Key On/Steering Faults

Key On/No Steering Faults

Key On

Key On/Faults Contactor Energized 13 Volts Directional Control—not in neutral position.

Key On/Faults Contactor Energized 13 Volts Operator Presence Closed

Key On/Faults

Key On/No Faults

Condition

B+ V

2.5V–.5V

5.0 V

B+ V

2.0 V

B+ V

2.0 V

B+ V

2.0 V

B+ V

< 3.0 V

B+ V

Pulsed 24V across coil Reading off time volts

B+ V

Reading

.0 V (Alarm On) < 3.0 V (No Alarm)

Example

Your Test Results

TROUBLESHOOTING & PIN BY PIN VOLTAGES

12-12

Steering End Limit Sensor (S34)

Steering Feedback Sensor (S32)

XA3-1:4

XA3-1:2

Speed Reduction (Option may be Jumpered)

X40:2

(Steering Request)

Speed Reduction (Option may be Jumpered)

X40:2

XA3-1:4

Speed Reduction (Option may be Jumpered)

X40:1

XA3-6:3

Battery Lock Switch (Option may be Jumpered)

X39:2

Battery Lock Switch (Option may be Jumpered)

X39:2

XA3-6:6

Battery Lock Switch (Option may be Jumpered)

X39:1

(Steering Request)

Feed to Cold Storage

X12:4

XA3-6:2

Key Switch

X12:3

(Steering Request)

Key Switch

X12:2

XA3-6:10

EM. Stop (Emergency Disconnect)

X12:1

Brake Pedal (Operator Presence)

X13:2

(Steering Request)

Brake Pedal (Operator Presence)

X13:2

XA3-6:4

Brake Pedal (Operator Presence)

X13:1

XA3-6:1

Name

Label

Page

Zone

Steer Motor

S37

S37 (B+)

S36

S36 (B+)

S1, S2

S12

Controller

All Voltages in Reference to battery Negtive.

15.0 V

(+/-) .3 V

B+ V

Reading

Key On S32 Activated

Key On S32 Not Activated

B+ V

Drive Unit Position To The Extreme Left or Right 0 V

Drive Unit Position Not To The Extreme Left or Right

Steering Wheel Rotated

Key On

Steering Wheel Rotated

Key On

Key On/Vehicle Speed Limited to 1 MPH when Switch Opens or Jumper Removed

Key On/Vehicle Not Speed Limited to Due to Limit Switch Status

Key On

Key On/Battery Lock Switch Not Activated

Key On/Battery Lock Switch Activated

Key On

Battery Plugged In/Emergency Stop Raised

Key On

Battery Plugged In

Key On/Operator Presence Switch (S12) Activated

Key On/Operator Presence Switch (S12) Not Activated

Key On

Condition

Pin By Pin Voltages Worksheet (Continued) Example

Your Test Results

TROUBLESHOOTING & PIN BY PIN VOLTAGES

XA2-6:12

Center Switch

24V

Control Handle

24V

Out

XA2-6:11

XA2-6:2

XA2-6:1

XA2-6:5

XA2-6:10

XA2-6:9

XA2-6:4

XA2-6:8

XA2-6:3

12-13

XA2-6:3

XA2-3:6

XA2-3:12

6 6 6 6 6 7

XA2-3:3

XA2-3:9

XA2-3:8

XA2-3:7

XA2-2:2

XA2-5:6

6 6

XA2-3:4

XA2-3:10

14 15

6 6

XA2-3:11

Zone

XA2-3:5

XA2-6:6

Steering Feedback Sensor (S33)

XA3-1:3

Page

XA2-6:6

Steering Feedback Sensor (S33)

Name

XA3-1:3

Label

Pump

Steer Motor

Controller

All Voltages in Reference to battery Negtive.

Key On/Top Limit Override (S25) Idle

Key On/Tilt/Sideshift Selection

Key On/Sideshift Left or Right Request (S9), (S10)

B+ at Rest.

B+ V at rest. Activated Left or Right Sideshift .8v

B+ V at rest. Reach or Retract 11.0 to 12.0

Tilt Up 2.3 V. SS Left 5.2 V.

Request (m4) Key On/Reach or Retract Request (S5), (S6)

B+ V at rest. Activated Retract 5.1V,

B+ V

B+ V at rest. Activated Retract 5.0V, Tilt Up 2.3 V. SS Left 5.2 V.

B+ V

B+ V at rest, than lowers to 24.9 V at full lift position

B+ at rest, than lowers to .5v at full tilt

B+ V at rest, than lowers to 24.9 V at full lower position

B+ V

2.5–0.5 V

Reading

Key On/Reach, Tilt Down or Sideshift Right

Key On

Key On/Retract, Tilt Up or Sideshift Left Request (m3)

Key On

Key On Lift

Key On/Lift (m2) Request

Key On/Lower (m1) Request

Key On/Lower

Key On S18 (Sideshift Left) Not Activated

Key On S18 (Sideshift Left) Activated

Key On S19 (Sideshift Right) Not Activated

Key On S19 (Sideshift Right) Activated

Key On S16 (Tilt Up) Not Activated

Key On S16 (Tilt Up) Activated

Key On S17 (Tilt Down) Not Activated

Key On S17 (Tilt Down) Activated

Key On S15 (Retract) Not Activated

Key On S15 (Retract) Activated

Key On S14 (Reach) Not Activated

Key On S14 (Reach) Activated

Key On

Key On, Lift or Lower Activated

Key On, Not Activated

Key On

Key On, Vehicle Lower Requested

Key On, Vehicle Lift Requested

Key On

Key On S33 Not Activated

Condition

Pin By Pin Voltages Worksheet (Continued) Example

Your Test Results

TROUBLESHOOTING & PIN BY PIN VOLTAGES

24V

0/24

24V

XA2-5:1

XA2-5:2

XA2-5:3

XA2-5:5

XA2-5:7

XA1-4:7

12-14 8

Temp. Sensor

15V

XA2-4:6

XA3-5:1

8 8

Temp. Sensor

15V

XA3-5:4

XA3-5:6

XA1-7:1

XA1-7:2

XA2-7:1

XA2-7:2 11 11

XA2-7:3

XA2-7:4

15V

XA1-7:4

XA1-7:3

XA3-5:2

XA3-5:3

Zone

XA3-5:5

XA2-4:2

XA2-4:8

XA2-4:4

8 8

15V

XA2-4:3

XA2-4:7

Temp. Sensor

XA1-4:6

XA1-4:8 8

XA1-4:3

XA1-4:2

XA1-4:4

15V

XA2-5:8 8

XA2-5:4

24V

Page

XA2-5:1

Name

XA2-5:6

Label

Pump

Traction

Steer Motor

Pump

Traction

Pump

Controller

All Voltages in Reference to battery Negtive.

No Test

Key On

No Test

Key On

Key On/Temp Increase Voltage 0 Volts at 75 Degrees

Key On

Key On Steer Motor Rotating

Key On

Key On/Temp Increase Voltage 0 Volts at 75 Degrees

Key On

Key On Lift Motor Rotating

Key On

Key On/Temp Increase Voltage 0 Volts at 75 Degrees

Key On

Key On Traction Motor Rotating

Key On

Key On/Mast Raising or Lowering

Key On

Key On/Top Limit Override (S25) Activated

Condition

Pin By Pin Voltages Worksheet (Continued)

15 V

Varies with Temperature/ Resistance of Thermistor

1.26 Volts at 75 Degrees

Pulsed 0/10 V

15.0 V

Varies with Temperature/ Resistance of Thermistor

1.15 Volts at 75 Degrees

Pulsed 0/10 V

15.0 V

Varies with Temperature/ Resistance of Thermistor

1.25 Volts at 75 Degrees

Pulsed 0/10 V

15 V

Reading Will Wary Depending On Load Approximately 1 Volt with No Load, Approximately 2.7 Volts with 4500 lbs.

24.0 V

Pulsed 0/24 V

24.0 V

B+ V

Reading

Example

Your Test Results

TROUBLESHOOTING & PIN BY PIN VOLTAGES

XA3-7:2

XA4-1:7

XA4-1:8 11 11 5 5 9 9 9 9

XA4-1:1

XA4-1:2

XA2-6:1

XA1-5:4

XA1-1:2

XA1-1:3

15V

XA3-7:4

15V

XA3-7:1

Page

XA3-7:3

Name

Label

Zone

Traction

Pump

Steer Motor

Controller

All Voltages in Reference to battery Negtive.

Relay Off

Relay On/Travel Alarm

Buzzer Off

Buzzer On

Horn Off

Horn On

No Test

Key On

No Test

Key On

Condition

Pin By Pin Voltages Worksheet (Continued)

24.0 V

B+ V

15 V

Reading

Example

Your Test Results

TROUBLESHOOTING & PIN BY PIN VOLTAGES

12-15

PLANNED MAINTENANCE 13. PLANNED MAINTENANCE Maintenance Locations.........................................................................................................13-1 Maintenance Intervals ..........................................................................................................13-2 Recommended Oils ..............................................................................................................13-3 Fluid Capacities ....................................................................................................................13-3

PLANNED MAINTENANCE Maintenance Locations 16

7, 8

6 14 20

12, 13, 17

9 11

9, 18

4 9, 18

13-1

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)

2000 Service Hours or 12 Months whichever comes first

X X X X X

Battery Connector

Lift Chains

1000 Service Hours or 6 Months whichever comes first

500 Service Hours or 3 Months whichever comes first

X X X X X

Lubricate. Lubricate. Lubricate. Lubricate. Lubricate.

Drive Unit

Check fluid level. Change fluid.

Forks

Check for cracks and distortions-check welds. Stopper pins properly engaged.

Function Controls

Travel, lift/lower & extend/retract control their perspective function.

Horn

Sounds when activated.

All Hydraulic Cons.

No leaks.

Hydraulic Reservoir

Check fluid level. Change filter. Change fluid.

X X X X

X X

Lights

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.

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 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.

13-2

PLANNED MAINTENANCE Service Data Recommended Oils & Fluid Capacities

• 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.

ITEM Refill Capacities Approx U.S. gal

ESR15N, ESR18N, ESR20N, EDR13N, ESS15N, ESS20N

Gear Box

1.2 (4.5)

Hydraulic System

8.7 (33)

13-3