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SERVICE MANUAL MODELS 2W5/2W6 WCX/WSX Series Walkie Counterbalance Stacker & Walkie Straddle Stacker 24V AC Powered Electric 3,000-4,000 lb. Capacities

SERVICE ©UniCarriers Americas Corporation 240 N. Prospect Street, Marengo, IL 60152 USA Tel: +1-815-568-0061 Fax: +1-815-568-0179 www.unicarriersamericas.com

PUBLICATION NO.: SM3UC-2W560

FOREWORD This manual contains maintenance and repair procedures for UniCarriers Americas Corporation (UCA) models 2W5 and 2W6 series. In order to assure your safety and the efficient functioning of the lift truck, this manual should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task. All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.

IMPORTANT SAFETY NOTICE The proper performance of service is essential for both the safety of the technician and the efficient functioning of the lift truck. The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately. Service varies with the procedures used, the skills of the technician and the tools and parts available. Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by UCA must first completely satisfy that neither personal safety nor the lift truck’s safety will be jeopardized by the service method selected.

TRUCK MODIFICATIONS Unauthorized forklift modification is not permitted. Per OSHA 1910.178, no modifications or alterations to a powered industrial truck, which may affect capacity, stability or safe operation of the forklift shall be made without the prior written approval of UniCarriers Americas Corporation [UCA], its authorized representative or a successor thereof. After receiving the approval of UniCarriers Americas Corporation, its authorized representative or a successor thereof, the data & capacity plate, decals, tags, operation and maintenance manuals shall also be changed appropriately. Only in the event that UniCarriers Americas Corporation is no longer in business and there is no successor to the business, the user may arrange for a modification or alteration to a powered industrial forklift, provided however, that the user shall: a. Arrange for the modification or alteration to be designed, tested and implemented by an engineer(s) expert in industrial forklifts for their safety; b. Maintain a permanent record of the design, test(s) and implementation of the modification or alteration; c. Approve and make appropriate changes to the data & capacity plate(s), decals, tags, and operation and maintenance manuals; d. Affix a permanent and readily visible label to the forklift stating the manner in which the forklift has been modified or altered together with the date of the modification or alteration, and the name and address of the organization that performed the modification or alteration.

INTRODUCTION This service manual has been prepared to provide necessary information concerning the maintenance and repair procedures for UniCarriers Americas Corporation (UCA) models 2W5 and 2W6 series. Any changes effected in the series after publication of this service manual will be announced in a technical bulletin. It is, therefore, recommended that each relevant technical bulletin be inserted in front of each section and be used together with the service manual as a reference. If a new model requires different service method or has undergone a major change, revised sections will be issued to replace the applicable sections. Each revised section will include the description of how to service the parts for the former specifications. The publication of a revised section will be announced in the technical bulletin. This service manual consists of ten sections as shown in the following table, which gives the updated symbols. When a revised service manual is issued, this ‘‘INTRODUCTION” sheet should be replaced with a revised one. Section

Symbol

GENERAL INFORMATION

(GI)

MAINTENANCE

(MA)

ELECTRICAL SYSTEM

(ES)

DRIVE ASSEMBLY (TRANSMISSION)

(DA)

MOTOR (TRACTION)

(MM)

BRAKE SYSTEM

(BR)

STEER ASSEMBLY

(ST)

HYDRAULIC COMPONENTS

(HD)

LOADING MECHANISM

(LM)

BODY & FRAME

(BF)

Edition: October 2015 Printing: October 2015 (01) Publication: SM3UC-2W560

BODY & FRAME

SECTION

CONTENTS HOOD & INSTRUMENT PANELS . . . . . . . . BF-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . BF-2 TIRE REPLACEMENT . . . . . . . . . . . . . . . . . BF-6 COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . BF-11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . BF-11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . BF-11

HOOD & INSTRUMENT PANELS There are three hoods on the 2W5/2W6 model: Dash (instrument panel) Top Cover (bonnet) Lower Hood All hoods are made of polycarbonate composite materials. SERVICE NOTE: These hoods and fasteners that hold the dash and top cover must be maintained, as per OSHA 1910-178 and B56, to keep unit in operation.

Removal Lower Hood 1. The hood can now be removed by pulling outward on the center of the hood to the left until it releases from the right side retaining brackets. Then slide out from the left side frame.

BF-2

HOOD & INSTRUMENT PANELS Removal (Cont’d) Instrument Panel Required Tools: 5mm Allen wrench 1. Use a 5mm Allen wrench to remove the four mounting bolts holding the instrument panel to the powerhead. Take care when removing instrument panel to catch the components behind the panel. Behind the two center bolts are two large spacers. The two outside bolts are each assembled through a flange bushing that acts as a spring guide for a spring. See component examples in the illustration at left.

Tiller Hinge Cover Required Tools: 4mm Allen wrench SERVICE NOTE: Make note of harness routing before disassembly. 1. Using a 4mm allen wrench, remove the three screws holding the tiller pivot/hinge cover in place and tape or tie wrap to tiller out of the way. SERVICE NOTE: If cover must be removed for any reason, the steerhead must be removed (see next step). Lower half of control head will need to be removed first if cover is to be removed from truck.

BF-3

HOOD & INSTRUMENT PANELS Steerhead Removal Required Tools: 5mm Allen wrench

Cord, wire tie to hold control handles secure and out of the way

1. Remove 7 screws using a 5mm allen wrench from the bottom half of the control head.

2. Separate the top half and remove the harness connector from the printed circuit board. 3. Disconnect sidetracker switches, if truck is equipped with sidetracker feature.

BF-4

HOOD & INSTRUMENT PANELS Steerhead Removal (Cont’d) SERVICE NOTE: The switch levers for the side tracker option are retained by the top half of the control head and will fall out if turned upside down, recommend using tape to hold in place.

BF-5

TIRE REPLACEMENT

There are many different sizes and compounds of drive tires used. Our standard size tire is 10” x 5” x 6-1/2”.

! CAUTION • Caution must always be exercised when pressing a new tire onto the hub. The dimensions from the face of the hub to the edge of the tire is very important in the operation of the truck, to clear the transmission housing. If pressing and dimensions are not maintained and the tire does rub the transmission, this could cause any of the following to occur: • A bond failure from heat. • Transmission housing could be worn beyond repair causing gears to fail. • Drive motor damaged due to excessive amp. draw. • Electrical components fail due to excessive amp. draw and/or heat.

!! WARNING • Do not remove the wheels unless you are familiar with the procedure. For wheel replacement, contact your Local Authorized Dealer. • Do not get under or ride on the forklift when it is supported only by a jack. Doing so could lead to a serious accident, including death in the case the jack comes off accidentally. • Use a jack with a capacity of 3.0 tons or more.

BF-6

TIRE REPLACEMENT

! CAUTION • Always park the forklift on a flat, level and solid surface. • Unload cargo from the forklift. • Do not turn the ignition switch to “ON” or “OFF”, or operate control levers from any position while truck is being serviced. • Disconnect the battery. • Make sure the tiller handle is in the brake on position. Check the forklift and its surroundings for safety. • Use hardwood blocks that do not slip easily and are strong enough to withstand the forklift weight. Do not use broken or cracked blocks or metal blocks that slip easily. • Use wood blocks of the following size: Width: 50 to 100 mm (1.97 to 3.94 in) larger than the longitudinal length of the frame. Length: 20 to 40 mm (0.79 to 1.57 in) larger than the width of the outside of base legs. • To prevent the forklift from inclining, do not place wood blocks of different heights under the right and left truck frame.

Drive Tire 1. Place the forklift on a level and solid surface. 2. Turn the ignition switch to the “OFF” position. 3. Place chocks in front of load wheels to prevent movement of the forklift. 4. Loosen the wheel nuts one or two turns each by turning them counterclockwise. 5. Jack unit so wheel is off the ground and block frame.

!! WARNING

Changing the drive tire - 2W5

• Do not operate the tiller handle. Doing so may cause the wood blocks on the ground to become unstable. • Stop jacking up the forklift when the tire is slightly raised off the ground. Jacking up the forklift excessively high could cause it to roll over. • Do not remove the wheel nuts until the drive tire is raised off the ground. 6. Support the forklift by putting additional wood blocks under each side of the front-end of the frame as shown at left. 7. Remove the wheel nuts and replace the drive tire.

!! WARNING Changing the drive tire - 2W6

• Never get under the forklift while it is supported only by the wood blocks. 8. Reinstall the wheel nuts and temporarily tighten them using the cross tighten method.

BF-7

TIRE REPLACEMENT Drive Tire (Cont’d) 9. Jack frame up and remove the wood blocks from the underside of the frame. 10. Lower the forklift slowly. 11. Tighten the wheel nuts to the specified torque (refer to BF-10). 12. Remove chocks from load wheel. 13. After replacing a tire, drive the forklift and check the tightening torque of each wheel nut again.

! CAUTION • Each wheel nut has a conical bearing surface and each hole in the rim is countersunk so that they can fit with each other. After attaching all wheel nuts, make sure each nut tightly fits with the countersunk hole. If wheel nuts are attached in the wrong direction, they will loosen easily and might cause bolts to break and the wheel to come off.

Load Wheels - 2W5 1. Place the forklift on a level and solid surface. 2. Turn the ignition switch to the “OFF” position. 3. Place chocks behind the drive tire or opposite load wheel to prevent movement of the forklift. 4. Jack unit so wheel is off the ground and block frame as shown at left.

!! WARNING • Stop jacking up the forklift when the tires are slightly raised off the ground. Jacking up the forklift excessively high could cause it to roll over. • Never get under the forklift while it is supported only by the wood blocks. 5. Using large snap ring pliers, remove retaining snap ring.

!! WARNING • Always wear safety glasses and gloves when removing the retaining ring. 6. Replace load wheel and seal. 7. Reinstall the retaining snap ring. 8. Jack frame up and remove the wood blocks from the underside of the frame. 9. Lower the forklift slowly. 10. Remove all chocks. 11. After replacing a tire, drive the forklift and check the retaining snap ring is secure.

BF-8

TIRE REPLACEMENT Load Wheels - 2W6 1. Place the forklift on a level and solid surface. 2. Turn the ignition switch to the “OFF” position. 3. Place chocks behind the drive tire to prevent movement of the forklift. 4. Jack unit the outrigger that requires the load wheel to be changed as shown at left.

!! WARNING • Stop jacking up the forklift when the tires are slightly raised off the ground. Jacking up the forklift excessively high could cause it to roll over. • Never get under the forklift while it is supported only by the wood blocks. 5. Using snap ring pliers, remove retaining snap ring on one load wheel axle at a time. NOTE: It is recommended to replace the snap rings.

!! WARNING • Always wear safety glasses and gloves when removing the retaining ring. 6. Slide (push) load wheel axle out of outrigger and load wheels. NOTE: It is recommended that you place a cloth (rag) under the load wheel as you remove it to catch bearings if they fall off of wheel. 7. Clean axle before installing into new load wheel and bearing. 8. Put one new retaining snap ring on one side of axle. 9. Install axle and the other new retaining snap ring. 10. Follow steps 5 through 8 for next load wheel. 11. Once both load wheels are replaced, raise outrigger and remove blocks. 12. Remove chock from drive tire. 13. After replacing a wheel, drive the forklift and check that the retaining snap rings are secure.

BF-9

TIRE REPLACEMENT Drive Tire and Load Wheel Specifications - 2W5  - standard

 - option Model

Tire

2W5 3000

Drive Tire Load Wheel

Tire size (Poly) Type

Poly



Tire size (Poly) Type

4000

10 x 5 (255 x 127) 

10.5 x 4.5 (266 x 114) Poly



Tightening Torque Model Wheel nut Nm (kgf/m, ft/lb)

2W5 series

Drive

157 to 196 (16 to 20, 116 to 145)

Drive Tire and Load Wheel Specifications - 2W6  - standard

 - option Model

Tire

2W6 3000

Drive Tire Load Wheel

4000

Tire size (Rubber)

10 x 5 (255 x 127)

Type



Rubber

Tire size (Poly) Type



4 x 2.75 (265 x 100) Poly



Tightening Torque Model Wheel nut Nm (kgf/m, ft/lb)

BF-10

Drive

2W6 series 157 to 196 (16 to 20, 116 to 145)

COUNTERWEIGHT !! WARNING • Use the correct capacity lifting devices no less than a 2 ton (4,000 lb) to lift counterweight. A. Counterweight B. Washer C. Bolt

Removal 1. Move the 2W5 to a level floor area. 2. Fully lower forks to floor and tilt mast forward. 3. Steer head tiller handle in vertical position and turn off ignition switch. 4. Remove battery and place on a pallet. 5. Remove battery tray and rollers if installed. 6. Remove counterweight covers. 7. Attach lifting device to counterweight lifting eye. 8. Remove bolt (B) & washer (C). 9. While lifting the counterweight slightly move lifting device and counterweight toward the mast side of the 2W5 until it has passed the counterweight rod in the lower frame of the unit.

!! WARNING • Do not operate mast or move the 2W5 without the counterweight in place, it could result in serious injury or death. 10. Remove counterweight from unit.

Installation 1. Using the same lifting equipment to remove the counterweight into frame. Make sure not to place on the counterweight rod. 2. Move slide, counterweight onto rod. 3. Once counterweight is completely on rod, keep the lift equipment attached while installing bolt (C) and washer (B). 4. Hand start bolt (C) and then use air powered impact wrench to fully tighten bolt (C). 5. Make sure counterweight is fully tightened down and against the frame. 6. Install counterweight covers, battery tray and rollers, if equipped. 7. Install battery and battery gates. 8. Test operation of unit in clear area before returning to operation.

BF-11

MEMO

BF-12

BRAKE SYSTEM

SECTION

CONTENTS BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . BR-2 Spring Applied Electromagnetic Release Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-2 Maintenance & Service . . . . . . . . . . . . . . . . BR-5 MANUAL BRAKE RELEASE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . BR-7 INSPECTION & SERVICE . . . . . . . . . . . . . . BR-9 Brake Removal . . . . . . . . . . . . . . . . . . . . . . BR-10 Brake Installation . . . . . . . . . . . . . . . . . . . . . BR-11

BRAKE SYSTEM Spring Applied Electromagnetic Release Brake Operating Principle As described, the service brake uses a spring applied or operated, electromagnetic release type system for the units service brake. The assembly is made up of four major components, as below: the stator or electromagnetic, the springs and armature plate, the friction disc lining rotor, and the splined hub. Electric Brake

BR-2

BRAKE SYSTEM Spring Applied Electromagnetic Release Brake (Cont’d) Electric Brake

Tiller Position for Brake ON The tiller arm brake ON position is either fully raised or fully lowered. This electromagnetic brake type also works with the motor controller’s brake on regen feature. The brake on regen will be activated any time the Interlock Brake switch is opened by handle movement to brake ON position (fully raised or fully lowered).

ke O

Bra

ke Bra On

Brake Off

Brake On

2W5

2W6

BR-3

BRAKE SYSTEM Spring Applied Electromagnetic Release Brake (Cont’d) If the motor controller sees drive motor amps are above a preset level, the motor will go into brake regen or plug mode, slowing the motor down electrically before removing electric voltage from the electric magnet in the brake assembly, as shown below:

A. Once the electromagnetic is deenergized (voltage off) B. The springs inside the brake C. Will apply against the armature plate, D. Which closes down on the floating friction disc to stop the drive motor/transmission.

BR-4

BRAKE SYSTEM Maintenance & Service Spring Applied Brake Specifications Item

Specification

Type Brake Disc

Electric release spring applied Floating, non-asbestos lined disc

Voltage Coil Resistor Maximum RPM’s

24V 14.9 ohms, maximum 5,000

Air Gap in (mm) Motor Mounting Bolt Torque

Standard 0.012 (0.3), maximum 0.032 (0.8) 7.8 Nm (69 in/lb)

Tools Required: Basic Hand Tools Nonmagnetic Feeler Gauge in metric Snap Ring Pliers 5mm Hex Socket or Wrench Vacuum Cleaner Personal Protection Equipment (i.e.; eye protection, dust protection) V.O.M.

BR-5

BRAKE SYSTEM Planned Maintenance !! WARNING • Always wear PPE when working on brake assembly, raise drive off floor. 1st Month or 200 hours • Refer to GI section for removing covers. • Clean and vacuum any dust from brake assembly. • Check that the assembly is not loose. • With battery plugged in, active (OFF) and deactive (ON) brake, listen for noises of armature plate hitting the pole faces of the stator. If no noises, may need more cleaning. • With the brake assembly in OFF position (operational), measure air gap. Refer to specification, if above maximum air gap, then replace floating friction disc (rotor). NOTE: While transporting large loads up and down grades, the friction disc faces will heat up and, in some cases, may produce odors which may also indicate shorter maintenance intervals. 6 Months or 600 Hours • Inspect for hub to friction disc wear. This will require removing steerhead tiller handle assembly. Refer to Section ST. • There should be little to no free play between hub and friction disc (rotor). • Should have even wear on all splines. • If friction disc has uneven wear, replace disc as soon as possible. • If broken spline is found, replace friction disc and hub before returning unit to service.

BR-6

MANUAL BRAKE RELEASE PROCEDURE !! WARNING • With brake released, use extreme caution when moving truck and block wheels when no movement is required. Never park truck with brake manually released on any incline. To manually release the brake follow these instructions, item by item, as listed below. 1. Remove units covers and locate brake assembly on top of drive motor (Fig. 1).

Fig. 1

Fig. 2 2. Block drive wheel. 3. Use two (2) screws, M5-0.8 x 45, and thread into brake housing and upper pressure plate. On newer production trucks, manual brake release screws are provided with the frame. They are mounted below the hydraulic pump and motor (Fig. 2).

BR-7

MANUAL BRAKE RELEASE PROCEDURE 1. Tighten both screws until brake pad clears brake rotor and is free to rotate. Truck brake is now released (off). To return brake to normal operation follow these instructions, item by item, as listed below.

2. Remove two (2) screws from brake pad on top of drive motor. 3. Brake is now returned to normal operation and will be applied until released electrically by tiller/steerhead move and brake switch. 4. Raise drive tire from floor and test brake operation. 5. Always test unit’s brake operation before returning to operation, in a clear area. 6. Remove blocks, unplug battery and install all hoods and covers before placing unit into operation.

BR-8

INSPECTION & SERVICE Measuring Air Gap NOTE: When measuring air gap use only nonmagnetic feeler gauges.

!! WARNING • When conducting air gap measurement, have drive tire off floor and unit blocked to prevent movement. Never work on this unit brake while unit is parked on an incline. Manually release brake to measure air gap. 1. With unit’s drive tire off floor, remove covers. Refer to GI section. 2. Unplug battery. 3. Using a vacuum, clean any brake dust or foreign material from assembly. 4. Only use the correct size screw for brake assembly, as shown below. Always cross tighten screw evenly. Once these screws are secure and tightened you can take your measurements.

5. Use non magnetic feeler gauge at a minimum of four (4) places to measure air gap. Maximum air gap, 0.0315 in. (0.8 mm); Normal, 0.0118 in. (0.3 mm). a. If air gap is below 0.0315 in. (0.8 mm) and there is no more than 0.0079 in. (0.2 mm) difference in measured air reading, the friction disc should not need to be replaced. b. If the air gap is over 0.0315 in. (0.8 mm) or larger than a 0.0079 in. (0.2 mm) difference in your measurement is seen, replace friction disc and hub. 6. After measurement or replacement is complete, loosen and remove release screws from brake assembly.

! CAUTION • Always completely remove manual release screws from brake assembly to prevent possible damage to friction disc. 7. While drive tire is still off floor, plug battery in and test brake operation. 8. If brake operation is working correctly, lower unit to floor and conduct operation brake check in a clear area. 9. Replace all hoods and covers before returning to service. 10. Air gap measurement should be recorded for reference in unit Planned Maintenance records.

BR-9

INSPECTION & SERVICE Brake Removal Required Tools / Parts: 4 mm Allen wrench

5mm Allen wrench

6mm Allen wrench

12mm Combination wrench

(2) 9/16 Combination wrenches

Wire cutters

Snap ring pliers

E-rings

Wire ties

Lubri-plate

Lock nut Battery Removal (refer to section GI-13, also review Battery Handling policy or procedure with customer/end user.) Hood and Instrument Panel Removal (refer to Body & Frame section)

Tiller Hinge Cover Required Tools: 4mm Allen wrench NOTE: Make note of harness routing before disassembly. Using a 4mm allen wrench, remove the two screws holding the tiller pivot/hinge cover in place and tape to tiller out of the way. NOTE: Lower half of control head will need to be removed first if taking cover off.

Tiller Mount Bracket Removal Required Tools: (2) 9/16 Combination wrenches

Wire cutters

Lock nuts

! CAUTION • Support tiller handle during disassembly of return spring to prevent unexpected movement/lowering of tiller handle. NOTE: Make note of harness routing before disassembly.

BR-10

INSPECTION & SERVICE NOTE: Mark connectors located by brake assembly to ease reassembly. 1. Remove wire ties and disconnect harness connectors. Tie main harness and tiller harness back out of the way. 2. Using (2) 9/16 wrenches slowly loosen the 2 nuts and bolts attaching the lower spring mount and tiller mount to the motor. Before removing both nuts and bolts fully check the spring and make sure all tension has been released from the spring. Discard lock nuts. 3. Remove 2 remaining bolts and nuts, remove tiller and mounting bracket from motor.

Brake Removal Required Tools: 5mm Allen wrench

Snap ring pliers

1. Remove the 3 mounting screws holding the brake assembly with a 5mm allen wrench and lift brake assembly off of motor. 2. Remove the snap ring and the spline brake drive hub from the top of the motor armature and inspect.

Brake Installation !! WARNING • Always wear PPE when working on brake assembly, raise drive off floor. • With brake released, use extreme caution when moving truck and block wheels when no movement is required. Never park truck with brake manually released on any incline. 1. Install manual release bolts, supplied with brake, into holes shown (*) and tighten with a 4mm Allen wrench to release brake spring pressure. 2. Install spline hub (B) onto motor shaft and woodruff key (supplied with motor). Secure snap ring (E) with snap ring pliers. NOTE: Do Not use hammer to install spline hub (B) or brake disc (C). 3. Align lower disc (D) with mounting holes in motor. 4. Install floating brake disc (C) as shown, ensuring that the disc moves freely on the spline shaft. NOTE: If the disc does not move freely, it may cause premature wear. 5. Align brake coil (A) with lower disc (D) to mounting holes in motor and install 3 mounting screws (F) finger tight.

BR-11

INSPECTION & SERVICE Brake Installation (Cont’d) 6. Using a 5mm allen wrench, tighten each bolt (1, 2, 3) in 1/4 turn increments, in sequence shown. Use a torque wrench to set to proper torque. (Torque: 7.8 Nm, 69 in/lb, for PN: 44000-GP20A) NOTE: Over torquing may cause brake to bind and cause premature wear. 7. Connect electrical connection.

!! WARNING • When conducting air gap measurement, have drive tire off floor and unit blocked to prevent movement. Never work on this brake unit while truck is parked on an incline. Manually release brake to measure air gap. 8. Verify air gap is within specifications per the brake inspection on BR-9. Air Gap:

Normal Maximum

0.012 in (0.3 mm) 0.032 in (0.8 mm)

9. After completing air gap procedure, remove manual release bolts and store in holder, located on truck’s frame.

! CAUTION • Always completely remove manual release screws from holes in the brake assembly to prevent possible damage to friction disc.

BR-12

DRIVE ASSEMBLY

SECTION

CONTENTS TRANSMISSION DRIVE ASSEMBLY . . . . . DA-2 Basic Operation . . . . . . . . . . . . . . . . . . . . . .DA-2 Gears, General Description . . . . . . . . . . . . . DA-3 TRANSMISSION REMOVAL . . . . . . . . . . . . DA-5 Motor Removal . . . . . . . . . . . . . . . . . . . . . . DA-6 Transmission Removal (Motor Already Removed) . . . . . . . . . . . . . . . . . . . . . . . . DA-7 TRANSMISSION DISMANTLING . . . . . . . . .DA-8 TRANSMISSION ASSEMBLY . . . . . . . . . . . DA-13

TRANSMISSION DRIVE ASSEMBLY Basic Operation The transmission used in UCA’s drive assembly enables the motor to turn with transmission in a vertical balanced column. Preloaded ball bearings are used in the transmission swivel, and tapered bearings on the output shaft contribute to the transmission’s ease of steering and quiet and dependable operation. Traction power delivered by the drive motor is transferred through the speed reduction gears (items 23 & 24) located in the upper portion of the lower transmission housing. The power is further transferred through the beveled gear shaft to the beveled gear (item 4), located in the lower portion of the lower transmission housing, and finally through the output shaft (item 12) to the drive wheel (as shown below). To Motor To Upper Transmission 1

37 36

12 3

24 15

19 18 7

34 32

29 26

8 9

10 Apply Loctite 603

Item

Description

Item

Final Drive Assembly

Gear Set

Description

O-Ring 140 x 3

Radial Steering Bearing

Wheel Nut

Plug - Drain M14-1.5

Bolt, M8 x 16 Class 8.8

Lower Pinion Bearing

Sealing Washer

Breather Valve

Shim Kit - Lower Pinion Adjusting

Bolt, M8 x 16 Class 8.8

Lubrications Nipple

Upper Pinion Bearing

Gear - Mate Spur

Plug - Fill M14 x 1.5

Spacer Sleeve

Gear - Input

Sealing Washer

Shim Kit - Upper Pinion Adjusting

Key - Woodruff 4 x 16

Lock Washer

Nut - Bearing Retainer M20-1.5

Nut - Spanner M12 - 1.75

Bolt, M8 x 35 Class 10.9

Axle Shaft

Drive Seal O-Ring

Bolt, M8 x 45 Class 10.9

Stud - Hub M14-1.5 x 33

Bearing Spacer

Knock Pin

Inner Axle Bearing

Shim Kit - Adjusting

Mounting Ring

Shim Kit - Adjusting

Shim - Adjusting

Transmission Case

Bolt, M16 x 1.5 Class 10.9

Bearing - Outer Axle

Seal, Oil 75 x 95 x 5

Axle Washer

Lock Washer

Seal, String Guard

Axle Cover

DA-2

Item

Description

TRANSMISSION DRIVE ASSEMBLY Gears, General Description As described before, there are two sets of gears in the UCA transmission. The upper hi-speed reduction gears which determine the speed and power of a unit and the beveled gear set which transfers the speed and power to the output shaft. The only standard gear ratio is 14:1, these gear ratios are not matched sets. NOTE: New locknuts must be ordered whenever replacing either motor, or transmission reduction gear. The beveled gear seat does not change from unit to unit and can only be purchased as a set (as shown at left). NOTE: As described later, these gears must be installed and adjusted to the proper backlash for quiet and efficient operation.

Planned Maintenance The maintenance of this drive assembly is much like any other assembly of this type. The following maintenance checks are required to be performed: Steer Bearing Lubricate the two (2) grease nipples on steer bearing every 30 days or 200 hours.

NOTE: Use Chevron LC Grease EP for standard operation and use Mobil 28 (synthetic) for freezer operation.

DA-3

TRANSMISSION DRIVE ASSEMBLY Gears, General Description (Cont’d) Planned Maintenance (Cont’d) Transmission Gear Fluid Every 30 days or 200 hours check oil level. After the first 200 hours of operation, and then every 12 months or 2400 hours, drain and replace gear oil (use SAE 80/90) approximately 3.5 pints.

Drive Wheel Mount Nuts After the first thirty days, or 200 hours, re-torque drive wheel nut to 100 ft/lb (135 Nm), then recheck torque and drive tire condition every 60 days or 400 hours going forward.

Mount Bolts After the first two days, or 200 hours, check all mounting bolts to frame, should be 57 ft/lb (77 Nm).

DA-4

TRANSMISSION REMOVAL Required Tools / Parts 4 mm Allen wrench

5mm Allen wrench

6mm Allen wrench

8mm Allen socket

10mm Combination wrench

12mm Combination wrench

13mm Combination wrench

(2) 9/16 Combination wrenches

1/2” Drive impact extension-12” long

19mm Impact swivel socket

19mm Impact socket

3/8” Extension-6” long with 5/16 Allen socket

Wire cutters

Battery lifting beam

(2) 4” x 4” x 6” Long blocks of wood

(1) 2” x 6” x 12” Block of wood

Wires ties

E-rings

Lock nut

Lubri-plate Battery Removal (refer to GI-13, also review Battery Handling policy or procedure with customer/end user.) Hood and Instrument Panel Removal (refer to Body & Frame section) Tiller Mount Bracket Removal (refer to Steer Assembly section) Brake Removal (optional but recommended if motor is to be disassembled for inspection.) Required Tools: 5mm Allen wrench 1. Remove the 3 mounting screws holding the brake assembly with a 5mm allen wrench and lift brake assembly off of motor.

DA-5

TRANSMISSION REMOVAL Motor Removal Required Tools: 8mm Allen socket

“O” Ring seal

13mm Combination wrench

1/2” Drive impact extension - 12” long

10mm Combination wrench

(2) 4” x 4” x 6” Long blocks of wood

19mm Impact swivel socket

Special drive motor gear nut socket P/N 38216-FS001

1. Remove the field and armature leads from the drive motor using a 10mm wrench on the field terminals and a 13mm wrench on the armature terminals. 2. Remove cable clamps and position motor cables and harness out of the way. 3. Jack up the truck and support it using 4” x 4” blocks of wood under side skids on the power head. 4. Using a 19mm socket, remove the 5 wheel nuts (#8) and remove the tire. 5. Turn the drive assembly so the 3 motor mounting bolts (#5) are visible from under the truck and remove them using a 8mm Allen socket. The bolts are secured with loctite and will require clean up or replacement before reassembly. Item #

DA-6

Description

Screw

Washer

O-Ring

Screw

Drive Motor Assembly

Transmission Assembly

Wheel Nut

Woodruff Key

Nut

Pinion Gear

TRANSMISSION REMOVAL Motor Removal (Cont’d)

! CAUTION • The motor is heavy; carefully lift the drive motor up and out of the transmission using care not to nick the gears (#11). Remove and discard the o-ring seal (#3) on the motor.

Transmission Removal (Motor Already Removed) Required Tools: 19mm Impact socket 3/8” Extension-6” long and 5/16 Allen socket (1) 2” x 6” x 12” Long block of wood (used as a spacer) 1. Lift the truck and drain the transmission fluid. Place a 2” x 6” x 12” wood spacer under the transmission. Support the bottom of the transmission on the pinion side, (a 3/8” drive extension-6” long with an Allen socket inserted through the middle motor mounting hole will also work) and lower the power head on the floor. 2. Remove the six transmission mounting bolts (#1) on previous page with a 19mm socket. The bolts are secured with loctite and will require clean up or replacement before reassembly. 3. Carefully lift power head high enough to clear transmission. The transmission should now be sitting on top of the wood spacer. Carefully slide the wood spacer and the transmission is sitting on out from under power head while supporting the transmission.

DA-7

TRANSMISSION DISMANTLING Tools 5mm Allen wrench

6mm Allen wrench

24mm Impact socket

30mm Impact socket

1/2 Inch Air impact

Pin punch

Brass drift

Hammer

Mallet/Dead blow hammer

Propane torch

Scraper

Press

Protective Glasses When the directive for protective glasses is given, protective glasses shall always be worn to avoid personal injury.

!! WARNING • Always wear safety glasses and only use an OSHA approved air nozzle of no more than 30 psi. 1. Drain oil from transmission. Remove transmission from truck as described on pages DA-6 & DA-7.

2. Use a 6mm allen wrench to remove the 10 screws holding the top cover in place. Use a mallet or dead blow hammer to remove the transmission top cover.

NOTE: The top cover is located by means of two dowel pins.

DA-8

TRANSMISSION DISMANTLING 3. Put wheel nuts on two adjoining wheel studs and securely mount transmission in vise with side cover facing up.

! CAUTION • Transmission is heavy. Use only a vise securely mounted to a work bench or floor, so transmission will not move. 4. Use a 5mm allen wrench to remove the eight screws holding the side cover in place.

5. Use a mallet/dead blow hammer to unseat the side cover.

NOTE: An O-ring seals the side cover. Use care not to damage sealing surfaces. 6. Remove O-ring and discard.

DA-9

TRANSMISSION DISMANTLING 7. Unstake the pinion shaft retaining nut.

8. Remove the pinion nut using a 30mm impact socket and 1/2 inch impact gun.

! CAUTION • Pinion nut is loctited. When removing the pinion nut, the transmission housing will try to turn. BE SURE to keep fingers away from gears while loosening nut with impact wrench. 9. Reinstall pinion nut, hand tighten. 10. Remove the ring gear retaining bolt using a 24mm impact socket and 1/2 inch air impact gun.

NOTE: Retaining bolt is installed with loctite and may require heating to remove the bolt. Heating head of bolt with propane torch for two minutes should be sufficient.

! CAUTION • When using torch, be sure all flammable objects have been removed from the area. 11. Remove transmission from vise. Support transmission housing and press axle shaft out of ring gear. NOTE: Inner axle bearing, seal and spacer/shims will come out together. Measure the thickness of the shims and note their position for later assembly.

DA-10

TRANSMISSION DISMANTLING 12. Remove axle & shim.

13. Remove ring gear.

14. Remove pinion nut and discard. Remove reduction gear, spacers and pinion shaft. NOTE: Measure the thickness of the shims and note their position for later assembly.

DA-11

TRANSMISSION DISMANTLING 15. If replacing bearings, make note of spacer placement and size/ number of any shims. 16. Check rubber vent in transmission top cover and replace if necessary.

DA-12

TRANSMISSION ASSEMBLY Tools 5mm Allen wrench

6mm Allen wrench

24mm Impact socket

30mm Impact socket

1/2 Inch Air impact

Pin punch

Brass drift

Hammer

Mallet/Dead blow hammer

Propane torch

Scraper

Press

250 ft/lb Torque wrench

Inch pound beam or Dial type torque wrench

Parts O-Ring - motor

O-Ring - side cover

Lock nut pinion

Loctite/574 sealer

Loctite 603

Axle seal

Shim pinion shaft, if needed

Shim pinion position, if needed

Shim axle shaft, if needed

Shim ring gear position, if needed

1. Clean up and inspect all parts. Clean up all sealing surfaces of sealant and internal/external threads of Loctite. 2. Do not install axle seal, loctite pinion nut, or ring gear bolt until all adjustments and checks have been made. 3. Pre lube axle and pinion bearings with a light oil. Install pinion shaft, shims/spacers and reduction gear. Install pinion nut and torque to 170 Nm (125 ft/lb). Rotate the pinion shaft, as the nut is to seat the bearings properly.

4. Check pinion bearing preload with a dial or beam type torque wrench. Rolling torque should be between 0.5 Nm (4.5 in/lb) and 0.8 Nm (7 in/lb). 5. Install inner axle bearing onto the axle shaft without the axle seal and install in transmission housing. Install spacer, shims and ring gear into the transmission and torque the ring gear retaining bolt to 300 mm (221 ft/lb). Rotate the ring gear as bolt is torqued to seat bearings properly. 6. Check axle bearing preload with a dial or beam type torque wrench using pinion shaft nut. Rolling torque should be between 1.2 Nm (10.6 in/lb) and 1.3 Nm (11.5 in/lb).

DA-13

TRANSMISSION ASSEMBLY 7. Paint at least six teeth with gear marking compound and check gear pattern. If adjustment is necessary it will also be necessary to go back and recheck pinion and axle bearing preloads. NOTE: If shims are added/removed to adjust pinion depth, the preload on the pinion bearings must be rechecked and readjusted, if necessary, to maintain proper bearing preload.

DA-14

TRANSMISSION ASSEMBLY 8. Remove axle and ring gear. 9. Remove inner axle bearing from axle shaft. 10. Set inner axle bearing into the bearing cup. Apply Loctite 574 sealer to the outside circumference of the axle seal and install.

11. Install spacer, shims and ring gear in housing.

12. Press axle shaft into inner bearing, spacers and ring gear. NOTE: Check alignment of splines on axle shaft and ring gear during pressing operation to prevent damage to splines. NOTE: If no press is available the axle shaft can be cooled in a freezer to shrink it. By working quickly it can be installed in the axle bearing and far enough into the ring gear so the ring gear mounting bolt can be used to finish pulling the axle shaft into the bearing. The temperature of the axle shaft must be allowed to equalize with the transmission housing before the ring gear mounting bolt is torqued. 13. Install two wheel nuts and secure in vise, as during disassembly.

! CAUTION • Transmission is heavy. Use only a vise securely mounted to a work bench or floor, so transmission will not move. 14. Remove the ring gear mounting bolt and apply Loctite 603 to the threads. Install the bolt and torque to 300 Nm (221 ft/lb).

DA-15

TRANSMISSION ASSEMBLY 15. Remove the pinion nut and apply Loctite 603 to threads. Install nut and use a torque wrench to torque the nut to 170 Nm (125 ft/lb), stake nut with a small punch.

16. Apply Loctite 574 sealer to the top of the transmission case and install the top cover. Apply Loctite 603 to the threads of the top cover bolts and torque the bolts down evenly to 33 Nm (24 ft/lb). 17. Install a new o-ring on the side cover and install. Torque the mounting bolts down evenly to 16 Nm (144 in/lb). 18. Grease steer bearing. 19. Remove transmission from vise and install in truck. 20. Fill gear case with 3.5 pints of SAE 80/90 gear lube. 21. Test truck for proper operation.

DA-16

ELECTRICAL SYSTEM

SECTION

CONTENTS BASIC ELECTRICAL TERMS . . . . . . . . . . . ES-2 FUNDAMENTAL LAWS OF ELECTRICITY . . . . . . . . . . . . . . . . . . . . . . ES-3 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . ES-5 Commonly Used Terms . . . . . . . . . . . . . . . . ES-5 General Electrical Symbols . . . . . . . . . . . . . ES-7 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . ES-8 Operational Features . . . . . . . . . . . . . . . . . . ES-8 MDI MULTIFUNCTION DIGITAL INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . ES-10 METER PANEL . . . . . . . . . . . . . . . . . . . . . . . ES-13 Optional Meter Panel & LED Function . . . . . ES-13 Detail of LCD . . . . . . . . . . . . . . . . . . . . . . . . ES-14 Meter Panel Explanation . . . . . . . . . . . . . . . ES-14 ECO PANEL NAVIGATION . . . . . . . . . . . . . . ES-20 DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . ES-24 ECO ADJUSTMENT CHANGE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . ES-31 ECO ADJUSTMENT OPTIONS . . . . . . . . . . ES-35 ECO ADJUSTMENT ADJUSTMENTS . . . . . ES-41 ECO ADJUSTMENT PASSWORD . . . . . . . . ES-45 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . ES-51 DESCRIPTION OF THE CONNECTIONS . . ES-55 PROGRAMMING & ADJUSTMENTS USING DIGITAL HAND SET . . . . . . . . . . . ES-56 HANDSET CONNECTION . . . . . . . . . . . . . . ES-57 HANDSET CONTROLLER SETTINGS . . . . ES-59 Function Configuration Main/Traction . . . . . ES-62 Config Menu Adjustments . . . . . . . . . . . . . . ES-65 Main Menu “Parameter Change” Functions List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-67 Main Menu “Tester” Functions List . . . . . . . . ES-70 Program VACC . . . . . . . . . . . . . . . . . . . . . . ES-72 Secondary/Pump Handset Menus Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . ES-74 Function Configuration Secondary/Pump . . ES-76 Other Functions . . . . . . . . . . . . . . . . . . . . . . ES-79 SELF DIAGNOSIS OF REMA PCB 1 . . . . . . ES-80 2W5/2W6 MULTIPLEXER (PCB) BOARD MANUAL PROGRAM PROCEDURE . . . . ES-87

COMBI AC1 ALARMS LIST . . . . . . . . . . . . . ES-90 Download HM from MDI . . . . . . . . . . . . . . . ES-92 Master Micrcontroller Alarms Overview . . . . ES-94 Alarm Index . . . . . . . . . . . . . . . . . . . . . . . . . ES-96 Master Warnings Overview . . . . . . . . . . . . . ES-106 Secondary / Pump Alarms Overview . . . . . . ES-111 Secondary / Pump Warnings Overview . . . . ES-116 LEGEND - 2W5/2W6 . . . . . . . . . . . . . . . . . . ES-121 SCHEMATIC - 2W5/2W6 . . . . . . . . . . . . . . . ES-122 POWER WIRING - 2W5/2W6 . . . . . . . . . . . . ES-123 CONTROL WIRING - 2W5 . . . . . . . . . . . . . . ES-124 CONTROL WIRING - 2W6 . . . . . . . . . . . . . . ES-125 CONTROL WIRING - 2W5/2W6 . . . . . . . . . . ES-126 CONTROL WIRING COMPONENT LIST 2W5/2W6 . . . . . . . . . . . . . . . . . . . . . . . . . . ES-128 WIRE ROUTING . . . . . . . . . . . . . . . . . . . . . . ES-129 Chassis Harness . . . . . . . . . . . . . . . . . . . . . ES-129 Brake Harness . . . . . . . . . . . . . . . . . . . . . . ES-130 Subharness Mast Height Switch - 2W5 . . . . ES-131 Subharness Mast Height Switch - 2W6 . . . . ES-131 Optional Work Light Harness . . . . . . . . . . . . ES-132 STEERHEAD WIRING . . . . . . . . . . . . . . . . . ES-133 TRUCK ELECTRONICS . . . . . . . . . . . . . . . . ES-134 BATTERY GATE AND ROLLER WITH SWITCH - 2W6 . . . . . . . . . . . . . . . . . . . . . ES-135 PIN CONNECTIONS . . . . . . . . . . . . . . . . . . . ES-136 MDI, ECO-SMART DISPLAY AND IGNITION SWITCH . . . . . . . . . . . . . . . . . . ES-137 TOGGLE SWITCH INSTALLATION OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-138 TROUBLESHOOTING ELECTRICAL PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . ES-141 TROUBLESHOOTING . . . . . . . . . . . . . . . . . ES-143 Main Power Check - Positive Side . . . . . . . . ES-147 Main Power Check - Negative Side . . . . . . . ES-149 Fuse 2 Checks . . . . . . . . . . . . . . . . . . . . . . ES-150 Fuse 3 Checks . . . . . . . . . . . . . . . . . . . . . . ES-151 K1 Contactor Circuit . . . . . . . . . . . . . . . . . . ES-151 Lower Circuit . . . . . . . . . . . . . . . . . . . . . . . . ES-152 Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . ES-152 Horn Circuit . . . . . . . . . . . . . . . . . . . . . . . . . ES-153 Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . ES-153 PCB1 Basic Checks . . . . . . . . . . . . . . . . . . ES-154 Motor Encoder Circuit . . . . . . . . . . . . . . . . . ES-155 MDI Circuit Checks . . . . . . . . . . . . . . . . . . . ES-156

BASIC ELECTRICAL TERMS Voltage is an electromotive force “EMF” and is an electrical pressure resulting from a difference in electrical potential between two (2) points. It may be compared to the pressure that forces water through a garden hose because of a difference in pressure at each end of the hose. Ampere is the measure of “current” or flow. Electrical current (measured in amps) is comparable to the flow of water in a garden hose. A Watt is electrical power. The number of watts is equal to volts times amps.

Ohms is the measure of electrical resistance or “friction”. Anything that slows down or resists the flow of electricity through a conductor is called resistance.

Polarity The Polarity between two points refers to the relative balance of electrons (negatively charged particles) and protons (positively charged particles). An excess of electrons gives a negative charge, an excess of protons will give a positive charge. This gives a negative and positive terminal on each battery. In a storage battery you can think in terms of current flowing from the positive terminal and back into the negative terminal. Direct Current (DC) When the flow of current is always in the same direction (not necessarily at the same amperage though), it is under the influence of a DC voltage. A battery is a typical example of DC voltage because the negative and positive terminals of the battery never change their polarity.

Alternating Current (AC) When a source of voltage periodically reverses polarity, it is said to be alternating. If a current flow is generated by an AC voltage, it will also be alternating. A good example of AC current is the electricity used in your home.

ES-2

FUNDAMENTAL LAWS OF ELECTRICITY 1. Matter consists of atoms. Atoms are made up of positive charges, protons, and negative charges, electrons. 2. In some materials, called “conductors”, the electrons are “free” to move from one atom to another when electrical pressure, voltage, is applied. Voltage is measured in volts. 3. The movement of electrons through a conductor resulting from the application of a voltage is called an electric current. The greater the voltage, the more electrons flow, and the greater is the current. Current is measured in amperes. 4. For simplicity, the direction of flow of an electric current is often considered to be from the positive terminal of battery or generator, through the circuit, and back to the negative terminal. 5. All conductors resist the flow of current to some extent, some more than others. This resistance is measured in ohms. The resistance of a conductor depend on: • Material. Some materials have greater resistance than others (copper, silver, aluminum and iron are good conductors). • Length of conductor. The longer the conductor, the greater the resistance. • Size (cross section) of conductor. The smaller the cross section, the greater the resistance. • Temperature of conductor. An increase in temperature usually increases resistance. 6. The voltage drop across any circuit element is directly proportional to its resistance to the current flowing through it. Ohm’s Law explains the interaction of voltage (E), current (I), and resistance (R), in any closed electrical circuit: Ohms =

Volts R=E Amps I

Amps =

Volts I= E Ohms R

Volts = Amps x Ohms E = I R 7. Magnetic field have a north pole and a south pole. The unlike poles of magnets attract each other. Like poles repel each other. 8. A current flowing through a wire or a coil of wire creates an electromagnetic field around the wire or coil. 9. The strength of an electromagnetic field depends on: • The number of turns of wire on the coil. The more turns, the stronger the field. • The amount of current flowing through the coil. The more the current, the stronger the field. • The type of core the coil has. A coil with an iron core has a much stronger magnetic field than an air coil. 10. Iron is attracted by electromagnetic fields and is pulled into them.

ES-3

FUNDAMENTAL LAWS OF ELECTRICITY 11. If a conductor passes through a magnetic field, or a magnetic field passes through a conductor, a voltage is generated in the conductor. The magnitude of such a voltage depends on: • The number of conductors. The more the conductors, the higher the voltage. • The strength of the magnetic field. The stronger the field, the higher the voltage. • The speed of the passage through the magnetic field by the conductors. The higher the speed, the greater the voltage. 12. If a coil’s magnetic field cuts the turns of a second coil, the voltage induced in the second coil will be more or less than the voltage in the first coil depending on whether there are more turns or less turns on the second coil. 13. Current carrying conductors located in magnetic fields try to move. Tremendous forces can be developed with high currents and strong fields. 14. A condenser (or capacitor) can temporarily store electricity releasing it as needed. A condenser has the capacity to store and release electricity many times a second. 15. UCA electric trucks and tractors use direct current - “DC”. In direct current circuits, one terminal of the voltage source is always positive, the other terminal always negative. The current always flows around the circuit in the same direction and - once established - remains unchanged in direction. 16. The cells of the storage battery store electricity in chemical form. The cells are usually connected in series so total battery voltage is the sum of the voltages of the individual cells. 17. Household current is usually alternating current - “AC” constantly changing from positive to negative, and the current is constantly changing its direction of flow in the circuit.

ES-4

ELECTRICAL SYSTEM Commonly Used Terms Anode Positive or Incoming terminal of a semiconductor device through which current flows into the device. Average Current On a pulsed system, the effective value of current that performs work. Average current can be read with a conventional D.C. Meter. Cathode Negative or Discharge terminal of a semiconductor. Collector The incoming or positive power terminal of a transistor. Controller Reversing (Plugging) The ability of the controller to bring the truck to a smooth stop. Diode A semiconductor consisting of an anode and a cathode. A diode will pass current easily in the direction from anode to cathode and block the flow of current in the other direction. Emitter or Drain The output power terminal of a transistor. Filtering The use of devices such as capacitors or small diodes to remove from a circuit the spikes of voltage which may be generated by switching of contactors or other circuit operations. Frequency Hz value of the sine waves the inverter is supplying. Frequency Modulation The method of obtaining adjustable speed control by varying the number of pulses per second. Gate The control element of a transistor. A small signal applied to this element will cause the transistor to conduct large amounts of current between anode and cathode. Hall Effect Transducer A semiconductor with a movable magnet, which increases or decreases an output voltage depending on the position of the magnet to the semiconductor. Heat Sink A mounting device for a semiconductors designed to dissipate any heat generated within the semiconductors.

ES-5

ELECTRICAL SYSTEM Commonly Used Terms (Cont’d) Module A small subpanel, epoxy encapsulated, containing the controls circuit electronic components such as; resistors, capacitors, diodes, etc. Oscillator A device composed of a small transistor and a resistor capacitor network used to generate pulses. Pulse Electrical energy which flows for a brief interval of time. Pulse Width Modulation The method of obtaining adjustable speed control by varying the width of the current pulses. Relay An electro magnetic control device with a weak current which acts as a switch for a circuit with a stronger current. Semiconductor Materials which allow a portion of source voltage to flow through them, but not as much as a true conductor such as; diodes, transistors, SCR’s, etc. Separately Excited Motor’s armature current, for speed and field current, for torque independently and simultaneously. Silicon Controlled Rectifier (SCR) A semiconductor rectifier used as a latching switch; i.e., it may assume either a conducting or nonconducting state (on, off). Slip A/C The difference between the frequency and the speed of the motor. Static Timer A timing device utilizing electronic components. Transistor A semiconductor device with three connection points; a very small current or voltage at one lead can control a much larger current flowing through the other two leads.

ES-6

ELECTRICAL SYSTEM General Electrical Symbols

ES-7

ELECTRICAL SYSTEM Introduction The COMBI AC1 inverter has been developed to perform all the electric functions that are usually present in walkie trucks. The controller can perform the following functions: • Controller for AC motors. • Pump controller for series wounded DC motors. • Drivers for ON/OFF lowering valve, brake, and horn. • Can bus interface • Interface for can bus tiller. • Sensorless control • Double microcontroller (one for main tasks, one for safety related tasks)

Operational Features • Speed control. • Optimum behavior on a slope if the speed feedback is used: • The motor speed follows the accelerator, starting a regenerative braking if the speed overtakes the speed set-point • Stable speed in every position of the accelerator. • Regenerative release braking based upon deceleration ramps. • Regenerative braking when the throttle is partially released (deceleration). • Direction inversion with regenerative braking based upon deceleration ramp. • Regenerative braking and direction inversion without contactors: only the main contactor is present. • Optimum sensitivity at low speeds. • Voltage boost at the start and with overload to obtain more torque (with current control). • The inverter can drive an electromechanical brake. • High efficiency of motor and battery due to high frequency commutations. • Modification of parameters through the programming hand set. • Internal hour-meter with values that can be displayed on the hand set. • Memory of the last five alarms with relative hour-meter and controller/traction motor temperature displayed on the hand set. • Test function within hand set for checking main parameters. • Direct communication between traction AC inverter and pump DC chopper.

ES-8

ELECTRICAL SYSTEM Operational Features (Cont’d) Diagnosis The microcontrollers continually monitor the inverter and the chopper and carry out diagnostic procedures on the main functions. The diagnosis is made in 4 points: 1. Diagnosis at start-up that checks: watch-dog, Current Sensors, Capacitor charging, phase’s voltages, pump motor output, contactor drivers, can-bus interface, presence of a start requirement, connection with the Can Tiller. 2. Standby Diagnosis that checks: watch-dog, phase’s voltages, pump motor output, Contactor Drivers, Current Sensors, canbus interface. 3. Driving diagnosis that checks: Watchdog, Current sensors, Contactor(s), can-bus interface. 4. Continuous Diagnosis that checks: controller temperature, motor temperature, Battery Voltage. Error codes are provided in two ways. The digital handset can be used, which gives detailed information about the alarm; the alarm code is also sent on the Can-Bus. It will be shown on the MDI, optional ECO panel, or CAN console software on a PC (graphic smart).

ES-9

MDI MULTIFUNCTION DIGITAL INDICATOR

LED Function Battery State of charge Five LEDs show the battery’s State of Charge. Four Green and one Red. With a fully charged battery, all the Green LEDs are illuminated. As the battery becomes discharged, the Green LEDs turn off progressively, one after the other, in proportion to the remaining charge of the battery. When the battery reaches 25% discharge the Red LED illuminates, and at 20% the Red LED flashes indicating a discharged battery and Pump Cutback.

DISPLAY Function Hour meter An alphanumeric liquid crystal display is fitted in the center of the unit that shows the Running Hours. With the tiller in the upright brake on, rotate the travel butterfly and the display will show Travel Hours. Operate the lift pump and the Pump Hours will be displayed while the pump is on.

ES-10

MDI MULTIFUNCTION DIGITAL INDICATOR Alarms The same display can also indicate the Alarm state, showing a Code corresponding to the type of Alarm. To attract attention, the Red LED will start flashing when an Alarm is generated. The first number flashed is the node where problem is detected. The second number is the alarm/warning code.

START UP Screen Software version NOTE: This is not an Alarm When the Ignition Switch is initially closed, the display shows the Eprom Version for a few seconds. A Shifting Spanner symbol also at this time. Other Information Three symbols inform the operator as follows: Turtle Symbol Shows activation of the “soft” mode of the truck. Maximum speed and acceleration are reduced (walkie mode). Shifting Spanner Symbol Appears when an Alarm Trouble Code or Maintenance Timer Alarm appears. Sand Glass Symbol This Symbol flashes when the hour meter is running.

ES-11

MDI MULTIFUNCTION DIGITAL INDICATOR MDI Accessing Hour Meters Total Hours Ignition on, Steer tiller in the up brake on position. Read hours in LCD display. Traction Hours With ignition on, Stand next to the truck with the steer tiller in the up brake on position. Rotate the butterfly in either direction and the traction hours will now be displayed in the LCD display.

!! WARNING • Do not lower the steer tiller when checking Traction hours. Lowering the steer tiller with the butterfly rotated, will result in sudden forward or reverse movement of the truck. Pump Hours Tiller handle must be up and with ignition on, press any of the lift buttons and the pump hours will be displayed in the LCD display.

!! WARNING • When checking pump hours, the pump will operate when the lift button is pressed. Make sure the load carry is clear of any loads and all pinch points are clear.

ES-12

METER PANEL Optional Meter Panel & LED Function Meter Panel Explanation The meter panel consists of two sections: LCD (Liquid Crystal Display) monitor and function keys. The Graphic Smart Display has five built-in red LEDs, which provide the operator with visually easy information about the status of some truck devices.

1. Battery This LED lights when the measured battery voltage is equal or less than 20% nominal battery voltage. 2. Wrench This LED blinks when truck is in alarm condition. 3. Not Used 4. Not Used

5. Not Used 6. Function Keys to navigate screens. 7. LCD Display refer to page ES-14.

ES-13

METER PANEL Detail of LCD

1. Battery Capacity 2. Performance Mode 3. Performance Cut-back 4. Hour Meter

5. Hour Meter Log t - Total Hours tr - Traction HM p - Pump HM 6. Throttle Level Bar Graph 7. Speedometer

Meter Panel Explanation When the ignition is in the ON position, backlighting makes the displays clearly visible to the forklift operator. It displays normal operation (battery capacity meter, hour meter, speedometer, etc.), malfunction and adjustment data. 1. Battery Capacity This meter indicates the remaining charge capacity of the battery. As the remaining capacity decreases, the number of black steps decreases. Before the last two black steps remain, discontinue forklift operation and charge the battery. The battery capacity meter has a 10-step display.

! CAUTION • Continued operation of the forklift with discharged battery may damage the battery and electric parts. 2. Power Modes Refer to pages ES-15 through ES-17.

ES-14

METER PANEL Meter Panel Explanation (Cont’d) 3. Turtle Mode (Soft Mode) The turtle symbol is normally off; when it appears (fixed) it shows activation of the “soft” mode of the truck, in which maximum speed and acceleration are reduced by the controller. 4. Hour Meter The number displayed on the bottom right side of the unit (number 4 shown on previous page) shows the hours worked. 5. Hour Meter The letter presence near the hour meter (number 5 shown on previous page) shows which hour meter is displayed: t - Total operating time of truck traction, pump, or traction pump. tr - Traveling time equal to the total time that the traction motor is operational. p - Loading time equal to the total time that the pump motor is operational. 6. Throttle The throttle level indication (number 6 on previous page) is displayed on the central top side of the unit; it is shown by ten notches. When the throttle level is minimum only a notch is displayed, when the throttle level is maximum all the ten notches are displayed. Each notch represents 1/10 of the difference between. 7. Speed The number displayed under the accelerator notches on the center of the unit (number 7 on previous page) shows the truck speed. The unit can be km/h or mph depending on the Speed Unit parameter setting. Push Button Switches Allow for the selection of the required mode and to change adjustment values. There are five push button switches PB1, PB2, PB3, PB4 and PB5. PB1 is used to scroll up a menu or change a value. PB2 is used to advance into a menu. PB3 is used to enter or select. PB4 is used to back out of a menu or to exit without making a change. PB5 is used to scroll down a menu or change a value.

ES-15

METER PANEL Meter Panel Explanation (Cont’d) Adjustment Item

Shift to Adjust Mode Push PB2 to Enter

Hour Meter Push PB4 to Exit Performance Mode (If Enabled)

Push PB2 twice to Enter Push PB4 twice to Exit

Adjustment

Details

Push PB2

Operating Screen ---> Hour Counter

Push PB4

Hour Counter ---> Operating Screen

Push PB5

t-Total Hrs ---> tr-Traction HM ---> p-Pump HM

Push PB1

p-Pump HM ---> tr-Traction HM ---> t-Total Hrs

Push PB2

Operating Screen ---> Hour Counter ---> Performance Mode

Push PB4

M-Manual ---> H-Hour Counter ---> Operating Screen

Push PB5

M-Manual ---> H-High ---> E-Economy

Push PB1

E-Economy ---> H-High ---> M-Manual

Change Hour Meter Total Hrs to Pump Performance Mode Can be enabled by a factory trained technician.

Mode M: Manual Mode The power levels for traveling can be set according to customer requests. Manual to High

ES-16

METER PANEL Meter Panel Explanation (Cont’d) NOTE: Contact your Local Authorized UCA Dealer for more information about how to set the Manual mode. Factory defaults: Traveling power level Mode E: Economy mode: For work requiring operation time to be saved or customers using the machine for a long time. Mode M Manual: Use for custom speed setting Mode H: High-power mode: For work or customers requiring higher traveling speed.

!! WARNING • After performance adjustment, operate the forklift slowly and carefully until you become accustomed to the new performance level. Be especially careful when the performance level has been increased. Higher performance levels can cause loads to shift, fall off or to be unstable during starts, which could result in serious injury or death.

Malfunctions and Warning Indications #1 LCD (Liquid Crystal Display) #2 Error Code #3 Malfunction Message #4 Battery Warning Mark #5 Exclamation Point

ES-17

METER PANEL Meter Panel Explanation (Cont’d) Malfunctions and Warning Indications (Cont’d) Battery Low If any malfunction occurs when the ignition is in the ON position, the LCD will display a message explaining the details of the malfunction. NOTE: During forklift operation, periodically check the battery capacity. Make every effort to recharge the battery before the battery low message appears. 1. Exclamation Point (!) The controller and the sensors act together to regulate the forklift’s electrical system. Whenever one of the malfunctions listed below occurs, the LCD will show an indication explaining the details of the malfunction. Control system malfunction (Traction, Cargo-handling) Overheating controller or motor

2. Battery warning mark Pump cut warning The bar display will start to flash when the battery capacity meter’s remaining capacity indication changes from 4 bars to 3 bars.

Press FN5 When the battery capacity meter display changes from 3 bars to 2 bars the pump cut/battery low message will be displayed.

When function key FN4 is pressed, the display will switch. The battery capacity meter will now show 2 bars and the battery warning mark will flash. The exclamation point will appear in the top right corner and lift/tilt function will be inoperable. The vehicle may be operated during pump cut. However, move the vehicle to a safe location, and promptly charge the battery.

ES-18

METER PANEL Meter Panel Explanation (Cont’d) Malfunctions and Warning Indications (Cont’d) Low voltage lock warning If the vehicle is subjected to continuous operation after the pump cut warning was activated, the low voltage lock warning will be activated. Then, the display will appear as shown at left. The vehicle cannot be operated during the low voltage lock warning. NOTE: The interval between the first appearance of the battery warning mark and interruption of the operation is dependent of the charge/ condition of the battery. When a malfunction is indicated, immediately suspend forklift operation. Contact your Local Authorized UCA Dealer for inspection and necessary repair.

!! WARNING • When the malfunction is indicated, immediately suspend forklift operation. Contact your Local Authorized UCA Dealer for inspection and necessary repair. The Drivers Recognition Option All 2W5/2W6 models have a drivers recognition code option. Your Local Authorized UCA Dealer can assist you in turning on this feature and setting up your driver codes. As you can see by the chart, the codes are very easy to enter once they are turned on.

ES-19

ECO PANEL NAVIGATION

ES-20

ECO PANEL NAVIGATION

ES-21

ECO PANEL NAVIGATION

ES-22

ECO PANEL NAVIGATION

ES-23

DIAGNOSTIC MODE

ES-24

DIAGNOSTIC MODE

ES-25

DIAGNOSTIC MODE

ES-26

DIAGNOSTIC MODE

ES-27

DIAGNOSTIC MODE

ES-28

DIAGNOSTIC MODE

ES-29

DIAGNOSTIC MODE

ES-30

ECO ADJUSTMENT CHANGE PARAMETERS

ES-31

ECO ADJUSTMENT CHANGE PARAMETERS

ES-32

ECO ADJUSTMENT CHANGE PARAMETERS

ES-33

ECO ADJUSTMENT CHANGE PARAMETERS

ES-34

ECO ADJUSTMENT OPTIONS

ES-35

ECO ADJUSTMENT OPTIONS

ES-36

ECO ADJUSTMENT OPTIONS

ES-37

ECO ADJUSTMENT OPTIONS

ES-38

ECO ADJUSTMENT OPTIONS

ES-39

ECO ADJUSTMENT OPTIONS

ES-40

ECO ADJUSTMENT ADJUSTMENTS

ES-41

ECO ADJUSTMENT ADJUSTMENTS

ES-42

ECO ADJUSTMENT ADJUSTMENTS

ES-43

ECO ADJUSTMENT ADJUSTMENTS

ES-44

ECO ADJUSTMENT PASSWORD

ES-45

ECO ADJUSTMENT PASSWORD

ES-46

ECO ADJUSTMENT PASSWORD

ES-47

ECO ADJUSTMENT PASSWORD

ES-48

ECO ADJUSTMENT PASSWORD

ES-49

ECO ADJUSTMENT PASSWORD

ES-50

SPECIFICATIONS Technical Specifications Inverter for traction AC asynchronous 3-phase motors plus chopper for DC series pump motors. Regenerative braking functions. Digital control based upon microcontroller Voltage:

24V

Inverter maximum current 24V:

350A (RMS) for 2’

Inverter operating frequency:

8kHz

Dc chopper Maximum current 24V:

350A for 2’

Chopper Operating frequency:

16kHz

External temperature working range:

-40°C (-40° F)+ 40°C (140° F)

Maximum heatsink temperature (start of the thermal cutback)

85°C (185°F)

Block Diagrams

Speed Feedback The motor control is based upon motor speed feedback. The speed encoder is incremental, with two phases shifted 90°. 12V+ is supplied to the encoder by an internal voltage regulator mounted in the controller.

ES-51

SPECIFICATIONS Fuses • Two 10A Control fuses supply power from ignition and K-1 Contactor to control circuits. • For protection of the power unit, a 400A fuse is mounted across the Battery Positive connection on the controller. Cooling of the controller Controller has a finned heatsink and cooling fans. Finned heatsink allows conductive cooling. Two fans are mounted to the bottom of the controller compartment to aid in cooling when necessary. CAN CAN Stands for Controller Area Network. It is a communication protocol for real time control applications. CAN operates at a data rate of up to 1 Megabits per second. It was invented by the German company Bosch to be used in the car industry to permit communication among the various electronic modules of a vehicle, connected as illustrated in this image:

CAN Advantages The complexity of today’s control systems requires more and more information communication; signals and data must flow between nodes. CAN offers the solution to many problems that arise from this complexity: • simplified design • fewer and smaller cables • improved reliability (fewer connections) • Improved analysis of problems (simple connection with a PC to read the data flowing through the cable) Wirings: power cables • The power cables length must not be changed. • Power cables must be tightened on controller power posts with a Torque of 13-15 Nm (114 - 132 in/lb).

ES-52

SPECIFICATIONS Protection and Safety Features Protection features The COMBI AC1 is protected against some controller damage and malfunctions: • Battery polarity inversion A line contactor to protect the controller against reverse battery polarity and for safety reasons. • Connection Errors All inputs are protected against connection errors. • Thermal protection If the controller temperature exceeds 85°C (185°F), the maximum current is reduced in proportion to the thermal increase. At 105°C (221°F) truck operation will stop.

• External agents The inverter is protected against dust and the spray of liquid to a degree of protection meeting IP65. Nevertheless, it is suggested to carefully study controller installation and position. With simple attention paid to mounting, the degree of controller protection can be strongly increased. • Protection against uncontrolled movements The main contactor will not close if: The Power unit is not functioning. The Logic or CANBUS interface is not functioning correctly. The CAN Tiller is not operating correctly. • Low battery charge (Lift Lockout) When the battery charge is low, the maximum current is reduced to half of the maximum current programmed and the lift will be in lockout; additionally, an alarm message is displayed. • Protection against accidental Start up Precise sequences of operations are necessary before the machine will start. Operation cannot begin if these operations are not carried out correctly. Requests for drive must be made after closing the ignition switch.

ES-53

SPECIFICATIONS ESD Electrostatic Discharge, or ESD, concerns the prevention of the effects of electric current due to excessive electric charge stored in an object. In fact, when a charge is created on a material and it remains there, it becomes an “electrostatic charge”; ESD occurs when there is a rapid transfer from a charged object to another. This rapid transfer has, in turn, two important effects: This rapid charge transfer can cause, by induction, on the signal wiring and thus create malfunctions; this effect is particularly critical in modern machines, with serial communications (can bus), which are spread throughout the truck and carry critical information. In the worst case and when the amount of charge is very high, the discharge process can cause failures in the electronic devices; the type of failure can vary from an intermittent malfunction to a complete failure of the electronic device. 1. Three ways can be followed to prevent damages from ESD: A) PREVENTION: when handling ESD-sensitive electronic parts, ensure the technician is grounded; test grounding devices on a daily basis for correct functioning; this precaution is particularly important during controller handling in the storage and installation phase. B) ISOLATION: use anti-static containers when transferring ESD-sensitive material. C) GROUNDING: when operating on sealed floors or using nonmarking tires, the frame of a truck can work like a “local earth ground”. Absorbing excess static charge, a good ground strap can divert the discharge current through a “safe” path to the floor.

ES-54

DESCRIPTION OF THE CONNECTIONS

! CAUTION • Exceeding these specifications could damage the bus bars’ internal threads, resulting in loose connections. • The order of phase cables UVW will effect the operation of forward and reverse. Confirm the operation of direction control with drive tire off of floor.

ES-55

PROGRAMMING & ADJUSTMENTS USING DIGITAL HAND SET Adjustments via Hand Set Adjustment of Parameters and changes to the inverter’s configuration are made using the Digital Hand set. The Hand set is connected via an adapter cable supplied with the hand set. Hand set p/n 29499-FS000, Replacement adapter cable p/n 29499-FS002. Description of Hand Set & Connection Digital hand sets used to communicate with AC inverter controllers must be fitted with EPROM CK ULTRA, minimum Release Number: 3.02.

!! WARNING • Do not adjust any adjustment items listed in the service manual as factory setting “DO NOT ADJUST”, or adjust any item listed above the published maximum setting. Making changes to the factory settings or above the maximum listed limit will cause the truck to operate outside of its design parameters. Making changes to any of the factory settings or above the maximum limit as listed in the Service Manual, will result in voiding the warranty of the controller and components of the electric system. • As with any electric powered industrial truck, when carrying out testing, reprogramming, or diagnosis, always raise the drive tire off the floor to avoid any accidental movement.

! CAUTION • Plug the ZAPI into a programmer port only. Voltages and other interface circuits can result in permanent damage to the programmer.

ES-56

HANDSET CONNECTION With ignition off, disconnect the J19 connector located to the right of the controller.

Connect the hand set adapter cable to the J19 plug.

Turn ignition on.

ES-57

HANDSET CONNECTION Description of the Hand Set Menu The section describes the Zapi handset set functions. Numbers inside the triangles correspond to the same number on the hand set keyboard buttons shown in the figure. The orientation of the arrow indicates the way to the next function. MAIN/TRACTION Handset Menus Flowchart

ZAPI Handset Menus Flowchart

ES-58

HANDSET CONTROLLER SETTINGS Handset Controller Settings, Main/Traction, Node 2 Chopper Name 2W5 AD1M2BC_X NS 1.00 2W6 AD1M2BC_X NS 1.00 2W5/2W6 Controller Options By Part Number 29310 2W5 29310-FS

707

708

709

710

711

712

713

714

ECO Smart

Absent

Present

Absent

Present

Absent

Present

Battery Gates

Absent

Present

Absent

Present

Absent

Present

Travel Alarm

Reverse

Forward & Reverse

Reverse

Forward & Reverse

2W6 29310-FS

607

608

609

610

611

612

613

614

ECO Smart

Absent

Present

Absent

Present

Battery Gates

Absent

Present

Absent

Present

Absent

Travel Alarm

Reverse

Forward & Reverse

Reverse

Forward & Reverse

Reverse

NOTE: The above settings are factory programmed in the controllers and should not be changed.

ES-59

HANDSET CONTROLLER SETTINGS Handset Controller Settings, Main/Traction, Node 2 Chopper Name 2W5 AD1M2BC_X NS 1.00 2W6 AD1M2BC_X NS 1.00 Handset Menu Parameter Change

Item

Default Value 2W5

Range

2W6

Acceler. Delay

2.0

Factory Setting Do Not Adjust

Acceler. Delay M

100%

10 - 100%

Pick Acc Delay

Release Braking

3.6

3.4 - 9.0 seconds

Tiller Braking

0.3

Factory Setting Do Not Adjust

Invers. Braking

1.5

0.3 - 1.5 seconds

Decel. Braking

7.0

Factory Setting Do Not Adjust

6.0

Factory Setting Do Not Adjust

Speed Limit Brk Max Speed FWD

100%

Max Speed FWD M Max Speed Back

100% 90%

Max Speed Back M Cutback Speed 1

85% 73%

100% 38%

28%

50 - 100% 10 - 100% 10 - 90% 10 - 100% 100% in M mode = 77% Max Factory Setting Do Not Adjust

Frequency Speed 1

0.60Hz

Factory Setting Do Not Adjust

Maximum Current

100%

Factory Setting Do Not Adjust

Pick Coast Speed

40%

Factory Setting Do Not Adjust

Acc Smooth

1.0

Factory Setting Do Not Adjust

Inv Smooth

1.0

Factory Setting Do Not Adjust

Stop Smooth

10Hz

Factory Setting Do Not Adjust

Brk Smooth

1.0

Factory Setting Do Not Adjust

Stop Brk Smooth

10Hz

Factory Setting Do Not Adjust

Auxiliary Time

0.0

Factory Setting Do Not Adjust

Delay EB. Tiller

2.0

Factory Setting Do Not Adjust

KW 2 Plaft. Delay

1.5

Factory Setting Do Not Adjust

Set Model

Connected to Node

2 = Traction 5 = Pump

Set Options

Part Number Sel.

2W6 607 to 614 2W5 707 to 714

Factory Setting Do Not Adjust

Battery Check

Level = 2

Factory Setting Do Not Adjust

Stop on Ramp

Factory Setting Do Not Adjust

Aux Output #1

Brake

Factory Setting Do Not Adjust

Quick Inversion

Belly

Factory Setting Do Not Adjust

Set Mot Temperature

Analog

Factory Setting Do Not Adjust

Imax Protection

100%

Factory Setting Do Not Adjust

Auto Power Off

Sp Rev/Brak

Opt #1

Factory Setting Do Not Adjust

Coast Less Pick

OFF

Factory Setting Do Not Adjust

A6V

Absent

Factory Setting Do Not Adjust

0 - 60 Minutes

Maint/Traction Settings, Adjustments Continued on Next Page

ES-60

HANDSET CONTROLLER SETTINGS Handset Controller Settings, Main/Traction, Node 2 Chopper Name 2W5 AD1M2BC_X NS 1.00 2W6 AD1M2BC_X NS 1.00 Main/Traction Settings, Adjustments Continued Handset Menu

Item

Adjustments

Set Battery Type

24V

Factory Setting Do Not Adjust

Adjust Battery

Value

Factory Setting Do Not Adjust

Hour Meter Time

Factory Setting Do Not Adjust

•

Default Value

Range

Throttle 0 Zone

Factory Setting Do Not Adjust

Throttle X Point

40%

Factory Setting Do Not Adjust

Throttle Y Point

60%

Factory Setting Do Not Adjust

Bat. Min. Adj.

0-9

Bat. Max. Adj.

0-9

Load HM from MDI

OFF

ON/OFF

Check Up Done

OFF

ON/OFF

Check Up Hours

200

100 - 1000 Hours

Check Up Type

Level = 0

0-3

Main Cont Volt

100%

Factory Setting Do Not Adjust

Aux Output Volt

100%

Factory Setting Do Not Adjust

Motor Cutback

150°C

Factory Setting Do Not Adjust

Motor Shutdown

160°C

Factory Setting Do Not Adjust

• Installing a new controller will cause an AL 02, AL 94 code and you will have a two minute time frame to update the controller hour meter. Turn off ignition, disconnect harness and connect handset, navigate the Load HM from MDI and turn setting to on. Disconnect hand set and reconnect harness.

ES-61

HANDSET CONTROLLER SETTINGS Function Configuration Main/Traction Config Menu “SET OPTIONS” Functions List To enter the CONFIG MENU it is necessary to push in the same time the right side top and left side top buttons. Then roll until the SET OPTION item appears on the hand set display. Push the ENTER button.

Opening Zapi Display Push ROLL UP + PARAMETER SET UP simultaneously to enter CONFIG MENU

The Display will show: SET MODEL Press ROLL UP or ROLL DOWN button until SET OPTIONS menu appear.

Set Options appears on the display Press ENTER to go into the SET OPTIONS

The display will show: EVP Type Press ROLL UP or ROLL DOWN button until the desired parameter is reached

ES-62

HANDSET CONTROLLER SETTINGS The desired parameter appears Press PARAMETER SET UP or PARAMETER SET DOWN button to modify the adjustment

Press OUT

Press ENTER to confirm Repeat the same from 5 to 12 points for the other adjustments.

The Display will show: SET OPTIONS Press ENTER to go in the SET OPTIONS MENU

ES-63

HANDSET CONTROLLER SETTINGS !! WARNING • All settings in set options menu are factory adjustment only. 1. PART NUMBER SEL • Factory setting DO NOT ADJUST 2. BATTERY CHECK • Value Represent Average Per Cell Voltage of Battery 3. STOP ON RAMP • Factory Setting DO NOT ADJUST 4. AUX OUTPUT #1 • Factory Setting DO NOT ADJUST 5. QUICK INVERSION • Factory Setting DO NOT ADJUST 6. SET MOT TEMPERATURE • Factory Setting DO NOT ADJUST 7. IMAX PROTECTION • Factory Setting DO NOT ADJUST 8. AUTO POWER OFF • Sets Time for Truck to Shut Down After a Predetermined Amount of Inactivity has Occurred. 9. SP REV/BRAK • Factory Setting DO NOT ADJUST 10. COASTLESS PICK • Factory Setting DO NOT ADJUST

ES-64

HANDSET CONTROLLER SETTINGS Config Menu Adjustments 1. SET BATTERY TYPE • Factory setting DO NOT ADJUST 2. ADJUST BATTERY • Factory Setting DO NOT ADJUST 3. HOUR METER TIME • Factory Setting DO NOT ADJUST 4. THROTTLE 0 ZONE • Factory Setting DO NOT ADJUST 5. THROTTLE X POINT • Factory Setting DO NOT ADJUST 6. THROTTLE Y POINT • Factory Setting DO NOT ADJUST 7. BAT. MIN ADJ. • 0-9 8. BAT. MAX ADJ. Adjust the upper level of the battery charge table (Level 0 to 9). See Page Number ES-79. 9. LOAD HM FROM MDI If the controller finds a difference in the hour meter it has stored and that of the MDI (e.g. a new control has been installed) an alarm (AL02, AL94) is given to alert the technician. The technician is given 2 minutes to react. If no action is taken, the MDI is updated with the controller’s hour meter value. Otherwise, set this option to ON to update the controller with the hour meter value from the MDI. 10. CHECK UP DONE Turn it on when the required Maintenance service has been executed to cancel the CHECK UP NEEDED warning. 11. CHECK UP HOURS Sets Time Interval for Check up Warning 100 to 1000 Hours 12. CHECK UP TYPE It specifies the handling of the CHECK UP NEEDED warning: • NONE: No CHECK UP NEEDED warning • OPTION#1: CHECK UP NEEDED warning shown on the hand set and MDI after 300 hours • OPTION#2: Equal to OPTION#1 but Speed reduction after 340 hours • OPTION#3: Equal to OPTION#2 but the truck definitively stops after 380 hours 13. MAIN CONT. VOLTAGE • Factory Setting DO NOT ADJUST

ES-65

HANDSET CONTROLLER SETTINGS Config Menu Adjustments (Cont’d) 14. AUX OUTPUT VOLTAGE • Factory Setting DO NOT ADJUST 15. MOTOR CUTBACK • Factory Setting DO NOT ADJUST 16. MOTOR SHUTDOWN • Factory Setting DO NOT ADJUST The Display asks: “ARE YOU SURE?” Press ENTER to accept the changes, or press OUT to discard them.

Parameter change continued on next page.

ES-66

HANDSET CONTROLLER SETTINGS Main Menu “PARAMETER CHANGE” Functions List To enter the MAIN MENU it is just necessary to push the ENTER button from the home display in the hand set. Opening Zapi Menu Press ENTER to go into the General Menu

The Display will show: PARAMETER CHANGE Press ENTER to go into the Parameter Change menu

The Display will show the first parameter Press either ROLL UP and ROLL DOWN to display the next parameter

The names of the Parameters appear on the Display When the desired Parameter appears, it’s possible to change the Level by pressing either PARAMETER SET UP or PARAMETER SET DOWN buttons.

Then Display will show the new level When you are satisfied with the result of the changes you have made, press OUT

ES-67

HANDSET CONTROLLER SETTINGS Main Menu “PARAMETER CHANGE” Functions List (Cont’d) 1. ACCELER. DELAY • Factory setting DO NOT ADJUST 2. ACCELER. DELAY M Seconds. It determines the acceleration ramping when operating in M performance made when equipped with the optional ECO SMART Meter Panel. 3. RELEASE BRAKING Seconds. It controls the deceleration ramp when the travel request is released. The parameter sets the time needed to decelerate the traction motor from 3.4 to 9.0 seconds. 4. TILLER BRAKING • Factory setting DO NOT ADJUST 5. INVERS. BRAKING Seconds. It controls the deceleration ramp when the direction switch is inverted during travel. The parameter sets the time needed to decelerate the traction motor from 0.3 to 10 seconds. 6. DECELERATION BRAKING • Factory setting DO NOT ADJUST 7. SPEED LIMIT BRK • Factory setting DO NOT ADJUST 8. MAX SPEED FWD Percentage. It determines the maximum speed in forward direction. 9. MAX SPEED FWD M Determines max speed in the forward direction when operating in M performance mode, when equipped with the optional ECO Smart meter panel.

!! WARNING • Do not set max speed BACK (reverse) higher than maximum 90% (2W5) and 73% (2W6). 10. MAX SPEED BACK Percentage. Must not be set higher than 90% (2W5) and 73% (2W6) maximum. Determines maximum speed in the reverse direction. 11. MAX SPEED BACK M Determines max speed in the reverse direction when operating in M performance mode, when equipped with the optional ECO Smart meter panel.

ES-68

HANDSET CONTROLLER SETTINGS Main Menu “PARAMETER CHANGE” Functions List (Cont’d) !! WARNING • Do not adjust cutback speed (walkie speed) higher than maximum 38% (2W5) and 28% (2W6). 12. CUTBACK SPEED 1 • Factory setting DO NOT ADJUST 13. FREQUENCY CREEP • Factory setting DO NOT ADJUST 14. MAXIMUM CURRENT Sets the maximum available AC current as a percentage of the current capacity rating of the controller. 15. ACCELERATION SMOOTH • Factory setting DO NOT ADJUST 16. INVERSION SMOOTH • Factory setting DO NOT ADJUST 17. STOP SMOOTH • Factory setting DO NOT ADJUST 18. BRK SMOOTH • Factory setting DO NOT ADJUST 19. STOP BRK SMOOTH • Factory setting DO NOT ADJUST 20. AUXILIARY TIME • Factory setting DO NOT ADJUST 21. DELAY EB TILLER • Factory setting DO NOT ADJUST 22. PLATF. DELAY • Not applicable

ES-69

HANDSET CONTROLLER SETTINGS Main Menu “TESTER” Functions List The TESTER functions are a real time feedback measurements of the state of the controller/motor/command devices. It is possible to know the state (active/off) of the digital I/Os, the voltage value of the analog inputs and the state of the main variables used in the motor and hydraulics control. Enter the home page in the hand-set display and roll for the TESTER item. 1. BATTERY VOLTAGE Voltage value with 1 decimal digit. Battery voltage value measured at the ignition on. 2. MOTOR VOLTAGE Percentage value. It is the voltage generated by the inverter expressed in percent of the actual battery voltage. 100% means the sine wave amplitude is close to the actual battery voltage; 0% means the sine wave amplitude is null. 3. VOLTAGE BOOSTER Percentage value. It is the additional voltage supplied to the motor expressed in percent of the actual battery voltage. (Note: when DC_ LINK COMPENSATION is set ON, the VOLTAGE BOOSTER reading will not match perfectly the booster setting because this latest one is calculated respect to the nominal battery voltage; VOLTAGE BOOSTER is expressed with respect to the actual battery voltage. 4. FREQUENCY Hz value. This is the frequency of the sine waves the inverter is supplying. 5. ENCODER Hz value. This is the speed of the motor shaft measured with the encoder. 6. SLIP VALUE Hz value. This is the slip between the frequency and the spread of the motor (SLIP VALUE = FREQUENCY-ENCODER). 7. CURRENT RMS Ampere value. Root Mean Square value of the line current in the motor. 8. BATTERY CHARGE Percentage value. It supplies the residual charge of the battery as a percentage of the full charge level. 9. TEMPERATURE °C value. This is the temperature of the inverter base plate. This temperature is used for the HIGH TEMPERATURE alarm detection. 10. MOTOR TEMPERATURE °C value. This is the temperature of the motor windings picked up with an analog sensor inside motor. This temperature is used to raise a warning or alarm in the controller when the motor temperature overtakes the MOTOR OVERTEMP settings.

ES-70

HANDSET CONTROLLER SETTINGS Main Menu “TESTER” Functions List (Cont’d) 11. ACCELERATOR Via CANBUS: -4096 to 4096, indicating the digital count of the rotational sensor. Values above 3896 and -3896 are required to achieve full speed. 12. HOURS METER Hours on main controller. 13. TILLER NEUTRAL ON/OFF. Indicates if Throttle is moved away from the Neutral position, forward or reverse. 14. TILLER BRAKE SWITCH ON/OFF. This is the level of the digital input CNA#1 in AmpSeal connector for the Tiller Brake Request: • ON + VB = When it is closed to a battery (key) voltage, the brake request is not active. • OFF GND = When it is not connected to a battery (key) voltage (or it is connected to GND), the brake request is active. 15. BELLY SWITCH ON/OFF. Indicates of BELLY SWITCH is pressed. ON + VB = When it is closed to a battery (key) voltage, the request of the Belly (to stop the movement) is active. • OFF GND = When it is not connected to a battery (key) voltage (or it is connected to GND), the Belly request is not active. 16. BACK / BRAKE (NOT USED) 17. BRAKE SW (NOT USED) 18. BATTERY GATE SW (For 2W6 with 13” Battery Box) ON/OFF Indicates presence of battery side gate (option) • ON + VB = When battery side gate is present • OFF GND = When battery side gate is not present

ES-71

HANDSET CONTROLLER SETTINGS Program VACC

NOTE: Locating Directions Forward Direction is with Forks Trailing. Reverse Direction is Forks Leading.

Flow chart showing to use the PROGRAM VACC function Opening ZAPI display Press ENTER to go into the General menu

The Display will show Press ROLL UP or ROLL DOWN button until PROGRAM VACC shows Display

The Display will show Press ENTER to go into the PROGRAM VACC function

ES-72

HANDSET CONTROLLER SETTINGS Program VACC (Cont’d) The Display will show VACC Settings. NOTE: The display will not change when the butterfly is rotated. Press ENTER to clear these values.

Display will Change to 0.0. - 0.0. Tiller card is now in TEACH MODE.

To set the Neutral position of the butterfly. Leave the butterfly in its OFF/NEUTRAL position then press and release both lift switches on the tiller control head one at a time.

Rotate Butterfly in the forward direction to its mechanical stop and hold. Depress Both Lower switches on the tiller control head one at a time to enter this value.

Rotate Butterfly in the reverse direction to its mechanical stop and hold. Depress Both Lift Switches on the tiller control head one at a time to enter this value. When finished, press OUT

The Display will ask: ARE YOU SURE? Press ENTER for yes, or OUT for NO. Pressing ENTER, save the values and exits the tiller card TEACH MODE. Pressing OUT, exits the teach mode without saving the values. When finished, the Display shows Press OUT to return to the Opening ZAPI Display Note: When finished go into tester program - accel and check that butterfly movement is equal in both directions. Readings in both directions should be even. Values should be 4095 and -4095, minimum values above 3896 and -3896 are necessary to obtain full speed.

ES-73

HANDSET CONTROLLER SETTINGS Secondary/Pump Handset Menus Flowchart

ES-74

HANDSET CONTROLLER SETTINGS Handset Controller Settings, Secondary/Pump, Node 5 Chopper Name 2W5 AD1M2BC_X NS 1.00 2W6 AD1M2BC_X NS 1.00 Handset Menu Parameter Change

Item

Default Value

Range

Pump Imax

Level = 9

Factory Setting Do Not Adjust

Speed Limit

100%

Factory Setting Do Not Adjust

Creep Speed

30%

Factory Setting Do Not Adjust

Compensation

10%

Factory Setting Do Not Adjust

PU. Acceler. Del

0.2

Factory Setting Do Not Adjust

PU. Deceler. Del

0.2

Factory Setting Do Not Adjust

Min EVP

26.2%

Factory Setting Do Not Adjust

Max EVP

87.0%

Factory Setting Do Not Adjust

Min EV1

63.1%

Factory Setting Do Not Adjust

Max EV1

96.8%

Factory Setting Do Not Adjust

Lowering Speed

100%

Factory Setting Do Not Adjust

EVP Open Delay

4.00

Factory Setting Do Not Adjust

EVP Close Delay

0.25

Factory Setting Do Not Adjust

EV1 Open Delay

0.00

Factory Setting Do Not Adjust

EV1 Close Delay

0.00

Factory Setting Do Not Adjust

Set Model

Connected to Node

2 = Traction 5 = Pump

Set Options

EVP Type

Analog

Factory Setting Do Not Adjust

EV1 Type

Digital

Factory Setting Do Not Adjust

Horn on Low Batt

OFF

ON/OFF

Charge for Horn

25%

20 - 30%

Set Temperature

None

Factory Setting Do Not Adjust

Hour Meter Time

Factory Setting Do Not Adjust

Fan Temperature

50°C

Factory Setting Do Not Adjust

Adjustments

ES-75

HANDSET CONTROLLER SETTINGS Function Configuration Secondary/Pump Config Menu “SET OPTIONS” Functions List 1. EVP TYPE • Factory setting DO NOT ADJUST 2. EV1 TYPE • Factory Setting DO NOT ADJUST 3. HORN ON LOW BATT ON/OFF: choose to determine if the horn sounds an alert with travel commands to indicate a low battery condition. 4. CHARGE FOR HORN %: Sets the battery discharge level used to sound the horn alert for low battery condition. 5. SET TEMPERATURE • Factory setting DO NOT ADJUST Config Menu “ADJUSTMENTS” Functions List 1. HOUR METER TIME • Factory setting DO NOT ADJUST 2. FAN TEMPERATURE • Factory Setting DO NOT ADJUST 3. PUMP IMAX • Factory Setting DO NOT ADJUST 4. SPEED LIMIT • Factory Setting DO NOT ADJUST 5. CREEP SPEED • Factory Setting DO NOT ADJUST 6. COMPENSATION • Factory Setting DO NOT ADJUST 7. PUMP ACCELERATION DELAY Factory Setting DO NOT ADJUST 8. PUMP DECELERATION DELAY • Factory Setting DO NOT ADJUST 9. MIN EVP • Factory Setting DO NOT ADJUST 10. MAX EVP • Factory Setting DO NOT ADJUST 11. MIN EV1 • Factory Setting DO NOT ADJUST

ES-76

HANDSET CONTROLLER SETTINGS Config Menu “ADJUSTMENTS” Functions List (Cont’d) 12. MAX EV1 • Factory Setting DO NOT ADJUST 13. LOWERING SPEED • Factory Setting DO NOT ADJUST 14. EVP OPEN DELAY • Factory Setting DO NOT ADJUST 15. EVP CLOSE DELAY • Factory Setting DO NOT ADJUST 16. EV1 OPEN DELAY • Factory Setting DO NOT ADJUST 17. EV1 CLOSE DELAY • Factory Setting DO NOT ADJUST Function Tester 1. MOTOR CURRENT Amperes. Measurement of the DC current in the motor controlled by the slave of combiac 1. 2. MOTOR VOLTAGE Volts. It is the voltage applied to the DC motor controlled by the slave of combiac 1, expressed in percentage of the nominal voltage. 3. HOURS METER Pump hours. 4. LIFT RGT TILLER On/Off: it indicates if the Right Hand LIFT switch (as viewed from ride-on position) of the handle is active. 5. LIFT LEFT TILLER On/Off: it indicates if the Left Hand LIFT switch (as viewed from rideon position) of the handle is active. 6. LOWER RGT - TILLER On/Off: it indicates if the Right Hand LOWER switch (as viewed from ride-on position) of the handle is active. 7. LOWER LIFT - TILLER On/Off: it indicates if the Left Hand LOWER switch (as viewed from ride-on position) of the handle is active. 8. HORN SW - TILLER On/Off: it indicates if the HORN switch of the handle is active 9. SET POINT EVP The parameter shows the setpoint of EVP valve.

ES-77

HANDSET CONTROLLER SETTINGS Function Tester (Cont’d) 10. ALARM OUTPUT On/Off: determines if the ALARM output is active or not. 11. EV3 On/Off: determines if the valve is open or closed. NOT USED 12. EV4 On/Off: determines if the valve is open or closed. NOT USED 13. HORN OUT On/Off: determines if the HORN output is active or not. 14. EV6 On/Off: determines if the valve is open or closed. NOT USED 15. EV7 On/Off: determines if the valve is open or closed NOT USED

ES-78

HANDSET CONTROLLER SETTINGS Other Functions Description of Hand Set “SAVE” Function NOT USED Description of Hand Set “RESTORE” Function NOT USED Battery charge detection setting The Battery Charge detection uses two settings that specify the Full Charge Voltage Level (100%) and the Discharged Voltage Level (20%). These two settings are the BAT MAX ADJ and the BAT MIN ADJ. It is possible to adapt the Battery Charge Detection to your specific battery, by changing these two settings (e.g. if the LOW BATTERY alarm occurs when the battery is not totally discharged, it is necessary to reduce the BAT MIN ADJ setting as indicated in the figure below). The range of adjustment for these parameter is ± 2.8% nominal battery. 24V NOMINAL BATTERY VOLTAGE

The Battery Charge detection follows this algorithm: 1. Battery voltages are sampled when the Battery current is zero. 2. The software calculates and stores the mean of the last 10 samples. The maximum of ten means is stored as Vbat. At Ignition-on, the battery voltage is sampled and compared to the stored value. The result of computations is used in a lookup table to determine the Discharge Percentage to be displayed. Threshold values can be changed with parameters BAT. MAX. ADJ. 3. The Discharge Indication can increase only at ignition-on. The battery charge is increased if the battery charge computed after ignition-on is greater than the last stored value by more than 30%.

ES-79

SELF DIAGNOSIS OF REMA PCB 1 !! WARNING • As with any electric powered industrial truck, when carrying out a testing, reprogramming or diagnostic procedure. Always raise the drive tire off the floor to avoid any unintentional movement. Disassemble and reassemble of steerhead instruction on page ST-6. NOTE: To ensure test accuracy it is recommended that program VACC be performed. Upon disassembly the following process must be followed prior to replacement of the REMA-PCB 84640-60 Version 1.2 & 1.3

Please note Fig A, Fig B, Fig C above Verify version of board (Fig B) prior to performing diagnosis. Incorrect version will provide false results.

ES-80

SELF DIAGNOSIS OF REMA PCB 1 STEP 1

Validate all switches are connected exactly as illustrated below Connections are critical as this will affect all following steps

Location and layout of all connections and switches on REMA PCB

VERSION 1.2 FUNCTION Speed Control

DESCRIPTION IC1, IC2

FUNCTION Pick 1

DESCRIPTION JP16

Emergency Reverse

Pick 2

JP17

Horn Switch

Click & Coast

JP11

Low Speed Switch

Spare 1.1 Unused

JP 20

Lift 1

JP14

Spare 2 Unused

JP 13

Lower 1

JP15

Spare 2.1 Unused

JP 21

Lift 2

JP12

ZAPI Unused

JP1 / JP2

Lower 2

JP10

CAN

CJ2

VERSION 1.3 FUNCTION

DESCRIPTION

FUNCTION

DESCRIPTION

Speed Control

IC1, IC2

Pick 1

JP16

Emergency Reverse

Pick 2

JP17

Horn Switch

Click & Coast

JP11

Low Speed Switch

Spare 1.1 Unused

JP 20

Spare 2 Unused

JP 13

Lift 1

JP10

Lower 1

JP12

Spare 2.1 Unused

JP 21

Lift 2

JP14

ZAPI Unused

JP1 / JP2

Lower 2

JP15

CAN

CJ2

ES-81

SELF DIAGNOSIS OF REMA PCB 1 Diagnosis Mode

With the ignition in the off position and battery disconnected

STEP 2

Locate mode select jumper on board (Fig A)

Jumper should be found in the (P)arking mode upon disassembly

Move the mode select jumper from (P)arking mode to (D)iagnosis mode STEP 3 Plug in battery

Turn the ignition to the ON position Example of Code AL 02-67

During the diagnostic procedure of the multiplexer (PCB) board the communication to the controller is interrupted Codes AL 05-69 and AL 02-67 will display on the multi-function display

STEP 4 Example of Code AL 05-69

ES-82

Verify codes are present

SELF DIAGNOSIS OF REMA PCB 1 Part 1 of REMA Self Diagnostic Procedure NOTE: If LED does not respond press function switch on the opposite side handle Observe the LED on the PCB Fig “C” STEP 5 “1” Indicates the start of the diagnostic procedure

Start of Part 1

Expected Result

Lift 2 (JP 14) Push the lift 2 function to test this input

STEP 6

No other function is selectable LED will change from “1” to “2” Start of Step

Expected Result

Lower 2 (JP 15) Push the lower 2 function to test this input

STEP 7 No other function is selectable LED will change from “2” to “3” Start of Step

Expected Result

Directional Control Neutral Band Unit will automatically pass this step if handle is in the neutral position

STEP 8 No other function is selectable LED will change from “3” to “4” Start of Step

Expected Result

Turn the butterfly in the rotation right direction as printed on the PC Board No other function is selectable

STEP 9

LED will change from “4” to “5” Start of Step

STEP 10

Expected Result

Turn the butterfly in the rotation left direction as printed on the PC Board No other function is selectable

LED will change from “5” to “6”

ES-83

SELF DIAGNOSIS OF REMA PCB 1 Start of Step

Expected Result

Horn Function (S3) Activate the S3 switch on the PC Board (Horn Function)

STEP 11

No other function is selectable

LED will change from “6” to “7” Start of Step

Expected Result

Low Speed Switch (S2) Activate the S2 switch on the PC Board (Low Speed Switch)

STEP 12

No other function is selectable

LED will change from “7” to “8”

Start of Step

Expected Result

Emergency Reverse (S1) Activate the S1 switch on the PC Board (Emergency Reverse)

STEP 13

No other function is selectable

LED will change from “8” to “9”

Part 1 Completed

STEP 14

This completes Part 1 of the self diagnostic procedure

If any of the previous steps do not pass, validate all switches and wiring. Upon retesting and duplicating results board is considered nonfunctional. All of the following switch tests, steps 14 through 19 can be bypassed by pressing the lift 2 switch (JP14).

ES-84

SELF DIAGNOSIS OF REMA PCB 1 Part 2 of REMA Self Diagnostic Procedure Version 1.2 will bypass all of the following steps, press (Lift 2) to complete test. NOTE: On Version 1.2 PCB or controller, pressing Lift 2 button will cause self test to go from Step 15 to 20. This is normal. Start of Part 2

Expected Result

Proportional Lift (JP 10) Push the Lift 2 button to bypass this switch test

STEP 15

The proportional feature is not used on this unit

LED will change from “9” to “A” Start of Step

Expected Result

Proportional Lower 1 (JP 12) Push the Lift 2 button to bypass this switch test

STEP 16 The proportional feature is not used on this unit LED will change from “A” to “b” Start of Step

Expected Result

Proportional Lower 1 (JP 12) Push the Lift 2 button to bypass this switch test

STEP 17

The proportional feature is not used on this unit

LED will change from “A” to “b” Start of Step

Expected Result

Proportional Lower 1 (JP 12) Push the Lift 2 button to bypass this switch test

STEP 18

The proportional feature is not used on this unit

LED will change from “A” to “b” Start of Step

Expected Result

Pick 1 (JP16) Push the Pick 1 button to test this input

STEP 19 LED will change from “d” to “E”

ES-85

SELF DIAGNOSIS OF REMA PCB 1 Start of Step

Successful Test

Pick 2 (JP17) Push the Pick 2 button to test this input

STEP 20

LED will change from “E” to “F”

Upon successful completion of Part 2 “F” will appear on LED

If any of the steps found in Part 2 of procedure do not pass, switches and wiring must be validated prior to replacing PC Board.

With the ignition in the on position and battery connected STEP 21 Move the mode select jumper from the (D)iagnose position to the (P)arking position

Verify LED Changes as Displayed

VER 1.2 “C.” will display on first ignition on after placing the park position

STEP 22

VER 1.3

Upon moving jumper LED will display “0” for 3 seconds followed by “C.” for 2 seconds

Turn the ignition to the off position and disconnect the battery Jumper should be placed in the (P)arking mode prior to reassembly STEP 23 Reassemble the handle assembly per page ST-6.

This completes the REMA-CAN PCB 84680-60 VER 1.2 or 1.3 Test Procedure

ES-86

2W5/2W6 MULTIPLEXER (PCB) BOARD MANUAL PROGRAM PROCEDURE This procedure is required any time a new steer head assembly or Multiplexer (PCB) board is installed. This procedure should also be performed if the operation of the Forward or Reverse functions change in any way. Disassembly and reassembly of the steer handle assembly must follow instruction per page ST-6. Observe all warnings and procedures as outlined in service manual.

!! WARNING • As with any electric powered industrial truck, when carrying out testing, reprogramming, or diagnosis, always raise the drive tire off the floor to avoid any accidental movement.

View and orientation for rotation left and rotation right, Connectors JP14 and JP15 must be connected.

ES-87

2W5/2W6 MULTIPLEXER (PCB) BOARD MANUAL PROGRAM PROCEDURE Teach procedure with pushbuttons: 1. Power supply switch OFF 2. Move Jumper from position “P(arking)” to position “T(each)” (Fig. A)

Fig. A 3. Connect the battery and turn the ignition to the ON position; the LED will show ZERO (Fig. B) During the teach procedure of the Mutliplexer (PCB) board the communication to the controller is interrupted. Codes AL 05-69 and AL 02-67 will display ON Fig. B 4. To teach the mechanical neutral position of the speed control. Be sure that the butterfly is in mechanical neutral position, and then enter the value by depressing the LIFT buttons connected to the Multiplexer (PCB) board one at a time for approximately five seconds. The center LED segment (Fig. C) will switch on.

Fig. C

5. To teach the forward direction, turn the butterfly to the mechanical stop in the “rotation left” direction as printed on the Multiplexer (PCB) board. Hold the butterfly in this position and enter the value by depressing the Lower buttons connected to the Multiplexer (PCB) board one at a time, for approximately five seconds. The bottom right LED segment (Fig. D) will switch on.

Fig. D

ES-88

2W5/2W6 MULTIPLEXER (PCB) BOARD MANUAL PROGRAM PROCEDURE 6. Release the butterfly back to the neutral position. 7. To teach reverse direction, turn the butterfly to the mechanical stop in the “rotation right” direction, as printed on the Multiplexer (PCB) board. Hold the butterfly in this position and enter the value by depressing the Lift buttons connected to the Multiplexer (PCB) board, one at a time for approximately five seconds. The top left LED segment (Fig. E) will switch on.

Fig. E

8. Release the butterfly back to the Neutral position. 9. With the ignition in the on position and the battery connected, move the jumper from position “T(each)” to position “P(arking)”, (Fig. F).

Fig. F (Decimal dot of the LCD switches ON) (Fig. G)

Fig. G 10. Teach procedure is completed. 11. Switch OFF the ignition. 12. The Multiplexer (PCB) board is ready for operation. 13. Switch on unit and verify operation of Multiplexer (PCB) board. 14. If unit does not operate Repeat steps 1 - 12. 15. Reassemble per page ST-6. 16. Upon successful test operation and reassembly of control handle lower the unit to the floor and test operate.

ES-89

COMBI AC1 ALARMS LIST The ALARMS logbook in the MAIN MENU records the alarms of the controller. It has a FIFO (First Input First Output) structure that means the oldest alarm is lost when the database is full and a new alarm occurs. The log can store up to five alarms with the following information: 1. The node AL02 = MAIN/TRACTION AL05 = SECONDARY/ PUMP 2. The alarm code 3. The times that each alarm occurs consecutively 4. The Hour Meter value when the first event of every alarm occurred 5. And the inverter temperature when the first event of every alarm occurred This function permits a deeper diagnosis of problems as the recent history can be revised. NOTE: If the same alarm is continuously happening, the controller does not use new memory of the logbook, but only updates the last memory cell increasing the related counter (point 3) of previous list). Nevertheless, the hourmeter indicated in this memory refers to the first time the alarm occurred. In this way, comparing this hourmeter with the controller hourmeter, it is possible to determine: • When this alarm occurred the first time. • How many hours are elapsed from the first occurrence to now • How many times it has occurred in said period.

Faults Diagnostic System The fault diagnostic system of the COMBIAC1 controller is divided into 2 main groups of faults: ALARMS: These are the faults which stop motor operation, which means the power bridge shutdown and, when possible, the LC is opened and EB is applied These are faults related to: • failures in the motor or controller that do not allow the power system to drive the machine • safety related failures WARNINGS: These are faults which do not stop the machine or that stop it with controlled regen braking. In other words, the controller is working well, but it has detected conditions requiring reduction in performance or inhibiting operation. These warnings are related to: • incorrect operation sequences • conditions which require performance reduction (like high temperatures, low battery, etc….)

ES-90

COMBI AC1 ALARMS LIST !! WARNING • Put the vehicle up on blocks to get the drive wheels up off the ground before beginning these test. • Do not stand, or allow anyone else to stand, directly in front of or beside the vehicle during the checkout. • All troubleshooting should be conducted using a fully charged battery. Failure to do so can influence test results and can cause misdiagnosis of problems. • Make sure the ignition is off, the throttles are in neutral, and all the switches open. • Wear safety glasses and use well-insulated tools.

Description of Handset and Connection Digital Hand Set used to communicate with AC inverter controllers must be fitted with EPROM CK ULTRA, minimum release number: 3.02

!! WARNING

ZAPI Handset Minimum release number 3.02

• Do not adjust any adjustment items listed in the service manual as factory setting “DO NOT ADJUST”, or adjust any item listed above the published maximum setting. Making changes to the factory settings, or above the maximum listed limit will cause the truck to operate outside of its design parameters. Making changes to any of the factory settings or above the maximum limit as listed in the service manual, will result in voiding the warranty of the controller and components of the electric system. • As with any electric powered industrial truck, when carrying out a testing, reprogramming, or diagnosis, always raise the drive tire off the floor to avoid any accidental movement.

! CAUTION • Plug the ZAPI into a programmer port only. Voltages and other interface circuits can result in permanent damage to the programmer.

ES-91

COMBI AC1 ALARMS LIST Download HM from MDI Alarm Code 02-94 Turn OFF ignition and read instructions below.

ES-92

COMBI AC1 ALARMS LIST Download HM from MDI (Cont’d)

ES-93

COMBI AC1 ALARMS LIST Master Microcontroller Alarms Overview Master error code

Related slave error code

Description

Effect

Machine status when the test is done

Restart procedure

Capacitor charge

Waiting for trac

Power capacitors voltage does not increase

Valve, pump, start-up traction stopped, Lc opened, Eb applied

Valve or pump or traction request

Vmn low

Waiting for trac

Motor output voltage lower than expected

Valve, pump, start-up traction stopped, Lc opened, Eb applied

Valve or pump or traction request

Vmn high

Waiting for trac

Motor output voltage higher than expected

Valve, pump, start-up traction stopped, Lc opened, Eb applied

Valve or pump or traction request

Power mos shorted

Waiting for trac

Short circuit on the power mosfets

Valve, pump, start-up traction stopped, Lc opened, Eb applied

Valve or pump or traction request

Coil short hw ko

Waiting for trac

Problem on the hardware circuit which manages shortcircuits on Lc/ Eb coils

Valve, pump, start-up traction stopped, Lc opened, Eb applied

Valve or pump or traction request

Coil shorted

Waiting for trac

Shortcircuit on LC or EB coils

Valve, pump, stby, traction traction stopped, Lc opened, Eb applied

Valve or pump or traction request

Driver shorted

Waiting for trac

Driver of Lc coil is shorted, so it is not able to open the Lc

Valve, pump, start-up, stby, traction stopped, Lc traction opened, Eb applied

Valve or pump or traction request

Contactor Driver

Waiting for trac

Driver of Lc coil is damaged (not able to close)

Valve, pump, stby, traction traction stopped, Lc opened, Eb applied

Valve or pump or traction request

Contactor Open

Waiting for trac

The Lc coil has been driven but Lc does not close

Valve, pump, stby, traction traction stopped, Lc opened, Eb applied

Valve or pump or traction request

Contactor closed

Waiting for trac

LC contact is stuck

Valve, pump, start-up traction stopped, Lc opened, Eb applied

Valve or pump or traction request

Aux driv. Shrt.

Waiting for trac

When the mos of EB is shorted

Valve, pump, start-up,stby traction stopped, Lc opened, Eb applied

Valve or pump or traction request

Aux driver open

Waiting for trac

Driver of Eb coil is damaged (not able to close)

Valve, pump, stby, traction traction stopped, Lc opened, Eb applied

Valve or pump or traction request

Pos aux short

Waiting for trac

Output of built in Valve, pump, start-up Smart Driver, which traction stopped, Lc supplies Eb coil opened, Eb applied positive, is high (= +batt) when the tiller switch is opened.

Valve or pump or traction request

Logic Failure #1

Waiting for trac

Overvoltage/ Undervoltage condition has been detected

Valve, pump, start-up, stby, traction stopped, Lc traction opened, Eb applied

Valve or pump or traction request

Logic Failure #2

Waiting for trac

Motor voltage feedback circuits are damaged

Valve, pump, stby, immediately traction stopped, Lc after Lc closing opened, Eb applied

Valve or pump or traction request

ES-94

COMBI AC1 ALARMS LIST Master Microcontroller Alarms Overview (Cont’d) Master error code

Related slave error code

Description

Effect

Machine status when the test is done

Restart procedure

Logic failure #3

Waiting for trac

Failure in the high current HW protection circuit

valve, pump, start-up, stby traction stopped, Lc opened, Eb applied

Valve or pump or traction request

Stby i high

Waiting for trac

In stby condition (no current applied to the motor) the current feedbacks are out of permitted stby range

Valve, pump, start-up, stby traction stopped, Lc opened, Eb applied

Valve or pump or traction request

Wrong Set Battery

Waiting for trac

The battery voltage is too low or too high (< 0,8 Vbatt OR > 1,2 Vbatt)

Valve, pump, start-up, stand-by traction stopped, Lc (only immediately opened, Eb applied after Lc closing)

Valve or pump or traction request

Analog input

Waiting for trac

Problem on the A/D conversion of Master uC

Valve, pump, start-up, stby, traction stopped, Lc traction opened, Eb applied

Valve or pump or traction request

Encoder Error

Waiting for trac

Problem on the encoder

Valve, pump, start-up, stby, traction stopped, Lc traction opened, Eb applied

Valve or pump or traction request

Watchdog

Waiting for trac

Master uC does not receive via canbus the correct stuffing bit from Slave uC

Valve, pump, start-up, stby, traction stopped, Lc traction opened, Eb applied

Key re-cycle

Hw Fault

Waiting for trac

Master uC has detected that slave uC is not able to stop traction enable or EB-LC enable

Valve, pump, start-up, stand-by traction stopped, Lc (only immediately opened, Eb applied after Lc closing)

Key re-cycle

No can msg N60

Waiting for trac

No can message from REMA tiller card

No can msg N5

Waiting for trac

No can message from slave uC

Valve, pump, start-up, stby, traction stopped, Lc traction opened, Eb applied

Key re-cycle

Wrong setpoint

Waiting for trac

Master uC has detected a Slave uC wrong hydraulic function setpoint

Valve, pump, continuous traction stopped, Lc opened, Eb applied

Key re-cycle

Safety Feedback

Waiting for trac

Master uC has detected a problem on the feedback of EVP driver

Valve, pump, traction stopped, Lc opened, Eb applied

Key re-cycle

ES-95

continuous

COMBI AC1 ALARMS LIST Alarm Index MAIN/TRACTION NODE 02 MICROCONTROLLER ALARMS OVERVIEW Alarm

Number

Alarm

MAIN WARNINGS OVERVIEW

Page Number

Alarm

Number

Alarm

Page Number

NO COMMUNICATION

ES-105

MOTOR LOCKED

WATCHDOG

ES-104*

THERMIC SENSOR KO ES-108

ES-110

LOGIC FAILURE #3

ES-102

HIGH TEMPERATURE

CONTACTOR CLOSED

ES-101

HS-TILLER MISMATCH ES-110*

ES-107

CONTACTOR OPEN

ES-101

MOTOR TEMPERATURE

ES-108

HARDWARE FAULT

ES-104

BATTERY LOW + BLINKING RED LED

ES-107

VMN HIGH

ES-99

CAN BUS KO

ES-110*

AUX DRIVE SHORTENED

ES-101

EEPROM KO

ES-108

WRONG SET BATTERY

ES-103

TILLER ERROR

ES-109

AUX DRIVER OPEN

ES-101

INCORRECT START

ES-107 ES-108*

STBY I HIGH

ES-103*

PLT-COAST MISMATCH

LOGIC FAILURE #1

ES-102*

CURRENT GAIN

ES-110

LOGIC FAILURE #2

ES-102

CHECK UP NEEDED + WRENCH SYMBOL

ES-108

CAPACITOR CHARGE

ES-98

SLIP PROFILE

ES-107 ES-107

NO CAN MESSAGE N5

ES-104*

PUMP WARNING “SHOWS ON HAND SET ONLY”

NO CAN MESSAGE N60

ES-104*

END TEACH OK “SHOWS ON HAND SET ONLY”

ES-109

CAN BUS KO

ES-105*

END TEACH ERROR “SHOWS ON HAND SET ONLY”

ES-109

VMN LOW

ES-98

TEACH ERROR “SHOWS ON HAND SET ONLY”

ES-109

DRIVER SHORTED

ES-100

WAITING FOR NODE “SHOWS ON HAND SET ONLY”

ES-109

CONTACTOR DRIVER

ES-100

COIL SHORTED

ES-100

WRONG SET POINT

ES-104

COIL SHORT HW KO

ES-100

ENCODER ERROR

ES-103

POS AUX SHORT

ES-101

POWER MOS SHORTED

ES-100

SAFETY FEEDBACK

ES-105

MDI HOURS (RESET HOURMETER)

ES-105

ANALOG INPUT

ES-103

*Codes shared by both sides of the controller node 2 and node 5 There will be an alternating display between node and fault.

ES-96

COMBI AC1 ALARMS LIST Alarm Index (Cont’d) SECONDARY/PUMP NODE 05 ALARMS OVERVIEW Alarm

Number

Alarm

SECONDARY WARNINGS OVERVIEW Page Number

Alarm

Number

Alarm

Page Number

WATCHDOG

ES-115*

EEPROM KO

ES-120

LOGIC FAILURE #1

ES-113

PUMP I=0 EVER

ES-118

PUMP VMN LOW

ES-112

PUMP STBY I HIGH

ES-118 ES-120*

PUMP VMN HIGH

ES-112

PUMP MOTOR TEMPERATURE

OUTPUT MISMATCH

ES-115*

HW FAULT VALVE

ES-117*

SAFETY FEED (TG)

ES-114*

BATTERY GATE SWITCH OPTION

ES-118

SAFETY FEED (EB)

ES-114*

EEP WARNING

ES-119

CAN INPUT MISMATCH

ES-114

RAM WARNING

ES-119

INPUT MISMATCH

ES-114

INCORRECT START

ES-119

WRONG SET POINT

ES-114

CURRENT SENSOR LOW

ES-117

WRONG ZERO

ES-113*

EVP DRIVER KO

ES-118 ES-118

CAN BUS KO TILLER

ES-115

WAITING FOR TRACTION

HW FAULT

ES-115

VALVE CONT DRIVER

ES-117

EVP DRIVER SHORTED

ES-112

VALVE DRIVER SHORTED

ES-117

ANALOG INPUT

ES-113

NO CAN MESSAGE #2

ES-115

*Codes shared by both sides of the controller node 2 and node 5

ES-97

VALVE COIL SHORTED ES-117 LIFT + LOWER “SHOWS ON HAND SET ONLY”

ES-119

COMBI AC1 ALARMS LIST Analysis and Troubleshooting of Master Microcontroller Alarms To Enter the MAIN MENU’ push the Enter button at the Home Page of the hand set display and Roll for the ALARMS item. Here is the ALARMS list: 1. AL60 “CAPACITOR CHARGE” Monitors the capacitor bank pre-charging system:

When the ignition is switched ON, the inverter tries to charge the power capacitors through a power resistance, and check if the capacitors are charged within a timeout. If they do not charge, an alarm is signaled; the main contactor is not closed. Troubleshooting: A. There is an external load in parallel to capacitor bank, which sinks current from the controller capacitors precharging circuit, thus preventing the caps from charging. Check if a lamp or a dc/ dc converter or an auxiliary load is placed in parallel to capacitor bank (+B => -B). B. The charging resistance is opened; insert a power resistance across line contactor power terminals; if the alarm disappears, it means the controller internal charging resistance is damaged. C. The charging circuit has a failure, inside the controller. D. There is a problem in the controller power section. 2. AL72

“VMN LOW”

Cause 1: start-up test. Before switching the LC on, the software checks the power bridge: it turns on alternatively the High side Power Mosfets and expects the phases’ voltage to increase toward the capacitor’s voltage. If the phases’ voltage does not increase, this alarm occurs. Cause 2: Motor running test. When the motor is running, the power bridge is ON, the motor voltage feedback is tested; if it is lower than commanded value, fault status is entered.

ES-98

COMBI AC1 ALARMS LIST Analysis and Troubleshooting of Master Microcontroller Alarms (Cont’d) Troubleshooting: A. If the problem occurs at start up (the LC does not close at all), check: • Motor internal connections (ohmic continuity) • Motor power cables connections are correct and tight • If motor phases windings/cables have leakages towards truck frame • If the motor connections are OK, the problem is inside the controller B. If the alarm occurs during motor running, check: • Motor connections • If motor phases windings/cables have leakages towards truck frame • That the LC power contact closes properly, with a good contact • If no problems are found on the motors or contactor, the problem is inside the controller. 3. AL41

“VMN HIGH”

Cause 1: Before switching the LC on, the software checks the power bridge: it turns on alternatively the Low side Power Mosfets and expects the phases’ voltage to decrease down to -BATT. If the phases’ voltage do not decrease, this alarm occurs. Cause 2: This alarm may occur also after the start up diagnosis is complete, and the LC is closed. In this condition, the phases’ voltages are expected to be lower than 1/2 Battery voltage. If it is higher than that value, fault status is entered. Troubleshooting: A. If the problem occurs at start up (the LC does not close at all), check: • Motor internal connections (ohmic continuity) • If motor phases windings/cables have leakages towards truck frame • If the motor connection are OK, the problem is inside the controller B. If the problem occurs after closing the LC (the LC closed and then opens back again), check: • Motor connections • If motor phases windings/cables have leakages towards truck frame • If no problem are found on the motors, the problem is inside the controller

ES-99

COMBI AC1 ALARMS LIST Analysis and Troubleshooting of Master Microcontroller Alarms (Cont’d) 4. AL89

“POWER MOS SHORTED”

Cause: Before switching the LC on, the software checks the power bridge: it turns on alternatively the Low side and High side Power Mosfets and expects the phases voltage to decrease down to –BATT (increase up to +Batt). If the phases’ voltage do not follow the commands, this alarm occurs. Troubleshooting: This type of fault is not related to external components; replace the controller. 5. AL80

“COIL SHORT HW KO”

Cause: The hardware circuit which manages short circuit protection of LC and EB coils has a problem. Troubleshooting: This type of fault is not related to external components; replace the controller. 6. AL76

“COIL SHORTED”

Cause: This alarm occurs when there is a short circuit of one of the coils connected to outputs of the Combiac1 (LC coil or EB coil). After the overload condition has been removed, the alarm is removed by releasing and then enabling a travel demand. Troubleshooting: The typical root cause for this error code is in the harness or in the load coil. So first check connections between controller outputs and loads for short circuits to –BATT. In case no failures/problems have been found externally, the problem is in the controller. 7. AL74

“DRIVER SHORTED”

Cause: The FET driver of the main contactor coil is shorted to -BATT. Troubleshooting: A. Check if there is a short or a low impedance pull-down between NMC and –BATT. B. The driver circuit is damaged in the controller. 8. AL75

“CONTACTOR DRIVER”

Cause: The LC coil FET driver is not able to drive the load. The device itself or its driving circuit is damaged.

ES-100

COMBI AC1 ALARMS LIST Analysis and Troubleshooting of Master Microcontroller Alarms (Cont’d) Troubleshooting: This type of fault is not related to external components; replace the controller. 9. AL38

“CONTACTOR OPEN”

Cause: The main contactor coil has been driven by the controller, but the contactor does not close. Troubleshooting: A. The wires to the LC coil are interrupted or not connected, so check the coil related wiring. B. It could also be a mechanical problem of the contact in the LC that is not working (does not pull-in) try replacing the LC. 10. AL37

“CONTACTOR CLOSED”

Cause: Before closing the LC coil, the controller checks if the contactor is stuck closed. The controller drives the motor bridge for some tens milliseconds, trying to discharge the capacitor bank. If they don’t discharge the fault condition is entered. Troubleshooting: Check the LC for stuck contacts or for something holding the voltage at +B high. 11. AL42

“AUX DRIVER SHORTED”

Cause: The FET driver of the electromechanical brake coil is shorted. Troubleshooting: A. Check if there is a short or a low impedance pull-down between NEB and –BATT. B. The driver circuit is damaged in the controller. 12. AL44

“AUX DRIVER OPEN”

Cause: The FET driver of the electromechanical brake coil is not able to drive the load. Troubleshooting: Replace the controller. 13. AL86

“POS AUX SHORT”

Cause: The output of the built in Smart Driver, which supplies the positive to the Electromechanical brake coil is high when the Tiller and the H&S switch are open.

ES-101

COMBI AC1 ALARMS LIST Analysis and Troubleshooting of Master Microcontroller Alarms (Cont’d) Troubleshooting: A. It is suggested to check the harness, in order to verify if a positive is connected to the Smart driver output connector. B. If, even disconnecting the wire from the connector pin, the output stays at high value, the problem is inside the controller and the Smart Driver is probably shorted. 14. AL54

“LOGIC FAILURE #1”

This fault is displayed when the controller detects an overvoltage or undervoltage condition. Overvoltage threshold is 45V, undervoltage threshold is 9V in the 24V controller. Troubleshooting of fault displayed at startup or in standby; in these cases it is very likely the fault is due to an undervoltage, so it is suggested to check: A. Key input signal voltage drops (below undervoltage threshold) due to external loads, like DC/DC converters starting-up, relay or contactor switching, or solenoids energizing / deenergizing. B. If no voltage transient is detected on the supply line and the alarm is present every time the ignition is switched ON, the failure is in the controller hardware. Troubleshooting of fault displayed during motor operation; in this case it can be an undervoltage or an overvoltage condition. A. If the alarm happens during traction acceleration or driving hydraulic functions, it is very likely it is an undervoltage condition; check battery charge condition power cable connections. B. If the alarm happens during release braking, it is very likely it is due to overvoltage condition; check line contactor contacts, battery power cable connections. 15. AL55

“LOGIC FAILURE #2”

Cause: Fault in the hardware section of the logic board which manages the phase’s voltage feedback. Troubleshooting: This type of fault is not related to external components, so when it happens it is necessary to replace the Controller. 16. AL17

“LOGIC FAILURE #3”

Cause: Hardware problem in the logic card circuit for high current (overload) protection. Troubleshooting: This type of fault is not related to external components, so, when it is present it is necessary to replace the controller.

ES-102

COMBI AC1 ALARMS LIST Analysis and Troubleshooting of Master Microcontroller Alarms (Cont’d) 17. AL53

“STBY I HIGH”

Cause: The current transducer or the current feedback circuit is damaged in the controller. Troubleshooting: This type of fault is not related to external components so, when it is present, it is necessary to replace the controller. 18. AL43

“WRONG SET BATTERY”

Cause: At start-up, the controller checks the battery voltage and verifies it is within a window around the nominal value. Troubleshooting: A. Check that the controller SET BATTERY parameter value matches the battery nominal voltage. B. Check that the TESTER MENU / BATTERY VOLTAGE parameter shows same value as the battery voltage measured with a voltmeter. If it is does not match, then do a “ADJUST BATTERY” function. C. Replace the battery. 19. AL96

“ANALOG INPUT”

Cause: This alarm occurs when the A/D conversion of the analog inputs gives frozen value, on all of the converted signals, for more than 400msec. The goal of this diagnosis is to detect a failure of the A/D converter or a problem in the code flow that omits the refreshing of the analog signal conversion. Troubleshooting: If the problem occurs permanently it is necessary to substitute the controller. 20. AL82

“ENCODER ERROR”

Cause: This fault is signaled in following conditions: the frequency supplied to the motor is higher than 40 Hz and the signal feedback from the encoder has a jump higher than 40 Hz in a few tens of mSec. This condition is related to a malfunctioning of the encoder. Troubleshooting: A. Check both the electric and the mechanical encoder functionality, check the wire are crimped well, etc. B. Check the encoder mechanical installation, if the encoder slips inside its compartment it could raise this alarm condition. C. Electromagnetic noise on the sensor bearing can be a cause for the alarm. In these cases try to replace the encoder. D. If the problem is still present after replacing the encoder, the failure is in the controller.

ES-103

COMBI AC1 ALARMS LIST Analysis and Troubleshooting of Master Microcontroller Alarms (Cont’d) 21. AL08

“WATCHDOG”

Cause: This is a safety related test. It is a self diagnosis test within the logic between Master and Slave microcontrollers. Troubleshooting: This alarm could be caused by a canbus malfunction, which obscures master-slave communication. Otherwise it is an internal fault of the controller. 22. AL40

“HARDWARE FAULT”

Cause: The master microcontroller has detected that the slave microcontroller is not able to stop the traction enable or LC-EB enable. Troubleshooting: The problem is inside the logic of the inverter, replace the controller. 23. AL67

“NO CAN MESSAGE N5”

Cause: No Can messages from the slave microcontroller. Troubleshooting: This alarm could be caused by a canbus malfunction, which obscures master-slave communication. Otherwise it is an internal fault of the controller which must be replaced. 24. AL 67

“NO CAN MESSAGE N60”

Cause: No Can messages from the REMA Tiller Handle. Troubleshooting: This alarm could be caused by a can bus malfunction, which obscures controller-tiller communication. Otherwise it is an internal fault of the controller or the handle, which must be replaced. 25. AL78

“WRONG SETPOINT”

Cause: This is a safety related test. The Master µC has detected a Slave µC wrong hydraulic function setpoint. Troubleshooting: This is a internal fault of the controller, it is necessary to replace it.

ES-104

COMBI AC1 ALARMS LIST Analysis and Troubleshooting of Master Microcontroller Alarms (Cont’d) 26. AL91

“SAFETY FEEDBACK”

Cause: This is a safety related test. Master µC has detected a problem on the feedback of EVP driver. Troubleshooting: This is a internal fault of the controller, it is necessary to replace it. 27. AL67

“CAN BUS KO”

Cause: The controller is not receiving messages from other nodes on the CANBUS. 28. AL94 OFF

“MDI ONLY” (RESET HOURMETER) TURN IGNITION

Cause: Indicates the hour meters of the MDI and controller do not match. Troubleshooting: This occurs after installing a new controller or MDI. Clearing the alarm can be done two ways. 1. Wait two minutes. The hours from the controller will be automatically loaded into the MDI. Resetting the hours to zero. 2. To keep the current hour meter reading, follow the instructions on page ES-92 to down load hour meter data into the new controller. 29. AL06

“NO COMMUNICATION”

Cause: The BDI is not communicating with the controller.

ES-105

COMBI AC1 ALARMS LIST Master Warnings Overview Master error code

Related Slave error code

Description

Effect

Machine status when the test is done

Restart procedure

Pump Warning

Slave has a warning

Slip profile

Error on the parameters of the slip profile setting.

Traction is stopped

start-up, stand-by, traction

Traction request

Forward/ backward

The travel demands are active in both directions at the same time

Traction is stopped

start-up, stand-by, traction

Traction request

Incorrect start

Incorrect starting sequence

Traction is stopped

start-up, stand-by, traction

Traction request

High temperature

The controller has reached the thermal cutback temperature 85°C

Traction controller reduces the maximum current linearly from Imax (85°C) down to 0A (105°C)

continuous

Battery low

Battery is <= 10% when the parameter BATTERY CHECK is set >0

The maximum current is reduced to half and speed is reduced (if CHECK OPTION = 1)

continuous

Eeprom ko

Error is detected in eeprom or in eeprom management

Controller works using Default parameters

continuous

Motor temperature

Motor temperature sensor is opened (if digital) or has overtaken the threshold of 150°C (if analog)

The maximum current is reduced to half and speed is reduced

continuous

Thermic sens ko

The output of the controller thermal sensor is out of range.

The maximum current is reduced to half and speed is reduced

continuous

Check up needed

Maintenance time is reached

plt-coast mis.

Traction is stopped

continuous

Tiller Error

Alarm from the REMA tiller Card

Traction is stopped

start-up, stand-by, traction

end teach ok

only in the console, if the teaching of the rema vacc is ok

end teach error

only in the console, if the teaching of the rema vacc is error

teach error

only in the console, if the teaching of the rema vacc is error

Current gain

The Maximum current gain parameters are @ the default values, which means the maximum current adjustment procedure has not been carried out yet

Controller works, but with low maximum current

start-up, stand-by

Waiting for node

Slave uC is in alarm condition, Master uC is waiting for it to resolve its error condition

ES-106

continuous

Traction request

COMBI AC1 ALARMS LIST Analysis and Troubleshooting of Master Warnings 1. HAND SET ONLY “PUMP WARNING” Cause: The slave has a warning. Troubleshooting: Connect to the slave with the handset and check the warning. 2. AL99 “SLIP PROFILE” Cause: There is an error on the choice of the parameters of the slip profile. Troubleshooting: Check in the hardware setting menu the value of those parameters. 3. AL79 “INCORRECT START” Cause: This is a warning for an incorrect starting sequence. Troubleshooting: The possible reasons for this alarm are (use the readings in the TESTER to facilitate the troubleshooting): A. A travel demand active at ignition on B. Brake (tiller) sensor is active at ignition on Check the wirings. Check the microswitches. It could be also an error sequence made by the operator. A failure in the logic is possible too; so when all of the above conditions were checked and nothing was found, replace the controller. 4. AL62 “HIGH TEMPERATURE” Cause: This alarm occurs when the temperature of the base plate is higher than 85°C (185°F). Then the maximum current decreases proportionally with the temperature increases from 85°C (185°F) up to 105°(221°F). At 105° (221°F) the Current is limited to 0 Amps. Troubleshooting: Improve the air-cooling of the controller. If the alarm is signaled when the controller is cold, the possible reasons are a thermal sensor failure or a failure in the logic card. In this case, it is necessary to replace the controller. 5. AL66 + BLINKING RED LED “BATTERY LOW” Cause: It occurs when the battery charge is calculated as being less than or equal to 20% of the full charge and the BATTERY CHECK setting is other than 0 (refer to SET OPTION menu).

ES-107

COMBI AC1 ALARMS LIST Analysis and Troubleshooting of Master Warnings (Cont’d) Troubleshooting: Charged the battery. If it doesn’t work, measure with a voltmeter the battery voltage and compare it with the value in the BATTERY VOLTAGE parameter. If they are different adjust the value of the ADJUST BATTERY function. 6. AL71 “EEPROM KO” Cause: It’s due to a HW or SW defect of the non-volatile embedded memory supporting the controller parameters. This alarm does not inhibit the machine operations, but the truck will work with the default values. Troubleshooting: If the alarm is persistent, contact the service department. 7. AL65 “MOTOR TEMPERATURE” Cause: This warning occurs when the temperature sensor is opened (if digital) or has overtaken the threshold of 150° (if analog). Troubleshooting: Check the thermal sensor inside the motor (use the MOTOR TEMPERATURE reading in the TESTER menu); check the sensor ohmic value and the sensor wiring. If the sensor is OK, improve the air cooling of the motor. If the warning is present when the motor is cool, then the problem is inside the controller. 8. AL61 “THERMIC SENSOR KO” Cause: The output of the controller thermal sensor is out of range. Troubleshooting: This type of fault is not related to external components; replace the controller. 9. AL98 + WRENCH SYMBOL “CHECK UP NEEDED” Cause: This is just a warning to call for the timed programmed maintenance. Troubleshooting: It is just enough to turn the CHECK UP DONE option to level ON after the maintenance is executed. 10. AL81 “PLT-COAST MISMATCH” (Not Used on 2W5/2W6)

ES-108

COMBI AC1 ALARMS LIST Analysis and Troubleshooting of Master Warnings (Cont’d) 10. AL81 “PLT-COAST MISMATCH” (Not Used on 2W5/2W6) 11. AL77 “TILLER ERROR” Cause: Alarm is communicated from the Tiller handle. Troubleshooting: See Tiller Documentation. 12. HAND SET ONLY “END TEACH OK” Cause: Confirms that teaching of the thumbwheel is successful. 13. HAND SET ONLY “END TEACH ERROR” Cause: Indicates the teaching of the thumbwheel was not successful. Troubleshooting: Attempt teach again. If alarm is persistent, check the Tiller handle. 14. HAND SET ONLY “TEACH ERROR” Cause: Indicate an error during the teaching of the thumbwheel. Troubleshooting: Attempt teach again. If alarm is persistent, check the Tiller handle. 15. HAND SET ONLY “WAITING FOR NODE” Cause: Slave microcontroller is in alarm. Master is waiting for resolution. Troubleshooting: Clear the alarm on the Slave.

ES-109

COMBI AC1 ALARMS LIST Analysis and Troubleshooting of Master Warnings (Cont’d) 16. AL92 “CURRENT GAIN” Cause: The Maximum current gain parameters are at the default values, which means the maximum current adjustment procedure has not been carried out yet. Troubleshooting: Do the correct adjustment procedure of the current gain parameters. 17. AL 64 HS-TILLER MISMATCH Cause: When input A29 is active, so should be A1, internally. The controller checks this condition, If not true, this alarm is given. Troubleshooting: Replace the controller. 18. AL67 “CAN BUS KO” Cause: The controller is not receiving messages from other nodes on the CANBUS 19. AL58 “MOTOR LOCKED” Cause: If the set point of frequency (commanded by tiller) is >20Hz and the encoder <0,6Hz for more than 5 sec, a blocked motor is assumed and this warning is given. The warning is cleared when tiller is released.

ES-110

COMBI AC1 ALARMS LIST Secondary/Pump Alarms Overview Slave error code

Related Master error code

Description

Effect

Machine status when the test is done

Restart procedure

Evp Driver Shorted

Waiting for Node

Evp driver is failed shorted (always ON)

valve, pump, traction stopped, Lc opened, Eb applied

start-up, stby

valve or pump or traction request

Pump Vmn Low

Waiting for Node

Pump motor output is too low, with respect to pwm applied

valve, pump, traction stopped, Lc opened, Eb applied

start-up, stby, during pump function

valve or pump or traction request

Pump Vmn High

Waiting for Node

Pump motor output is too high, with respect to pwm applied

valve, pump, traction stopped, Lc opened, Eb applied

during pump function

valve or pump or traction request

analog input

Waiting for Node

Problem on the A/D conversion of uC

valve, pump, traction stopped, Lc opened, Eb applied

continuous

valve or pump or traction request

logic failure#1

Waiting for Node

Overvoltage/Undervoltage condition has been detected

valve, pump, traction stopped, Lc opened, Eb applied

continuous

valve or pump or traction request

Wrong Zero

Waiting for Node

The outputs of the amplifiers (used to measure the motor currents and voltage) are checked to be near null. This alarm occurs when current signals are >2,85V or <2,15V. Voltage signals >3V or <2V at the init

valve, pump, traction stopped, Lc opened, Eb applied

init (for iv,iw,huw,hvw)

rpm>20Hz(lv,lu)

valve or pump or traction request

Safety Feed (TG)

Waiting for Node

Slave uC has detected a problem on the feedback of Lc driver

valve, pump, traction stopped, Lc opened, Eb applied

continuous

Key re-cycle

Safety Feed (Eb)

Waiting for Node

Slave uC has detected a problem on the feedback of Eb driver

valve, pump, traction stopped, Lc opened, Eb applied

continuous

Key re-cycle

Wrong setpoint

Waiting for Node

Slave uC has detected a Master uC wrong hydraulic function setpoint

Valve, pump, traction stopped, Lc opened, Eb applied

continuous

Key re-cycle

Input MisMatch

Waiting for Node

Slave uC has detected a mismatch between its input (digital, analog and encoder) and correspondent Master uC inputs

Valve, pump, traction stopped, Lc opened, Eb applied

continuous

Key re-cycle

CAN Input MisMatch

Waiting for Node

Slave uC has detected a mismatch between its can input (rema tiller) and corresponding Master uC can inputs(rema tiller)

Valve, pump, traction stopped, Lc opened, Eb applied

continuous

Key re-cycle

Output MisMatch

Waiting for Node

Slave uC has detected a condition that the Master uC is driving traction motor in an incorrect way (not corresponding to the status of operator commands)

Valve, pump, traction stopped, Lc opened, Eb applied

continuous

Key re-cycle

watchdog

Waiting for Node

Master uC does not receive via canbus the correct stuffing bit from Slave uC

valve, pump, traction stopped, Lc opened, Eb applied

continuous

Key re-cycle

can bus ko tiller

Waiting for Node

Can messages from rema tiller are unreadable

valve, pump, traction stopped, Lc opened, Eb applied

continuous

Key re-cycle

No can Msg #2

Waiting for Node

Can messages from Master uC are unreadable

valve, pump, traction stopped, Lc opened, Eb applied

continuous

Key re-cycle

Hw Fault

Waiting for Node

Slave uC has detected that Master uC is not able to stop hydraulic functions

valve, pump, traction stopped, Lc opened, Eb applied

start-up (EVP related test)stby (pump chopper related test)

Key re-cycle

ES-111

COMBI AC1 ALARMS LIST Analysis and Troubleshooting of Slave Alarms 1. AL93 “EVP DRIVER SHORTED” Cause: The EVP driver is shorted. Troubleshooting: Check if there is a short or a low impedance between the negative of the coil and -BATT. Otherwise the driver circuit is damaged and the controller must be replaced. 2. AL28 “PUMP VMN LOW” Cause: The pump motor output is lower than expected, considering the pwm applied. Troubleshooting: A. If the problem occurs at start up (the LC does not close at all), check: • Motor internal connections (ohm continuity) • Motor power cables connections • If the motor connection are OK, the problem is inside the controller B. If the problem occurs after closing the LC (the LC closed and then opens back again), check: • Motor connections • If motor windings/cables have leakages towards truck frame • If no problem are found on the motors, the problem is inside the controller C. If the alarm occurs during motor running, check: • Motor connections • If motor windings/cables have leakages towards truck frame • That the LC power contact closer properly, with a good contact • If no problem is found on the motors, the problem is inside the controller. 3. AL29 “PUMP VMN HIGH” Cause: This test is carried out when the pump motor is turning (pwm applied). The pump motor output is higher than expected, considering the pwm applied. Troubleshooting: it is suggested to check: A. Motor connections B. If motor windings/cables have leakages towards truck frame C. If no problem are found on the motors, the problem is inside the controller

ES-112

COMBI AC1 ALARMS LIST Analysis and Troubleshooting of Slave Alarms (Cont’d) 4. AL97 “ANALOG INPUT” Cause: This alarm occurs when the A/D conversion of the analog inputs does not change, on all of the converted signals, for more than 400msec. The goal of this diagnosis is to detect a failure of the A/D converter or a problem in the code flow that omits the refreshing of the analog signal conversion. Troubleshooting: If the problem occurs permanently it is necessary to replace the controller. 5. AL19 “LOGIC FAILURE #1” Cause: This fault is displayed when the controller detects an over voltage or under voltage condition. Over voltage threshold is 45V, under voltage threshold is 9V in the 24V controller. Troubleshooting of fault displayed at startup or in standby; in these cases it is very likely the fault is due to an under voltage, so it is suggested to check: A. Key input signal down-going pulses (below under voltage threshold) due to external loads, like DC/DC converters startingup, relays or contactor switching, solenoids energizing / deenergizing. B. If no voltage transient is detected on the supply line and the alarm is present every time the ignition is switched ON, the failure is probably in the controller hardware, so it is necessary to replace the controller. Troubleshooting of fault displayed during motor driving; in this case it can be an under voltage or an over voltage condition. A. If the alarm happens during traction acceleration or driving hydraulic functions, it is very likely it is an under voltage condition; check battery charge condition, power cable connection. B. If the alarm happens during release braking, it is very likely it is due to over voltage condition; check line contactor contact, battery power cable connection. 6. AL67 “WRONG ZERO” Cause: The outputs of the amplifiers (used to measure the motor currents and voltage) are checked to be near null. This alarm occurs when current signals are outside of a prescribed window. Troubleshooting: This type of fault is not related to external components; replace the controller.

ES-113

COMBI AC1 ALARMS LIST Analysis and Troubleshooting of Slave Alarms (Cont’d) 7. AL54 “SAFETY FEED (TG)” Cause: This is a safety related test. Slave µC has detected a problem on the feedback of Lc driver. Troubleshooting: This is a internal fault of the controller, it is necessary to replace it. 8. AL54 “SAFETY FEED (EB)” Cause: This is a safety related test. Slave µC has detected a problem on the feedback of Eb driver. Troubleshooting: This is a internal fault of the controller, it is necessary to replace it. 9. AL59 “WRONG SETPOINT” Cause: This is a safety related test. Slave µC has detected a Master µC wrong traction function set point. Troubleshooting: This is a internal fault of the controller, it is necessary to replace it. 10. AL58 “INPUT MISMATCH” Cause: This is a safety related test. Slave µC has detected a mismatch between its input (digital, analog and encoder) and corresponding Master µC inputs. Troubleshooting: This is a internal fault of the controller, it is necessary to replace it. 11. AL57 “CAN INPUT MISMATCH” Cause: This is a safety related test. Slave µC has detected a mismatch between its CAN input (tiller) and the corresponding inputs on the Master microcontrollers. Troubleshooting: This is a internal fault of the controller, it is necessary to replace it.

ES-114

COMBI AC1 ALARMS LIST Analysis and Troubleshooting of Slave Alarms (Cont’d) 12. AL53 “OUTPUT MISMATCH” Cause: This is a safety related test. Slave µC has detected that the Master µC is driving traction motor in a wrong way (not correspondent to the status of operator commands). Troubleshooting: This is a internal fault of the controller, it is necessary to replace it. 13. AL08 “WATCHDOG” Cause: It is a self-diagnosis test within the logic between Master and Slave microcontrollers. Troubleshooting: This alarm could be caused by a can bus malfunctioning, which obscures master-slave communication. Otherwise it is an internal fault of the controller which must be replaced. 14. AL69 CAN BUS KO TILLER Cause: No Can messages are being received from the tiller. Troubleshooting: This alarm is caused by a can bus malfunction, which obscures tillercontroller communication. Check wiring and connections. If good, them replace the tiller card. 15. AL99 “NO CAN MESSAGE#2” Cause: No Can messages from the master microcontroller. Troubleshooting: This alarm could be caused by a can bus malfunctioning, which obscures master-slave communication Otherwise the problem is inside the logic, replace the controller. 16. AL83 “HW FAULT” Cause: The slave has detected that the master microcontroller is not able to stop hydraulic functions. Troubleshooting: This type of fault is not related to external components; replace the controller.

ES-115

COMBI AC1 ALARMS LIST Secondary / Pump Warnings Overview Slave error code

Related Master error code

Description

Effect

Machine status when the test is done

Restart procedure

Current Sensor Low

Pump Warning

Pump chopper current sensor feedback too low (below 0,5V)

Pump motor stopped

stby

pump request

Hw Fault Valve

Pump Warning

Problem on the EN-EVS

On/off valves stopped

start-up

valve on/off request

Valve Coil Shorted

Pump Warning

Shortcircuit on On/off coils

On/off valves stopped

start-up, stby, during valve function

valve on/off request

Valve driver shorted

Pump Warning

One or more on/off valve drivers shorted (always ON)

On/off valves stopped

start-up, stby

valve on/off request

Valve Cont driver

Pump Warning

One or more on/off valve drivers opened (not able to close, so not able to drive the valve)

On/off valves stopped

during valve function

valve on/off request

Evp Driver Ko

Pump Warning

Evp driver open (not able to close, so not able to drive the valve)

Evp stopped

during Evp function

valve evp request

Pump Stby I high

Pump Warning

Pump chopper current sensor feedback too high (above 0,8V)

Pump motor stopped

start-up, stby

pump request

Pump I=0 ever

Pump Warning

Pump current feedback is always 0A even when pump motor is running

Pump motor stopped

pump function

pump request

motor temperature

Pump Warning

Pump motor temperature high

Pump chopper maximum current reduced to half

continuous

waiting for trac

ALARM XXX

Slave is waiting the master

incorrect start

Pump Warning

Wrong sequence in hydraulic function request

pump/valve stopped

continuous

ram warning

Pump Warning

checksum ram failed

continuous

eep warning

Pump Warning

checksum eeprom failed

init

lift+lower

Pump Warning

lift+lower request

eeprom ko

Pump Warning

eeprom is not online, or the parameters in triplicate are different

Pump motor temperature

Pump Warning

high temperature

Pump Warning

Pump motor stopped

continuous

When the parameter SET TEMPERATURE is set, the temperature of the motor is >150°c

Maximum current is halfed

continuous

When the parameter maximum current is 100% the current is reduced lineary from 85°c to 105°C

Pump chopper maximum current reduced proportionally to T increase

continuous

ES-116

to do a correct sequence

hydraulic request

COMBI AC1 ALARMS LIST Analysis and Troubleshooting of Slave Warnings 1. AL91 “CURRENT SENSOR LOW” Cause: The pump chopper current sensor feedback is too low (below 0.5V). Troubleshooting: This type of fault is not related to external components; replace the controller. 2. AL81 “HW FAULT VALVE” Cause: The slave has detected that the master microcontroller is not able to stop hydraulic valves functions Troubleshooting: This fault is not related to external components, replace the controller. 3. AL98 “VALVE COIL SHORTED” Cause: This alarm occurs when there is a short circuit on an on/off valve coil. Troubleshooting: A. If the fault is present at start up, it is very likely that the hw over current protection circuit is damaged, it is necessary to replace the controller. B. If the fault is present when the controller drives the outputs, the problem is located in the harness and or in the valve coils. Check for a short circuit of the negative coils’ connection to -BATT. 4. AL96 “VALVE DRIVER SHORTED” Cause: One or more on/off valve drivers are shorted. Troubleshooting: Check if there is a short or a low impedance between the negative of one of those coils and -BATT. Otherwise the driver circuit is damaged and the controller must be replaced. 5. AL95 “VALVE CONT DRIVER” Cause: One or more on/off valve drivers are not able to drive the load (cannot close). Troubleshooting: The device or its driving circuit is damaged. If device and circuit are okay replace the controller.

ES-117

COMBI AC1 ALARMS LIST Analysis and Troubleshooting of Slave Warnings (Cont’d) 6. AL92 “EVP DRIVER KO” Cause: The EVP valve driver is not able to drive the load (cannot close). Troubleshooting: The device or its driving circuit is damaged. If device and circuit are okay replace the controller. 7. AL56 “PUMP STBY I HIGH” Cause: In standby condition (pump motor not driven), the feedback coming from the current sensor in the pump chopper gives a value too high (>0,8). Troubleshooting: This type of fault is not related to external components; replace the controller. 8. AL52 “PUMP I=0 EVER” Cause: This test is carried out when the pump motor is running, and it verifies that the current feedback sensor is not constantly stuck to 0. Troubleshooting: A. Check the motor connection, that there is continuity. If the motor connection is opened, the current cannot flow, so the test fails and the error code is displayed. B. If everything is ok for what it concerns the motor, the problem could be in the current sensor or in the related circuit. 9. AL85 “BATTERY GATE SWITCH OPTION” (used on 2W6 with 13” battery only) Cause: This warning occurs when the sensor is opened or has overtaken the threshold of 105°C (221°F) (if analog), the battery gates are not installed correctly at start-up, or when battery gate is not in place during operation. Troubleshooting: • Check battery gates are installed completely. • If gates are installed, check wiring to controller. 10. AL94 “WAITING FOR TRACTION” Cause: The controller receive from the CAN the message that Master controller is in fault condition; as a consequence the pump controller itself cannot enter an operative status, but has to WAIT for the Master controller coming out from the fault condition.

ES-118

COMBI AC1 ALARMS LIST Analysis and Troubleshooting of Slave Warnings (Cont’d) 11. AL90 “INCORRECT START” Cause: This is a warning for an incorrect starting sequence. Troubleshooting: The possible reasons for this alarm are (use the readings in the TESTER to facilitate the troubleshooting): A. A hydraulic function demand active at ignition on B. Deadman sensor active at ignition on Check the wirings. Check the microswitches. It could be also an error sequence made by the operator. A failure in the logic is possible too; so when all of the above conditions were checked and nothing was found, replace the controller. Troubleshooting: This fault is not related to external components. 12. AL88 “RAM WARNING” Cause: Checksum of the ram failed. Troubleshooting: This fault is not related to external components. 13. AL87 “EEP WARNING” Cause: Eeprom checksum failed Troubleshooting: Try to execute a CLEAR EEPROM operation (refer to Hand set manual). Switch the ignition off and on to check the result. If the alarm occurs permanently, it is necessary to replace the controller. If the alarm disappears, the previously stored parameters will have been replaced by the default parameters. 14. “LIFT + LOWER” Cause: This alarm occurs when both forks movement requests (Lift + Lower) are active at the same time. Troubleshooting: Check the wiring of the Lift and lower inputs (use the readings in the TESTER to facilitate the troubleshooting). Check the micro switches for failures. A failure in the logic is possible too. So, when you have verified the travel demand switches are fine working and the wiring is right, it is necessary to replace the controller.

ES-119

COMBI AC1 ALARMS LIST Analysis and Troubleshooting of Slave Warnings (Cont’d) 15. AL13 “EEPROM KO” Cause: It’s due to a HW or SW defect of the non-volatile embedded memory supporting the controller parameters. This alarm does not inhibit the machine operations, but the truck will work with the default values. Troubleshooting: Try to execute a CLEAR EEPROM operation (refer to Hand set manual). Switch the ignition off and on to check the result. If the alarm occurs permanently, it is necessary to replace the controller. If the alarm disappears, the previously stored parameters will have been replaced by the default parameters. 16. AL64 “PUMP MOTOR TEMPERATURE” Cause: This warning occurs when the temperature sensor is opened (if digital) or has overtaken the threshold of 150° (if analog). Troubleshooting: Check the thermal sensor inside the motor (use the MOTOR TEMPERATURE reading in the TESTER menu); check the sensor ohm value and the sensor wiring. If the sensor is OK, improve the air-cooling of the motor. If the warning is present when the motor is cool, then the problem is inside the controller.

ES-120

LEGEND - 2W5/2W6 Std.

Opt.

ES-121

SCHEMATIC - 2W5/2W6

ES-122

POWER WIRING - 2W5/2W6 12

1 11

2 3 4 5

6 7 U

8 15

V W

10 13

Item 1

Description

Item

Description

Battery Plug Cable Assembly

Controller to Motor U Cable

Cable #11

Cable #19

Cable #13

Line Contactor Assembly

Controller

Electric Brake Assembly

Cable #21

Drive Unit

Controller to Motor V Cable

Hydraulic Unit

Controller to Motor W Cable

Fuse-400A

Cable #15

ES-123

ES-124

737

727 941

J34 P34 Work Light

727 941

361 600 632 204

304 460 210

719 729 723 220 722

PA Connector

P35 Left P36 Right

J27 Mast Height Switch

201 931 240

718 430 450 510 520

550 540 736 440

340 320 717 330 960 240

- 300 210

J4 Brake Switch Motor Temp Sensor

930 -

P4 Chassis Harness

210 300 310 747 930

340 330 320 -

370 350 320 330 340

910,930, 940,950

715 711

530,531,725,721 722

P19 Handset

430-1 960-1 440-1 450-1 460-1

960 430 737 420 460 450 440 J19 Handset

Not Used

J22 Eco Smart Display

520 510 910 530

560 950 540 550

P22 Chassis Harness

530 910 510 520

550 540 950 560

Fuse 3

21 21

Fuse 2

712,721,723

531 511 521 912 911 P31 Eco Smart E2

23 727

610 Fans 600 620 630 J23 J24

P33 Aux/Hyd Function

632 718

240 717 361 931 301

J33 Main Chassis Aux/Hyd Function

304 727 204 718 632

301 931 361 717 240

MDI

430-1 960-1

CP2 to Steerhead See Steerhead Wiring

460-1 450-1 440-1

MDI (meter)

CONTROL WIRING - 2W5

P35 Left P36 Right

ES-125 727 941

201 931 240

361 600 632 204

304 460 210

J28 Left Battery Gate Switch

J27 Mast Height Switch

J29 Right Battery Gate Switch

12 719 729 723 220 722

203 951 204

J34 P34 Work Light

727 941

202 952 203

737

PA Connector

718 430 450 510 520

550 540 736 440

340 320 717 330 960 240

- 300 210

J4 Brake Switch Motor Temp Sensor

930 -

P4 Chassis Harness

340 330 320 -

210 300 310 747 930

370 350 320 330 340

910,930, 940,950

715 711

P19 Handset

530,531,725,721 722

Not Used

J22 Eco Smart Display

520 510 910 530

560 950 540 550

P22 Chassis Harness

530 910 510 520

550 540 950 560

Fuse 3

21 21

Fuse 2

712,721,723

531 511 521 912 911 P31 Eco Smart E2

430-1 960-1 440-1 450-1 460-1

960 430 737 420 460 450 440 J19 Handset

610 Fans 600 620 630 J23 J24

P33 Aux/Hyd Function

632 718 204 727 304

240 717 361 931 301

J33 Main Chassis Aux/Hyd Function

304 727 204 718 632

301 931 361 717 240

MDI

430-1 960-1

CP2 to Steerhead See Steerhead Wiring

460-1 450-1 440-1

MDI (meter)

CONTROL WIRING - 2W6

CONTROL WIRING - 2W5/2W6 27 3 32

J26 Steerhead

4 2

520 510 910 530 P26 Steerhead Harness

330 320

J9 Brake

30 34

300 930 340 J5 Brake Switch

To Steerhead 32

950 550 540 560 J25 Encoder

33 210 930-1

J30 Motor Temp Sensor

725,940

35 727 726

719,720

37 728 729 P32 Travel Alarm

ES-126

CONTROL WIRING - 2W5/2W6 Standard - 2W5 / Optional - 2W6 717,718

BOTTOM OF VALVE ASSEMBLY SHOWN SPOOL VALVE SWITCHES S11, S12, S13

42 CONNECT N.O. (NORMALLY OPEN) TO V (VIOLET) WIRES

301,361

44 43 41

303,363

302,362

631,632

Standard - 2W6 40 717,718

631,632

ES-127

CONNECT COM (COMMONT) TO W/B (WHITE-BLACK) WIRES

CONTROL WIRING COMPONENT LIST - 2W5/2W6 Item

Description

Item

Description

PA Connector for Controller

Sub Harness

J19 Handset Connector

Optional Work Light Harness

P19 Handset Connector

J26 Steerhead Connector

P31 Eco Smart E2 Connector

P26 Steerhead Harness Connector

J33 Main Chassis Aux/Hyd Funtion Connector

J9 Brake Connector

P33 Aux/Hyd Function Connector

J5 Brake Switch Connector

P6 MDI (Meter) Connector

Inductive Proximity Brake Switch

P4 Chassis Harness Connector

J25 Encoder Connector

J4 Brake Switch Motor Temp Sensor Connector

J30 Motor Temp Sensor Connector

P22 Chassis Harness Connector

Brake Harness

J22 Eco Smart Display Connector

Optional Light Switch

J23 Fan Connector

Optional Strobe Light

J24 Fan Connector

P32 Travel Alarm Connector

J27 Mast Height Switch Connector

Optional Travel Alarm

P34 Work Light Connector

Electric Horn

J34 Work Light Connector

L4 Lowering Solenoid Valve Coil (2W5 / Optional 2W6)

P35 Left Work Light Connector

Dump Valve (Standard 2W5 / Optional 2W6)

P36 Right Work Light Connector

S11 Lift Manual Valve Switch (Standard 2W5 / Optional 2W6)

Key Switch/Optional Toggle Switch

S12 Lower Manual Valve Switch (2W5)

Line Contactor Assembly

S12 Optional Auxilliary Manual Valve Switch (Optional 2W6)

Fuse 2 & 3-10A

S13 Optional Auxilliary Manual Valve Switch (Optional 2W5 Only)

Chassis Harness

J28 Left Battery Gate Switch Option (2W6 Only)

Optional Eco Smart Meter Assembly

J29 Right Battery Gate Switch Option (2W6 Only)

AC MDI Meter Assembly

ES-128

WIRE ROUTING Chassis Harness Routing

Circuit No.

From

Terminal

Color

Note

204

AC1 COMBI

A35

CONNECTOR - J33

W/V

210

AC1 COMBI

A22

CONNECTOR - J4

BATT GATE S20

240

AC1 COMBI

CONNECTOR - J33

B/OR

300

V <723>

CONNECTOR - J4

301

V <300>

CONNECTOR - J33

LIFT S11

304

AC1 COMBI

A20

CONNECTOR - J33

V/W

2W5 TRUCK ENABLE

320

AC1 COMBI

CONNECTOR - J4

R/W

MAST HEIGHT S10

330

AC1 COMBI

CONNECTOR - J4

B/W

340

AC1 COMBI

CONNECTOR - J4

Y/B

BRAKE S5

361

AC1 COMBI

A32

CONNECTOR - J33

W/B

LIFT S11

420

GY/B <430>

CONNECTOR - J19

430

AC1 COMBI

A25

CONNECTOR - J19

GY/B

440

AC1 COMBI

A16

CONNECTOR - J19

W/R

450

AC1 COMBI

A26

CONNECTOR - J19

G/W

460

AC1 COMBI

A21

CONNECTOR - J19

Y/R

510

AC1 COMBI

A27

CONNECTOR - J22

W/OR

511

W/OR <510>

CONNECTOR - P31

W/OR

520

AC1 COMBI

A28

CONNECTOR - J22

W/L

521

W/L <520>

CONNECTOR - P31

W/L

CAN LO CAN HI

530

L1 - K1 LINE CONTACTOR COIL

L1-1

CONNECTOR - J22

531

L1 - K1 LINE CONTACTOR COIL

L1-1

CONNECTOR - P31

540

AC1 COMBI

A14

CONNECTOR - J22

OR/B

ENCODER

550

AC1 COMBI

A13

CONNECTOR - J22

L/W

ENCODER

560

GY/B <430>

CONNECTOR - J22

GY/B

ENCODER

600

AC1 COMBI

A33

CONNECTOR - J24

FAN

610

B <600>

CONNECTOR - J23

FAN

620

OR <717>

CONNECTOR - J23

FAN

630

OR <717>

CONNECTOR - J24

FAN

632

AC1 COMBI

A34

CONNECTOR - J33

B/Y

711

K1 - LINE CONTACTOR

F2 - FUSE

R/B

(+) BATT

712

F2 - FUSE

S4 - KEY SWITCH

712-1

R <712>

S4 - KEY SWITCH

R/B

715

K1 - LINE CONTACTOR

F3 - FUSE

716

F3 - FUSE

OR <717>

717

AC1 COMBI

CONNECTOR - J33

718

AC1 COMBI

A24

CONNECTOR - J33

Y/L

719

AC1 COMBI

HORN - H1

(-)

720

OR <717>

HORN - H1

(+)

721

S4 - KEY SWITCH

S4-2

L1 - K1 LINE CONTACTOR COIL

L1-1

721-1

S4 - KEY SWITCH

S4-4

V <721>

V/B

722

AC1 COMBI

A12

L1 - K1 LINE CONTACTOR COIL

L1-2

G/Y

723

V <721>

AC - COMBI

A10

725

L1 - K1 LINE CONTACTOR COIL

726

V <301>

L1-1

STROBE LIGHT

(+)

S14 - LIGHT SW

S14-4

ES-129

WIRE ROUTING Chassis Harness (Cont’d) Routing

Circuit No. 727

From S14 - LIGHT SW

Terminal S14-2

Terminal

CONNECTOR - J33

Color

Note

R/B

728

OR <717>

CONNECTOR - P32

(+)

TRAVEL ALARM - H2

729

AC1 COMBI

CONNECTOR - P32

(-)

TRAVEL ALARM - H2

736

AC1 COMBI

A15

B/W <330>

B/W

737

AC1 COMBI

A18

CONNECTOR - J19

910

BATTERY

B (-)

CONNECTOR - J22

911

B <910>

CONNECTOR - P31

912

B <911>

CONNECTOR - P31

930

BATTERY

B (-)

CONNECTOR - J4

931

B <930>

CONNECTOR - J33

B B

940

BATTERY

B (-)

STROBE LIGHT

(-)

950

B <930>

CONNECTOR - J22

960

AC1 COMBI

CONNECTOR - J19

430-1

CONNECTOR - P19

CONNECTOR - P6

GY/B

440-1

CONNECTOR - P19

CONNECTOR - P6

W/R

450-1

CONNECTOR - P19

CONNECTOR - P6

G/W

460-1

CONNECTOR - P19

CONNECTOR - P6

Y/R

960-1

CONNECTOR - P19

CONNECTOR - P6

MAST HEIGHT (-) ENCODER MDI

Brake Harness Circuit No. 210

Routing From

Terminal

CONNECTOR P4

CONNECTOR J30

Terminal

Color

Note

BLACK

CABLE #14

300

CONNECTOR P4

CONNECTOR J5

BLACK

CABLE #15

310

CONNECTOR P4

CONNECTOR J18

BLACK

CABLE #16

320

CONNECTOR P4

CONNECTOR J9

BLACK

CABLE #11

330

CONNECTOR P4

CONNECTOR J9

BLACK

CABLE #10

340

CONNECTOR P4

CONNECTOR J5

BLACK

CABLE #9

350

CONNECTOR P4

MALE CONNECTOR FULLY INSULATED

BLACK

CABLE #12

370

CONNECTOR P4

FEMALE CONNECTOR FULLY INSULATED

BLACK

CABLE #13

510

CONNECTOR P22

CONNECTOR P26

BLACK

CABLE #7

520

CONNECTOR P22

CONNECTOR P26

BLACK

CABLE #8

530

CONNECTOR P22

CONNECTOR P26

BLACK

CABLE #5

540

CONNECTOR P22

CONNECTOR J25

BLACK

CABLE #3

550

CONNECTOR P22

CONNECTOR J25

BLACK

CABLE #4

560

CONNECTOR P22

CONNECTOR J25

BLACK

CABLE #1

747

CONNECTOR P4

CONNECTOR J18

BLACK

CABLE #17

910

CONNECTOR P22

CONNECTOR P26

BLACK

CABLE #6

Y/G

CABLE

930

CONNECTOR P4

CONNECTOR J5

930-1

CONNECTOR J30

<930>

930-2

CONNECTOR J18

<930>

950

CONNECTOR P22

CONNECTOR J25

ES-130

Y/G Y/G D

BLACK

CABLE #2

WIRE ROUTING Subharness Mast Height Switch - 2W5 Routing

Circuit No. 201

From

Terminal

V <301>

To CONNECTOR J27

Terminal

Color

Note

MAST HEIGHT (+) MAST HEIGHT

240

CONNECTOR J27

CONNECTOR P33

B/OR

301

CONNECTOR P33

S11 - LIFT

N.O.

302

V <301>

S12 - HYD FUNCT 2

N.O.

303

V <302>

S13 - HYD FUNCT 3

N.O.

361

CONNECTOR P33

S11 - LIFT SWITCH

COM

W/B

362

W/B <361>

S12 - HYD FUNCT 2

COM

W/B

363

W/B <362>

S13 - HYD FUNCT 3

COM

W/B

631

OR <717>

L5 - DUMP VALVE

632

CONNECTOR P33

L5 - DUMP VALVE

B/Y

717

CONNECTOR P33

L4 - LOWER VALVE

718

CONNECTOR P33

L4 - LOWER VALVE

Y/L

727

CONNECTOR P33

CONNECTOR J34

R/B

LIGHT (SWITCHED)

931

CONNECTOR P33

CONNECTOR J27

MAST HEIGHT (-)

941

B <931>

CONNECTOR J34

LIGHT (-)

Subharness Mast Height Switch - 2W6 Routing

Circuit No.

From

201

V <301>

202 203

Terminal

CONNECTOR J27

V <201>

CONNECTOR J29

CONNECTOR J28

CONNECTOR J29

Terminal A

Color

Note

MAST HEIGHT (+)

BATT GATE - R (+)

W/BR

204

CONNECTOR J28

CONNECTOR P33

W/V

BATT GATE

240

CONNECTOR J27

CONNECTOR P33

B/OR

MAST HEIGHT

301

CONNECTOR P33

S11 - LIFT

N.O.

302

V <301>

S12 - HYD FUNCT 2

N.O.

303

V <302>

S13 - HYD FUNCT 3

N.O.

304

V <301>

CONNECTOR P33

V/W

TRUCK MODEL JUMPER

361

CONNECTOR P33

S11 - LIFT

COM

W/B

362

W/B <361>

S12 - HYD FUNCT 2

COM

W/B

363

W/B <362>

S13 - HYD FUNCT 3

COM

W/B

631

OR <717>

L5 - DUMP VALVE

632

CONNECTOR P33

L5 - DUMP VALVE

B/Y

717

CONNECTOR P33

L4 - LOWER VALVE

718

CONNECTOR P33

L4 - LOWER VALVE

727

CONNECTOR P33

CONNECTOR J34

R/B

LIGHT (SWITCHED)

931

CONNECTOR P33

CONNECTOR J27

MAST HEIGHT (-)

941

B <931>

CONNECTOR J34

LIGHT (-)

951

B <931>

CONNECTOR J28

BATT GATE - L (-)

952

B <931>

CONNECTOR J29

BATT GATE - R (-)

ES-131

WIRE ROUTING Optional Work Light Harness Routing

Circuit No.

From

727

CONNECTOR P34

730 941 942

Terminal

CONNECTOR P35

R/B <727>

CONNECTOR P34

B <941>

Terminal

Color

R/B

CONNECTOR P36

R/Y

CONNECTOR P35

CONNECTOR P36

ES-132

Note

STEERHEAD WIRING 1

Item

Description

Steer Handle Harness

CP2 Connector

J26 Steerhead Connector

ES-133

TRUCK ELECTRONICS

1 2

3 4 3 5

Item

Description

Controller

Line Contactor Assembly

Fan Assembly

Electric Horn

Back Up Alarm

ES-134

BATTERY GATE AND ROLLER WITH SWITCH - 2W6

Item 1

Description Battery Gate Ind Prox Switch

ES-135

PIN CONNECTIONS

Pinouts Pins

Circuit #

Wire

Description

340

Y/B

BRAKE INPUT (PROX)

320

R/W

E BRAKE COIL (+)

717

CONTACTOR

330

B/W

E BRAKE COIL (-)

960

MDI

240

B/OR

719

HORN (-)

729

TRAVEL ALARM (-)

723

KEY SWITCH (+)

722

G/Y

LINE CONTACTOR (-)

550

L/W

ENCODER PHASE A

540

OR/B

ENCODER PHASE B

736

B/W

E BRAKE CHECK INPUT

440

W/R

MDI

737

MDI

304

V/W

TRUCK TYPE INPUT WSX=HIGH, WCX=OPEN

460

Y/R

MDI

210

MOTOR TEMP SENSOR (+)

718

Y/L

LOWER VALVE COIL (-)

430

GY/B

ENCODER / MDI (+)

450

G/W

MDI

510

W/OR

ECO SMART CAN LO

520

W/L

ECO SMART CAN HI

361

W/B

HYD SPOOL SWITCH INPUT

600

COOLING FANS (-)

632

B/Y

DUMP VALVE (-)

204

W/V

BATTERY GATE INPUT (PROX)

MAST HEIGHT INPUT (PROX)

17 18 19

29 30 31

ES-136

ES-137

Max Torque Value: 4 Nm (35 in/lb)

Lockwasher

2 x nut

21 23

ECO Smart Installation

2W5 Only

2W6 Only

11 6

Key Switch Assembly AC MDI Meter Assembly Hood

9 10 11

Grommet Grommet

Meter Panel Weldment

Screw

ECO Smart Display

Toggle Switch Face Plate

Flanged Dash Bushing

Toggle Switch Assembly

Washer

Foam Rest Pad

Spring

Pocket Assembly

Screw

Rivnut

4 6

Spacer - Dash Mounting

3 5

Dashboard

Description Screw

Item #

MDI, ECO-SMART DISPLAY AND IGNITION SWITCH

TOGGLE SWITCH INSTALLATION - OPTION Service Kit PN: 25155-FS002 For Walkie / Walkie Rider Models Parts should be installed into dash in this order: Switch Spacer Faceplate Lock Washer (2) Nuts

Service Kit

1. Turn the ignition switch to the off position. 2. Raise the drive tire off the floor and disconnect the battery connector. 3. Remove any covers if necessary. 4. Disconnect the wire harness push-on terminals from the existing toggle switch to allow removal of the existing switch. NOTE: Assemble toggle switch kit as shown in Photos #1 - #8 below. 5. Once the toggle switch has been installed, reinstall the push-on terminals or connector. 6. Replace the covers that were removed and secure all mountings. 7. Reconnect the battery connector and test operation. 8. Lower the drive tire to the ground.

Install spacer onto switch.

PHOTO 1 Remove the adhesive back from under side of faceplate.

PHOTO 2

ES-138

TOGGLE SWITCH INSTALLATION - OPTION Install the faceplate over switch/spacer and firmly press faceplate onto spacer to create the assembly.

PHOTO 3 Remove faceplate/spacer assembly from switch.

PHOTO 4 Install faceplate/spacer assembly into the dash using spacer to center into the hole. Ensure faceplate is in correct orientation. (ON [l] is up/fwd)

PHOTO 5

Install switch up through dash and align the notch of switch with tab on faceplate.

PHOTO 6

ES-139

TOGGLE SWITCH INSTALLATION - OPTION Install the lock washer onto the switch.

PHOTO 7

Install first nut onto switch and tighten. Next, install second nut and tighten to first nut (jam nut).

PHOTO 8

ES-140

TROUBLESHOOTING ELECTRICAL PROBLEMS !! WARNING • Working on electrical systems is potentially dangerous. You should protect yourself against uncontrolled operation, high current arcs, and outgassing from lead acid batteries. Always wear PPE equipment to reduce or avoid injury to yourself.

! CAUTION • Uncontrolled Traction Operation - Some conditions may cause the traction system to be energized. Disconnect the motor or jack up the vehicle and raise the drive wheels off the ground/floor before attempting any work on the traction motor control circuitry. In some cases you may have to disconnect the drive motor. • Uncontrolled Hydraulic Operation - Some conditions could cause the hydraulic system to run uncontrolled. Disconnection of the pump motor may be necessary to make sure the hydraulic system has oil in it and the load carrying device forks are free and clear to move, before attempting any work on the pump motor control circuitry. • High Current Arcs - Batteries can supply very high power (current), and arcs may occur if the battery or its supply cables are short circuited. Always open the battery circuit before working on the motor control circuit. Wear safety glasses, insulated gloves, or use properly insulated tools to prevent shorts, if system indicates a shorter circuit. • Lead Acid Batteries - Charging or discharging generates hydrogen gas, which can build up in and around the batteries. Follow the battery manufacturer’s safety recommendations. Wear safety glasses and other PPE equipment.

ES-141

TROUBLESHOOTING ELECTRICAL PROBLEMS Sometimes, things we cannot see are difficult to understand. Such is the case with electricity. But, we can certainly see the results of electricity at work. In electric forklift drive control systems, when electricity is able to “flow” properly, the traction motor runs and the forklift operates properly. When that electrical flow is interrupted strange things can happen. Components do not work or work intermittently, fuses blow and in extreme cases, wires can become so hot they could cause the insulation to break down and melt. This section will guide you through basic electrical troubleshooting. As with any other aspect of service work, it takes time and patience to develop skills. But, if you take your time, read the Service Manual and the Training Manual carefully and follow the steps recommended by UCA, you will be able to troubleshoot and repair even complicated and involved problems. The Logic of Electrical Troubleshooting For some technicians, electrical problems are what they like to work on the least. It’s easier to fix a problem that can be “seen” as some electrical problems can be elusive. However, if you take your time to carefully analyze the problem and outline some logical steps to solve it, you will find that most electrical problems are pretty basic. Remember for current to work, you need a Battery or a Source for electrical power, a Load such as a motor or contactor and Continuity, which means wires and conductors that are free of resistance. If any of these factors are missing, the circuit is broken and current will not flow. Troubleshooting Procedure It’s helpful to have a routine procedure or approach when troubleshooting a problem, a method with which you are familiar and that gives you the most information with minimum time and effort. A general rule of thumb when performing electrical troubleshooting is to: “Do the easiest and quickest checks first.” Is the lift truck’s battery charged? This approach means looking for the obvious things first, such as damage to wires or buss bars, excessive corrosion on wires and connectors. Fuses should be checked with a VOM meter. Don’t trust your eyes on this check! A fuse that may “look good” may be blown. After this step, you should begin developing a sound “plan of attack” before going any further on the forklift. Some of the most frustrating and confusing electrical problems are made more difficult with a haphazard and random troubleshooting approach. It’s important that the checks you make will give you the answers you need. If you test the wrong component, use the wrong test equipment or forget to calibrate a meter, you may get incorrect or useless information. Don’t forget, there is a time to “walk away from the problem”. When that “time” occurs is different for each person but the important point to remember is that it is very easy to become confused when troubleshooting electrical problems. If, after 30 to 45 minutes, you have not reached a solution to an electrical problem, it’s usually a good idea to take a break and walk away from the problem to think about it for a few minutes. This is when you need to go over your “plan of attack” and find out exactly what you know about the problem you are working on.

ES-142

TROUBLESHOOTING The UCA approach to solving electrical problems is to find out what circuits and what components are working properly. This is an “Elimination Process” that leads you to the solution by finding out what is not causing the problem. The most important part of this procedure is to make sure you are using meters or test instruments properly and you are achieving the correct results and readings when you make your test. Always write down your results in case you must relay this information to someone else. Troubleshoot With Your Senses Your senses can be used in troubleshooting an electrical problem. Even though we cannot see current flowing through a wire, the effects of it can be seen: Lights illuminate, motors spin, contactors energize and so forth. And, too much current flowing through a wire may cause that wire to feel warm. Touching, sight, and sound as testing methods should be tried first before using test equipment to troubleshoot. A Troubleshooting Approach As mentioned before, it is frustrating to try and solve an electrical problem with a haphazard procedure. It wastes time and will sometimes result in more problems. A logical and well thought out plan is the key to quickly diagnosing and repairing electrical problems. 1. Raise Drive Tire from the floor and Block Unit. 2. Evaluate the problem This may seem simple but sometimes the problem on the repair order may not be the same as the actual problem. Also, there may be other problems or symptoms that were overlooked. Check not only the listed problems, but also all other components as well. Some may be on the same circuit or may interrelate. This is a good opportunity for you to use your senses as a testing method. 3. Determine the Conditions Under Which the Problem Occurs Talk to the operator! Does the problem occur after the shift is almost over? Is the truck pulling a grade? Is there sufficient charge in the battery? Were any components or accessories installed recently? What about corrosion? Is the customer washing or steam cleaning the truck? Is proper battery maintenance being observed? Is the battery “boiling over” during charge into the bottom of the truck? 4. Consult the Service Manual Turn to the appropriate section of the Service Manual for the troubleshooting procedure. 5. Use the wiring schematic to determine the flow of power and which components are in that system. When you have a service problem with an electrical truck, you should make sure the following steps occur: 6. Talk to the operator to verify the problem. Get all the details you can. 7. Test the truck yourself and begin looking for obvious problems, i.e. damage, vandalism, bad battery, etc. 8. Have a Service Manual or Training Manual available to refer to. 9. Make sure you have proper equipment such as VOM Meter, AMP Meter, and a handset for the panel you are working on.

ES-143

TROUBLESHOOTING 10. Perform all steps listed in the Service Manual, (for the control systems your Unit is equipped with) including discharging the commutation condenser, (if equipped) checking for loose connectors and checking all fuses with a VOM Meter. As you progress down through troubleshooting the problem, you’ll need to check certain components. Detailed instructions for checking any component can usually be found in the Service Manual or the Training Manual. Use common sense and reasoning for any components where exact and detailed checkout procedures are listed. If you use proper test equipment and use the equipment correctly, you should be able to progress through the troubleshooting until you discover the problem.

Troubleshooting Do’s and Don’ts There are several basic items to be aware of when servicing PMC Controlled Units. Although the PMC Service Guide contains complete information, we believe these are particularly important as they could save you time and money. • DO Attend factory training schools. • DO Use a current service manual for trouble shooting. • DO Raise the drive tire off the floor. • DO Unplug the battery and discharge the capacitor using a 50500 ohm resistor between battery + and battery - on the controller, when testing for open circuit, replacing component parts, removing control wires, etc. • DO Check battery polarity for proper positive to positive and negative to negative connections. • DO Check resistance from both + and - sides of battery plug (on truck) to truck frame. Ground Test Resistance should be greater than 80,000 ohms between truck negative and positive, and the frame. Connect a VOM meter between the positive and negative battery connector on the truck. Resistance should be greater than 80,000 ohms. If the resistance is lower than stated above, it indicates an error in wiring, a shorted component, etc. • DO Check the battery for proper charge level, condition, cleanliness, water level, etc. • DO Use a volt-ohm meter. • DO Take a few minutes to carefully analyze the problem (refer to the service manual) • DO Contact UCA to report any major problems. • DO Remove all fuses and use a VOM to check. • DON’T Use a jumper wire to check circuits, except where manual directs you to do so. • DON’T Use a screw driver to discharge capacitors or check for power. You could short out another component part. • DON’T Work on lift truck unless properly trained and authorized.

ES-144

TROUBLESHOOTING Basic Power Check !! WARNING • During troubleshooting, ensure drive tire is off the ground and blocked up to prevent accidental movement of the truck. • All trouble shooting should be conducted using a fully charged battery. Failure to do so can influence test results and can cause mis-diagnosis of problems. • Tests should be followed out in order. Skipping steps could lead to mis-diagnosis and unnecessary repairs. Test Conditions: Unless instructed otherwise. Battery plugged in; connect V.O.M. to battery negative, set to D.C. volts.

ES-145

THIS PAGE INTENTIONALLY LEFT BLANK

ES-146

TROUBLESHOOTING Main Power Check - Positive Side

ES-147

TROUBLESHOOTING

ES-148

TROUBLESHOOTING Main Power Check - Negative Side

ES-149

TROUBLESHOOTING Fuse 2 Checks

Fuse 2 Power Checks to Controller Complete.

ES-150

TROUBLESHOOTING Fuse 3 Checks

Fuse 3 Power Checks to Controller Complete.

K1 Contactor Circuit

K1 Contactor Checks Complete

ES-151

TROUBLESHOOTING Lower Circuit

Lower Circuit Checks Complete

Lift Circuit

Lift Circuit Checks Complete

ES-152

TROUBLESHOOTING Horn Circuit

Horn Circuit Checks Complete

Brake Circuit

Brake Circuit Checks Complete

ES-153

TROUBLESHOOTING PCB1 Basic Checks

PCB1 Checks Complete

ES-154

TROUBLESHOOTING Motor Encoder Circuit

Motor Encoder Checks Complete

ES-155

TROUBLESHOOTING MDI Circuit Checks

MDI Circuit Checks Complete

ES-156

GENERAL INFORMATION

SECTION

CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . GI-2 2W5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI-2 2W6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI-5 MODEL CODE FOR IDENTIFICATION . . . . GI-8 SERIAL NUMBER IDENTIFICATION . . . . . . GI-9 DATA PLATE INFORMATION . . . . . . . . . . . . GI-10 WARNING SYMBOLS & LEVELS . . . . . . . . GI-11 Warning Levels . . . . . . . . . . . . . . . . . . . . . . GI-11 Prohibitory Symbols . . . . . . . . . . . . . . . . . . GI-12 GENERAL PRECAUTIONS . . . . . . . . . . . . . GI-13 Servicing General Precautions . . . . . . . . . . . GI-13 Precautions for Electrical System Inspection . . . . . . . . . . . . . . . . . . . . . . . . GI-14 Precautions for Battery Handling . . . . . . . . . GI-15 Jacking, Lifting or Towing . . . . . . . . . . . . . . GI-15 TOOLS REQUIRED TO SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . GI-16 CONVERSION CHART - METRIC TO INCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . GI-17 TORQUE CHART AND EQUIVALENTS . . . . GI-18 Torque Wrenches . . . . . . . . . . . . . . . . . . . . GI-18 Metric Wrench & SAE Wrench Equivalent Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI-18 Standard Metric Torque Values . . . . . . . . . . GI-19 CONVERSION FACTORS . . . . . . . . . . . . . . GI-20 INCH (SAE) AND METRIC FASTENERS . . . GI-21 STANDARD SPEED & LIFT . . . . . . . . . . . . . GI-27 PAINT & DECAL . . . . . . . . . . . . . . . . . . . . . . GI-28 2W5/2W6 . . . . . . . . . . . . . . . . . . . . . . . . . . GI-28

SPECIFICATIONS 2W5

MAIN TRUCK - 2W5 (for reference only)

BASED ON 3F385 MAST, 42 IN (1070 MM) FORKS AND MINIMUM BATTERY SPECIFICATIONS 2W5

Model code Item

WCXT2W5G30

WCXT2W5G40

Rated Load Capacity

lb (kg)

Refer to Truck Data Plate

Power Type - Electric

voltage

Load center

in (mm)

24 (610)

to Face of Forks

in (mm)

78.3 (1990)

Width

in (mm)

37.3 (950)

Wheelbase

in (mm)

61 (1550)

Front Overhang

in (mm)

9.6 (245)

Rear Overhang

in (mm)

7.7 (195)

Tread - Center of Tire

in (mm)

32.8 (835)

Overall Length

Minimum Turning Radius

Outside (Chassis)

in (mm)

69.4 (1765)

Minimum Right Angle Stack

48"L x 40"W pallet - add clearance

in (mm)

127 (3225)

Length x Width x Thickness

in (mm)

42 x 4 x 1.5 (1070 x 100 x 40)

Spread (o.d.) - Min. / Max.

in (mm)

10 (255) / 31.6 (800)

Lowest point

in (mm)

2.5 (60)

Under Frame, center of wheelbase

in (mm)

3.7 (90)

Full Load - 5 min rating

11.2

Approach Angle

Not Available

Ramp Breakover Angle

Departure Angle

Fork

Ground Clearance Gradeability Maximum

Grade Clearance

GI-2

SPECIFICATIONS 2W5 (Cont’d) MAIN TRUCK - 2W5 (for reference only)

BASED ON 3F385 MAST, 42 IN (1070 MM) FORKS AND MINIMUM BATTERY SPECIFICATIONS 2W5

Model code Item

2W Lifting Speed 3F

2W Lowering Speed 3F

Travel Speed

Drawbar Pull Maximum

Pump Motor

Hydraulic Valve ¹

Battery Data ²

WCXT2W5G40

Full Load

fpm (mm/sec)

Not Available

Empty

fpm (mm/sec)

Not Available

Full Load

fpm (mm/sec)

30 (152)

Empty

fpm (mm/sec)

50 (254)

Full Load

fpm (mm/sec)

Not Available

Empty

fpm (mm/sec)

Not Available

Full Load

fpm (mm/sec)

50 (254)

Empty

fpm (mm/sec)

50 (254)

Full Load

mph (km/h)

2.8 (4.5)

Empty

mph (km/h)

2.9 (4.7)

Full Load - 3 min rating

lb (kN)

Empty - 3 min rating

lb (kN)

1023 (4.55)

lb (kg)

Refer to Truck Data Plate

Truck Weight Traction Motor

WCXT2W5G30

Type Rating

596 (2.65)

AC kW (HP)

Type Rating @ 20% duty cycle

891 (3.96)

3.9 (5.2) DC

kW (HP)

Lift/Lower

4.77 (6.4) Electric & Manual

Tilt

Manual

Weight Minimum/Maximum

lb (kg)

950 / 1500 (430 / 680)

Maximum. - W x L x H ("X" x "Y" x "Z")

in (mm)

35.75 x 13.5 x 32 (905 x 340 x 815)

Lead Acid

Type

Capacity - Maximum

Ah/6h

840

Lead Length - Position B / SB-175 Red

in (mm)

20 (505)

¹ Optional Manual Auxiliary Lever control is available. ² Battery compartment size: with adjustable retainers - 30.9 x 13.5 x 32 (785 x 340 x 815) w/optional rollers & side gates - 31.1 x 13.5 x 31 (790 x 343 x 787)

GI-3

SPECIFICATIONS 2W5 (Cont’d) MAST - 2W5 (for reference only) Height

THREE STAGE (Full Free 3F)

TWO STAGE (Wide View 2W)

Mast Name

Maximum Fork Height in (mm)

Free Lift without Backrest in (mm)

Tilt Angle Forward/ Backward

Overall Height

Top of Standard LBR

Lowered Mast Position in (mm)

Extended Mast Position in (mm)

Mast (OHL)

With Backrest

Without Backrest

2W270

106 (2700)

3.9 (95)

3/3

48 (1220)

71.1 (1810)

155.8 (3960)

129.8 (3300)

2W300

118 (3000)

3.9 (95)

3/3

48 (1220)

77.0 (1960)

167.5 (4255)

141.6 (3600)

2W330

130 (3300)

3.9 (95)

3/3

48 (1220)

82.9 (2110)

179.4 (4560)

153.4 (3900)

2W350

138 (3500)

3.9 (95)

3/3

48 (1220)

88.2 (2240)

187.3 (4760)

161.3 (4100)

3F385

152 (3850)

46.9 (1190)

3/3

48 (1220)

71.1 (1810)

200.7 (5100)

168.0 (4270)

3F430

169 (4300)

52.8 (1340)

3/3

48 (1220)

77.0 (1960)

218.4 (5550)

185.7 (4720)

3F475

187 (4750)

58.7 (1490)

3/3

48 (1220)

82.9 (2110)

236.1 (6000)

203.5 (5170)

3F515

203 (5150)

64.0 (1625)

3/3

48 (1220)

88.2 (2240)

252.0 (6405)

219.4 (5575)

3F550

217 (5500)

68.9 (1750)

3/3

48 (1220)

93.1 (2365)

265.6 (6750)

233.0 (5920)

AISLE - 2W5 (for reference only) Right Angle Stacking Aisle Requirements Load Width (in.)

Load Length - in. (mm) 30 (760)

32 (815)

36 (915)

40 (1020)

42 (1070)

48 (1220)

30 (760)

109 (2770)

111 (2820)

115 (2925)

119 (3025)

122 (3100)

128 (3255)

32 (815)

109 (2770)

111 (2820)

115 (2925)

119 (3025)

121 (3075)

128 (3255)

36 (915)

109 (2770)

111 (2820)

115 (2925)

119 (3025)

121 (3075)

127 (3230)

40 (1020)

109 (2770)

111 (2820)

115 (2925)

119 (3025)

121 (3075)

127 (3230)

42 (1070)

109 (2770)

111 (2820)

115 (2925)

119 (3025)

121 (3075)

127 (3230)

48 (1220)

108 (2745)

110 (2795)

115 (2925)

119 (3025)

121 (3075)

127 (3230)

Based on 4” (100 mm) clearance between base leg and adjacent pallets. Aisle dimensions are minimum. Recommend 6”-10” (150-255 mm) additional clearance for ease of operation. Add 2” (50 mm) for hang-on side shifter.

90° Equal Intersecting Aisle Requirements Load Width (in.)

Load Length - in. (mm) 30 (760)

32 (815)

36 (915)

40 (1020)

42 (1070)

48 (1220)

30 (760)

66 (1680)

67 (1705)

68 (1730)

69 (1755)

70 (1780)

32 (815)

67 (1705)

68 (1730)

69 (1755)

71 (1805)

36 (915)

67 (1705)

68 (1730)

69 (1755)

70 (1780)

72 (1830)

40 (1015)

69 (1755)

70 (1780)

71 (1805)

72 (1830)

73 (1855)

42 (1070)

70 (1780)

71 (1805)

72 (1830)

73 (1855)

74 (1880)

48 (1220)

73 (1855)

74 (1880)

75 (1905)

76 (1930)

78 (1980)

Aisle dimensions are minimum. Recommend 6”-10” (150-255 mm) additional clearance for ease of operation. Add 2” (50 mm) for hangon side shifter.

GI-4

SPECIFICATIONS 2W6

Main Truck - 2W6 (for reference only)

Based On 3F385 Mast, 42 IN (1070 Mm) Forks And Minimum Battery Specifications Model code

2W6

Item WSXT2W6S30

WSXT2W6S40

WSXT2W6G30

Rated Load Capacity

lb (kg)

Refer to Truck Data Plate

Power Type - Electric

voltage

Load center

in (mm)

24 (610)

Overall Length

to Tip of Base Legs

in (mm)

74.0 (1880)

78.5 (1995)

to Face of Forks

in (mm)

44.2 (1120)

48.7 (1235)

Width - Power Head

in (mm)

33.0 (840)

Wheelbase

in (mm)

Front Overhang

in (mm)

6.4 (165)

Rear Overhang

in (mm)

7.7 (195)

in (mm)

48.2 (1224)

Tread - Center of Tire

WSXT2W6G40

Load Wheels (w/42" Base Leg)

59.9 (1521)

64.4 (1636)

Minimum Turning Radius Outside

in (mm)

Minimum Right Angle Stack

42" I.D. Base Legs - add load length & clearance

in (mm)

See Right Angle Stacking Aisle Requirements (refer to page 80)

Length x Width x Thickness

in (mm)

42 x 4 x 1.5 (1070 x 100 x 40)

Spread (o.d.) - Min. / Max.

in (mm)

8 (205) / 31.6 (800)

Lowest point - skid pad

in (mm)

0.6 (15)

Under Frame, center of wheelbase

in (mm)

1.85 (47)

11.4

Fork

Ground Clearance Gradeability Maximum

Full Load - 5 min rating

GI-5

67.8 (1723)

72.4 (1838)

SPECIFICATIONS 2W6 (Cont’d) Main Truck - 2W6 (for reference only)

Based On 3F385 Mast, 42 IN (1070 Mm) Forks And Minimum Battery Specifications 2W6

Model code Item

WSXT2W6S30

Grade Clearance

2W Lifting Speed 3F

2W Lowering Speed 3F

Travel Speed

Drawbar Pull Maximum

Pump Motor

Ramp Breakover Angle

Departure Angle

Full Load

fpm (mm/sec)

Not Available

Empty

fpm (mm/sec)

Not Available

Full Load

fpm (mm/sec)

30 (152)

Empty

fpm (mm/sec)

50 (254)

Full Load

fpm (mm/sec)

Not Available

Empty

fpm (mm/sec)

Not Available

Full Load

fpm (mm/sec)

50 (254)

Empty

fpm (mm/sec)

50 (254)

Full Load

mph (km/h)

3.6 (5.8)

Empty

mph (km/h)

3.7 (5.9)

Full Load - 3 min rating

lb (kN)

830 (3.7)

Empty - 3 min rating

lb (kN)

888 (3.9)

lb (kg)

Refer to Truck Data Plate

13.9

12.8

Type Rating

AC kW (HP)

3.9 (5.2)

Type Rating @ 20% duty cycle

Battery Data ²

WSXT2W6G40

Not Available

DC kW (HP)

4.7 (6.4)

Hydraulic Valve ¹

Outrigger

WSXT2W6G30

Approach Angle

Truck Weight Traction Motor

WSXT2W6S40

Electric Height

in (mm)

4 (100)

Width - nominal I.D min/ max (2 in increments)

in (mm)

36 - 52 (915 - 1320)

Length (face of fork to tip of base legs)

in (mm)

29.8 (760)

Weight Minimum/Maximum

lb (kg)

Consult Factory

950 / 1500 (430 /680)

Maximum. - W x L x H ("X" x "Y" x "Z")

in (mm)

31.9 x 8.9 x 32 (810 x 225 x 810)

31.9 x 13.5 x 32 (810 x 340 x 815)

Lead Acid

Type

Capacity - Maximum

Ah/6h

Lead Length - Position B / SB-175 Red

in (mm)

E Consult Factory

840 20 (505)

¹ Optional Manual Lift/Lower or Auxiliary Lever controls are available. ² Battery compartment size: WSXT2W6S30/ WSXT2W6S40 with adjustable retainers - 30.9 x 9.5 x 32 (785 x 240 x 815) WSXT2W6G30/ WSXT2W6G40 with adjustable retainers - 30.9 x 13.5 x 32 (785 x 340 x 815) WSXT2W6G30/ WSXT2W6G40 w/optional rollers & side gates - 31.1 x 13.5 x 31 (790 x 343 x 787)

GI-6

SPECIFICATIONS 2W6 (Cont’d) MAST - 2W6 (for reference only)

TWO STAGE (Wide View 2W)

Overall Height

Free Lift without Backrest in (mm)

Tilt Angle Forward/ Backward

Top of Standard LBR

Mast (OHL)

With Backrest

Without Backrest

2W270

106 (2700)

3.8 (95)

48 (1220)

71.3 (1815)

155.7 (3955)

130.0 (3305)

2W300

118 (3000)

3.8 (95)

48 (1220)

77.2 (1965)

167.5 (4255)

141.9 (3605)

2W330

130 (3300)

3.8 (95)

48 (1220)

83.2 (2115)

179.3 (4555)

153.7 (3905)

2W350

138 (3500)

3.8 (95)

48 (1220)

88.5 (2250)

187.2 (4755)

161.5 (4105)

3F385

152 (3850)

46.9 (1190)

48 (1220)

71.3 (1815)

200.9 (5105)

168.3 (4275)

3F430

169 (4300)

52.8 (1340)

48 (1220)

77.2 (1965)

218.7 (5555)

186.0 (4725)

3F475

187 (4750)

58.7 (1490)

48 (1220)

83.1 (2115)

236.4 (6005)

203.7 (5175)

3F515

203 (5150)

64.0 (1625)

48 (1220)

88.5 (2250)

252.3 (6410)

219.7 (5580)

3F550

217 (5500)

68.9 (1750)

48 (1220)

93.4 (2375)

265.9 (6755)

233.3 (5930)

Mast Name

THREE STAGE (Full Free 3F)

Height

Maximum Fork Height in (mm)

Lowered Mast Position in (mm)

Extended Mast Position in (mm)

AISLE - 2W6 (for reference only) WSXT2W6S30/ WSXT2W6S40 Right Angle Stacking Aisle Requirements with 42” Base Legs Load Length - in. (mm)

Load Width (in.)

30 (760)

32 (810)

36 (915)

40 (1015)

42 (1070)

48 (1220)

30 (760)

75 (1905)

84 (2135)

32 (810)

75 (1905)

85 (2160)

36 (915)

75 (1905)

76 (1930)

88 (2235)

40 (1015)

75 (1905)

76 (1930)

81 (2055)

90 (2285)

Based on 1” (25 mm) clearance between base leg and adjacent pallets. Aisle dimensions are minimum. Recommend 6”-10” (150-255 mm) additional clearance for ease of operation.

WSXT2W6G30/ WSXT2W6G40 Right Angle Stacking Aisle Requirements with 42” Base Legs Load Length - in. (mm)

Load Width (in.)

30 (760)

32 (810)

36 (915)

40 (1015)

42 (1070)

48 (1220)

30 (760)

80 (2030)

89 (2260)

32 (810)

80 (2030)

90 (2285)

36 (915)

80 (2030)

92 (2340)

40 (1015)

80 (2030)

81 (2055)

85 (2160)

94 (2390)

Based on 1” (25 mm) clearance between base leg and adjacent pallets. Aisle dimensions are minimum. Recommend 6”-10” (150-255 mm) additional clearance for ease of operation.

AISLE - 2W6 (for reference only) 90° Equal Intersecting Aisle Requirements Base Leg Inner Dimension (I.D.)

90° Intersection Aisle Outer Dimension (O.D.)

WSXT2W6S30, WSXT2W6S40

WSXT2W6G30, WSXT2W6G40

44.3 (1125)

65 (1650)

66 (1675)

Nominal

Actual

36 (915)

36.2 (920)

38 (965)

38.2 (970)

46.3 (1175)

66 (1675)

67 (1700)

40 (1015)

40.2 (1020)

48.3 (1230)

67 (1700)

68 (1725)

42 (1070)

42.2 (1070)

50.3 (1280)

68 (1725)

69 (1755)

44 (1120)

44.2 (1125)

52.3 (1330)

69 (1755)

70 (1780)

46 (1170)

46.2 (1175)

54.3 (1380)

71 (1805)

48 (1220)

48.1 (1220)

56.2 (1430)

72 (1830)

50 (1270)

50.1 (1275)

58.2 (1480)

73 (1855)

74 (1880)

Based on 48” load length and 1” (25 mm) clearance between base leg and adjacent pallets. Aisle dimensions are minimum. Recommend 6”-10” (150-255 mm) additional clearance for ease of operation.

GI-7

MODEL CODE FOR IDENTIFICATION 2W5 model variation (long model code) breakdown W

2W5



V DESTINATION V: North America - Designed to meet UL "E" BRAND : UniCarriers LOAD CAPACITY / LOAD CENTER 30: 3,000 lb 40: 4,000 lb BODY FRAME G: Long 13.25" BASIC MODEL 2W5: Walkie Counterbalance Truck STEERING TYPE T: Top Mount MOTOR TYPE X: AC Traction Motor 24V BODY TYPE C: Counterbalance MODEL TYPE W: Walkie

2W6 model variation (long model code) breakdown W

2W6



V DESTINATION V: North America - Designed to meet UL "E" BRAND : UniCarriers LOAD CAPACITY / LOAD CENTER 30: 3,000 lb 40: 4,000 lb BODY FRAME G: Long 13.25" S: Short 9.5" BASE MODEL 2W6: Walkie Straddle Truck STEERING TYPE T: Top Mount MOTOR TYPE X: AC Traction Motor 24V BODY TYPE S: Straddle MODEL TYPE W: Walkie

GI-8

SERIAL NUMBER IDENTIFICATION All UCA industrial trucks have been identified by a serial number which contains a short model code as shown below: 2W53-93XXXXX or 2W54-93XXXXX 2W63-93XXXXX or 2W64-93XXXXX This serial number with short model code will also be stamped in the frame by the transmission, as shown below.

GI-9

DATA PLATE INFORMATION 2W5 / 2W6 Models

1. Model Number (Long Model Code) 2. Serial Number (Chassis No.) 3. UL Type (“E” or “EE”) 4. Battery Type 5. Mast Type 6. Percent of Grade 7. Maximum Tilt Degree 8. Battery Maximum Amp Hours

9. Battery Voltage 10. Attachment (Model & Serial Number) 11. Maximum Battery Weight 12. Minimum Battery Weight 13. Truck Weight Less Battery 14. Load Center 15. Fork Height 16. Maximum Lifting Capacity

*S/N is also stamped in frame near motor mount. This data plate is located on the top of the power head frame. Knowing the model and serial number for this unit is very helpful whenever ordering repair parts. For any further information and specifications on this unit or any other, contact your Local Authorized Dealer.

GI-10

WARNING SYMBOLS & LEVELS Always follow the warnings given in this Service Manual and any located on the truck to avoid accidents and/or injuries from occurring.

Warning Levels Warning text is given in three levels and provides information on the risks, describes the consequences and instructs how to avoid accidents.

!! DANGER • Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

!! WARNING • Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

! CAUTION • Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury. SERVICE NOTE: Marks the risk of a breakdown and/or material damage if the service procedure is not followed.

GI-11

WARNING SYMBOLS & LEVELS Prohibitory Symbols NO SMOKING If smoking occurs in situations where a restriction against smoking is stated, a serious accident can occur.

OPEN FLAMES PROHIBITED If open flames are used in situations where open flames are prohibited, a serious accident can occur.

GENERAL PROHIBITION If the prohibition is ignored, a serious accident can occur.

PROTECTIVE GLASSES When the directive for protective glasses is given, protective glasses shall always be worn to avoid personal injury

GI-12

GENERAL PRECAUTIONS Servicing General Precautions !! DANGER • The forklift service area must be well ventilated and free of flammable objects and materials. • If servicing the forklift in an area that has previously been closed off or poorly ventilated, open all windows and doors and thoroughly ventilate the area before starting the service procedure to ensure that there is no buildup of hydrogen gas or carbon monoxide. • Be extremely careful whenever handling flammable materials and other dangerous objects. • Do not smoke during service operations. • Before beginning disassembly and inspection, remove all rings, your watch and other metallic objects from your body to prevent an accidental short circuit. • Turn the ignition to the OFF position and disconnect the battery plugs before beginning the disassembly and inspection procedure. • When removing the battery or the counterweight chock the wheels. Never remove the battery or the counterweight when the forklift is raised on jacks.

!! WARNING • Exercise care when working around high-temperature, rotating or sliding area of the forklift. Avoid burns and other serious injuries. • Use the proper tools for the disassembly and inspection procedures. Use the designated special service tools, if required. • When disconnecting pressurized pipes or hoses, release the pressure from the line before removing. • Use only the specified nuts and bolts to install parts. Tighten the nuts and bolts to the specified torque as required. • Do not carelessly dispose of discarded oil from oil changes and part cleaning operations. Dispose of the oil following established procedures. Always contact your local agencies.

! CAUTION • Carefully analyze all symptoms during troubleshooting. This will allow you to make repairs safely and efficiently. After completing a troubleshooting and repair procedure, carefully check to make sure that all existing problems have been rectified. • Make alignment marks on parts to be disassembled, as required, for easier and proper reassembly. Marks should be made in areas of the parts that will not affect function. • When removing wires, note the color codes and remember the wiring configuration before removal.

GI-13

GENERAL PRECAUTIONS Servicing General Precautions (Cont’d)

! CAUTION • Under no circumstances should electrical components (controllers, motors, battery charging units and wiring) be steam-cleaned. • Clean internal areas of the controllers, motors and battery charger (the areas near the magnetic switches) with an OSHA air nozzle (never with steam). Following cleaning, check the insulation resistance. • Carefully check all removed oil seals, gaskets, packing materials, O-rings, lock washers, cotter pins and selflocking nuts against the instructions on each section to see whether or not they can be reused. If they cannot be reused, they must be replaced with new ones. If replacement parts are required, refer to the Parts Manual distributed by UCA. Be sure that the replacement parts have the correct part number. Use only genuine OEM parts. • Use only the specified lubricants and sealants.

Precautions for Electrical System Inspection !! WARNING • When using a circuit tester, be very careful not to use the wrong range (A, V or Ω) and/or polarity. You could damage the unit’s electrical components, burn out wires, or cause electrical arcs, or damage tester.

! CAUTION • Turn the ignition to the OFF position and disconnect the battery plugs when disconnecting or connecting the print board connectors. Disconnecting and/or connecting the main print board or meter print board connectors with the ignition ON and the battery plugs in place can damage the print board. Exercise care. • Avoid twisting and turning the print board connectors when connecting and/or disconnecting them. This can result in poor connector connections. • When disconnecting connectors, do not pull on the wire attached to the connector. Always hold the connector body. • Static electricity can damage the main and meter print boards. Be sure to eliminate static electrical charges when handling the print boards. • Following completion of the inspection procedure, once again check that all of the leads are connected to their original terminals.

GI-14

GENERAL PRECAUTIONS Precautions for Battery Handling !! DANGER • Do not permit open flames in close proximity to the battery when handling it, this could result in serious injury or death. • It is possible to burn yourself when working with a battery, as battery acid is a corrosive solution. Be careful not to allow your eyes, skin, clothing or painted surfaces to come in direct contact with the battery fluid. If the fluid should come in contact with anything, immediately flush the contacted area with water. • If large amounts of battery fluid have been spilled or leaked over an area, immediately neutralize the spill with some neutralizing agent (sodium bicarbonate, calcium hydroxide, carbonate soda, etc.). Rinse the area with a large volume of water. • Highly-explosive hydrogen gas leaks from the battery. If this gas is ignited by sparking from a short circuit in the battery terminal area, an explosion and serious injury or death can result. Avoid this danger by not placing tools and other metallic objects on top of the battery where they might short the battery terminals. • Hydrogen gas escaping from the battery can also be ignited by static electricity in the area. Again, an explosion can result. Never wipe or dust the battery upper surface and terminal areas with a completely dry cloth as this will generate static electricity. Never cover the battery with a vinyl sheet or similar object to protect it. This can also generate static electricity. Clean the battery with a damp cloth. • Never entrust battery maintenance procedures to personnel who are not familiar with the techniques and safety precautions required for battery maintenance.

!! WARNING • Fluid leakage from a loosely closed battery electrolyte filler cap can cause many problems. Always be sure that the filler cap is tightly closed.

Jacking, Lifting or Towing !! DANGER • Always perform jacking or lifting operation on a flat and solid surface. • Be sure to use wooden blocks of sufficient strength to support the weight of vehicle. • Never use cracked or broken wooden blocks. These may cause unstable support, resulting in serious injury or death. • Never place wooden blocks or different heights side by side under the vehicle or the mast.

GI-15

TOOLS REQUIRED TO SERVICE PRODUCTS Mechanical, electrical, hydraulic, and maintenance service on these products can be performed with many standard hand tools. Various size roll pins are used throughout all of our products. The removal and installation ca be made by the use of hardened steel punches of various diameters and length. In some cases, the replacement of hydraulic cylinder packing requires the use of the packing installer tool or guide to ease installation of the packing. Due to the various sizes and continual changes, a standard engine piston ring compressor can be used effectively for this service. All basic electrical services can be performed with standard hand tools, a good VOM (Volt Ohm Meter) and AMP Meter. We have added tool requirements in some of the servicing sections. These tools may include impact tools, lifting straps, hoist, torque wrench and jacks which are readily available locally, from automotive supply companies. Always use good quality tools to ensure your safety and the safety of others. Current special tools for this model is the Zapi handset, Part #29499-FS000. Grease fitting -Alemite Z737 and special motor gear nut socket Part #38216-FS001.

GI-16

CONVERSION CHART - METRIC TO INCHES Feeler Gauges, Micrometers, Calipers mm

inches

0.01

0.0004

0.35

0.0138

0.69

0.0272

0.02

0.0008

0.36

0.0142

0.70

0.0276

0.03

0.0012

0.37

0.0146

0.71

0.0279

0.04

0.0016

0.38

0.0150

0.72

0.0283

0.05

0.0020

0.39

0.0154

0.73

0.0287

0.06

0.0024

0.40

0.0157

0.74

0.0291

0.07

0.0028

0.41

0.0161

0.75

0.0295

0.08

0.0031

0.42

0.0165

0.76

0.0299

0.09

0.0035

0.43

0.0169

0.77

0.0303

0.10

0.0039

0.44

0.0173

0.78

0.0307

0.11

0.0043

0.45

0.0177

0.79

0.0311

0.12

0.0047

0.46

0.0181

0.80

0.0315

0.13

0.0051

0.47

0.0185

0.81

0.0319

0.14

0.0055

0.48

0.0189

0.82

0.0323

0.15

0.0059

0.49

0.0193

0.83

0.0327

0.16

0.0063

0.50

0.0197

0.84

0.0331

0.17

0.0067

0.51

0.0201

0.85

0.0335

0.18

0.0071

0.52

0.0205

0.86

0.0339

0.19

0.0075

0.53

0.0209

0.87

0.0342

0.20

0.0079

0.54

0.0213

0.88

0.0346

0.21

0.0083

0.55

0.0216

0.89

0.0350

0.22

0.0087

0.56

0.0220

0.90

0.0354

0.23

0.0091

0.57

0.0224

0.91

0.0358

0.24

0.0094

0.58

0.0228

0.92

0.0362

0.25

0.0098

0.59

0.0232

0.93

0.0366

0.26

0.0102

0.60

0.0236

0.94

0.0370

0.27

0.0106

0.61

0.0240

0.95

0.0374

0.28

0.0110

0.62

0.0244

0.96

0.0378

0.29

0.0114

0.63

0.0248

0.97

0.0382

0.30

0.0118

0.64

0.0252

0.98

0.0386

0.31

0.0122

0.65

0.0256

0.99

0.0390

0.32

0.0126

0.66

0.0260

1.00

0.0394

0.33

0.0130

0.67

0.0264

0.34

0.0134

0.68

0.0268

GI-17

TORQUE CHART AND EQUIVALENTS Torque Wrenches Newton Meters

Wrenches

in/lb

ft/lb

inches

1.13

13.56

15/64

2.26

27.12

9/32

3.39

40.68

5/16

4.52

54.24

11/32

5.65

67.80

13/32

100

11.30

81.36

7/16

150

16.95

94.92

15/32

200

22.60

108.48

1/2

250

28.25

122.04

9/16

300

33.90

100

135.60

19/32

350

39.55

110

149.16

5/8

400

45.20

120

162.72

11/16

450

50.85

130

176.18

3/4

500

56.50

140

189.84

13/16

550

62.15

150

203.40

7/8

600

67.80

160

216.96

15/16

650

73.45

170

230.52

1-1/32

700

79.10

180

244.08

1-1/16

750

84.75

190

257.64

1-3/16

800

90.40

200

271.20

1-1/4

850

96.05

210

284.76

1-7/16

900

101.70

220

298.32

1-5/8

950

107.32

230

311.88

1-29/32

1000

113.00

240

325.44

2-3/16

2-3/8

1 in/lb = 0.11298 Nm

1 ft/lb = 1.3558 Nm

Metric Wrench and SAE Wrench Equivalent Sizes The following wrenches are roughly interchangeable: 4mm is close to 5/32 8mm is close to 5/16 11mm is close to 7/16 12mm is close to 15/32 15mm is close to 19/32 19mm is close to 3/4 23mm is close to 29/32

GI-18

TORQUE CHART AND EQUIVALENTS Standard Metric Torque Values Property, Class Size and Pitch M5 x 0.8

Property, Class

10.9**

12.9***

8.8* Nm

in/lb

5-6

44-53

7-8

62-71

8-10

71-88

M6 x 1

8-10

71-88

12-14

106-124

14-16

124-142

M8 x 1.25

20-25

177-221

30-35

---------

ft/lb

M8 x 1.25

---------

22-26

34-40

26-30

M10 x 1.5

40-45

30-33

60-65

44-48

70-75

52-55

M12 x 1.75

70-80

48-51

100-110

74-81

115-130

85-96

M14 x 2

110-125

52-59

155-180

114-133

180-210

133-155

M16 x 2

170-190

125-140

240-270

177-199

280-320

207-236

M20 x 2.5

340-380

251-280

450-500

332-369

550-600

406-443

M24 x 3

580-650

428-479

800-900

590-664

900-1050

664-774

M30 x 3.5

1150-1300

858-959

1600-1800

1180-1328

1850-2100

1364-1549

M36 x 4

2000-2250

1479-1660

2800-3150

2065-2323

3250-3700

2397-2729

* Property class 8.8, Protective Treatment CMHC Specification “H” (zinc phosphate), applies also to internally threaded fasteners made of property class 8 material. ** Property class 10.9, Protective Treatment CMHC Specification “H” (zinc phosphate), applies also to internally threaded fasteners made of property class 10 material. ***Property class 12.9, Protective Treatment CMHC Specification “H” (zinc phosphate), applies also to internally threaded fasteners made of property class 12 material.

GI-19

CONVERSION FACTORS To Convert From

Multiply By

bar

psig

14.5

C°

F°

(C° x 1.8) - 32

gal/h

oz/h

128

g/h

oz/h

0.03527

g/kWh

oz/BHPh

0.0263

g/m

U.S. gal/1000 cu. ft

0.0091

J/1

BHP/100 cfm

0.0683

2.205

kgm

liter/ft

23.730

kg/h

U.S. gal/h

0.32

Bhp

1.341

liter

gal (U.S.)

0.2642

liter/s

cfm

2.119

liter/s

U.S. gal/min

15.85

3.281

m K/w

btu/h/F°/ft

5.678

mg/m

oz/cu. ft

1 x 10

0.0394

ft/lb

0.738

GI-20

INCH (SAE) AND METRIC FASTENERS Introduction Fasteners such as bolts, nuts, cap screws, and studs are made to specifications that best describe the mechanical strength and harness of that fastener. Any fastener used in a design application has been selected in accordance with its specifications. Parts used on these trucks come from many different sources and a few other countries. There are several standards used by these companies and the countries in which they are manufactured. Many of these fasteners are similar but cannot be used as a direct replacement. Commonly threaded fasteners of each specification have identification marks for that specification. This specification is called “grade” for SAE standards and “property” for metric standards. The metric system used is described as SI (International System of Units, also call SI in all languages). The SI system of measurement is described in ISO Standard 1000, 1973. All service personnel must use replacement fasteners that have the same specifications. This section will describe the identification of some of the more common fasteners found on our trucks.

Understanding Threads As seen in the figure below, the thread design is specified by a series of numbers and letters for inch and metric fasteners. The diameter of the shank of the fastener is shown first in the series, e.g. M12=12mm, M20-20mm (1/2=1/2inch, 3/4=3/4inch).

GI-21

INCH (SAE) AND METRIC FASTENERS SAE Fasteners The number of threads per inch is not normally shown for the inch nomenclature and only the UNC (Unified National Coarse) or UNF (Unified National Fine) are shown. Because a UNC or UNF fastener has a standard number of threads per inch for a specific diameter. The length of a shank is most often indicated as part of the description of a fastener. This length is shown in inches for inch fasteners and in millimeters for metric fasteners.

Common Description for Cap Screws INCH

METRIC

1/2 X 13 UNC X 1-1/2 A B C D

M12 X 1.75 X 50 A B C

A= SHANK DIAMETER B= NUMBER OF THREADS PER UNIT C= TYPE OF THREAD D= SHANK LENGTH

A= THREAD DIAMETER B= PITCH C= LENGTH

Strength Identification The most common property classes for metric fasteners are 8.8 and 10.9. The property class is marked with a number on the head of the cap screw or on a nut. Property classes less than 8.8 are often not marked. Grades for inch bolts go from 2 to 8. Grade 2 fasteners normally do not have marks. The following tables show the marks that identify the grades and property classes for different fasteners.

!! WARNING • When any threaded fasteners must be replaced the new fasteners must be of the same strength or greater than the original fasteners, and must also be the correct size. Service Note: • Identification marks are according to bolt strength. An increase in the number of marks indicates increased bolt strength.

GI-22

INCH (SAE) AND METRIC FASTENERS Chart 1. Bolt and Screw Designations

GI-23

INCH (SAE) AND METRIC FASTENERS Chart 2. Stud and Nut Designations

GI-24

INCH (SAE) AND METRIC FASTENERS Chart 3. Torque Nut Designations

GI-25

INCH (SAE) AND METRIC FASTENERS Chart 4. Torque Nut with Nylon Insert Designations

GI-26

STANDARD SPEED & LIFT TEST !! DANGER • All tests should be carried out in a safe area away from normal operational traffic. Follow all plant safety regulations when performing tests.

Speed Test Track

Example: 60 divided by 10 seconds = 6 mph 60 divided by 18 seconds = 3.3 mph

Lift Speed Test Mast Height (inches) = Distance 12 Lift Speed Time (seconds) = Time 60 D = Feet/min. T Example: 12 divided by 270 = 0.04 60 divided by 14 seconds = 4.2 4.2 divided by 0.04 = 105 ft/min.

GI-27

PAINT & DECAL 2W5/2W6

5 5

11 1

Item No.

Description

Qty

Data Plate (Consult Factory with Model & Serial Number)

Label (Mast Caution)

Label (General Warning)

Label (No Riding)

Label (Warning Battery Gates)

Label (24V)

Fuse Label (10A 24V DC)

Label (Caution Fork)

Label (Caution Hydraulic Oil)

For complete information, refer to Parts Catalog.

GI-28

HYDRAULIC SYSTEM

SECTION

CONTENTS SERVICE DATA AND SPECIFICATIONS . . HD-2 General Specifications . . . . . . . . . . . . . . . . HD-2 Inspection and Adjustment . . . . . . . . . . . . . HD-3 Adjusting Shim . . . . . . . . . . . . . . . . . . . . . . HD-4 Tightening Torque . . . . . . . . . . . . . . . . . . . . HD-4 TROUBLE DIAGNOSES AND CORRECTIONS . . . . . . . . . . . . . . . . . . . . HD-5 PRECAUTIONS AND PREPARATION . . . . HD-9 Special Service Tool . . . . . . . . . . . . . . . . . . HD-9 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . HD-10 Hydraulic Circuit Diagram . . . . . . . . . . . . . . HD-10 Disassembly and Assembly . . . . . . . . . . . . HD-11 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . HD-20 OIL PUMP (GEAR PUMP) . . . . . . . . . . . . . . HD-21 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . HD-21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . HD-21 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . HD-22 Test Procedures . . . . . . . . . . . . . . . . . . . . . HD-22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . HD-24 Installation . . . . . . . . . . . . . . . . . . . . . . . . . HD-25 Combo Valve Disassembly . . . . . . . . . . . . . HD-26 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . HD-26 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . HD-26 Hydraulic Test . . . . . . . . . . . . . . . . . . . . . . . HD-26 TILT CYLINDER - 2W5 ONLY . . . . . . . . . . . HD-29 Construction . . . . . . . . . . . . . . . . . . . . . . . HD-29 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . HD-29 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . HD-30 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . HD-31 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . HD-32 Installation . . . . . . . . . . . . . . . . . . . . . . . . . HD-32

LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . HD-33 Construction . . . . . . . . . . . . . . . . . . . . . . . HD-33 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . HD-35 Installation (2W, 3F) . . . . . . . . . . . . . . . . . . HD-39 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . HD-40 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . HD-40 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . HD-41 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . HD-41 FULL-FREE CYLINDER . . . . . . . . . . . . . . . HD-42 Construction . . . . . . . . . . . . . . . . . . . . . . . HD-42 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . HD-43 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . HD-43 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . HD-44 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . HD-44 Installation . . . . . . . . . . . . . . . . . . . . . . . . . HD-45 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . HD-45 OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . HD-46 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . HD-46

SERVICE DATA AND SPECIFICATIONS General Specifications Oil Pump (Gear Pump) Applied model

2W5 / 2W6 series Regular capacity

Pump type

M-9300-0141

Drive type

Direct coupled to motor

Gear system

Single, Zero-backlash type

Normal discharge

cc (in³) / rev.

Maximum pressure

MPa (bar, kg/cm², psi)

8.3 (0.506) 20.6 (206, 210, 3,000)

Control Valve Combo Manual / Electric Applied model

2W5 / 2W6 series Manual / Electric

Valve type

Bucher 520-9

Main relief set pressure

MPa (bar, kg/cm², psi)

20.6 (206, 210, 3,000)

Relief valve type

Cartridge

Plunger type

Cylinder, spring return

Rated flow rate

US gal / min.

Tilt Cylinder (2W5 Only) Applied model

2W5 series

Stroke

mm (in)

65 (2.56)

Cylinder I.D.

mm (in)

70 (2.75)

Cylinder O.D.

mm (in)

82 (3.22)

Piston rod diameter

mm (in)

30 (1.18)

Tilt angle (Forward-backward)

2W, 3F

3°/ 5°

Lift (Mast) Cylinder 2W

Cylinder I.D.

Mast name mm (in)

45 (1.77)

Cylinder O.D.

mm (in)

52 (2.05)

Piston rod diameter

mm (in)

35 (1.38)

Full-Free Cylinder Mast name

Cylinder I.D.

mm (in)

70 (2.76)

Cylinder O.D.

mm (in)

84 (3.31)

Piston rod diameter

mm (in)

50 (1.97)

HD-2

SERVICE DATA AND SPECIFICATIONS General Specifications (Cont’d) Micron Filter Applied model

2W5 / 2W6 series

Filter type

Filter paper (cartridge) type

Filtration size

µm

Inspection and Adjustment Hydraulic Oil Type and Capacity Applied model Hydraulic oil type

2W5 / 2W6 series Standard

Daphne Fluid AW32 BH-U

Freezer operation Oil capacity

Mobil DTE 13M

ℓ (US gal, Imp gal)

13.0 (3.5, 2.9)

Oil Pump (Gear Pump) Unit: mm (in) Item Gear shaft O.D.

Pump type Bucher 520-9

Usable limit

Remarks

20.961 (0.8252)

Regular capacity

Tilt Cylinder (2W5 Only) Unit: mm (in) Item

Usable limit

Remarks

Clearance between cylinder head bushing and piston rod

0.2 (0.008)

Clearance between cylinder tube and piston

0.2 (0.008)

Lift Cylinder Unit: mm (in) Item

Usable limit

Remarks

Clearance between cylinder head bushings and piston rod

0.2 (0.008)

Clearance between cylinder tube and piston ring

0.2 (0.008)

HD-3

SERVICE DATA AND SPECIFICATIONS Adjusting Shim Unit: mm (in) Item

Usable limit

Remarks

Shim for aligning full-free cylinder parallel to inner mast

1.0 (0.039)

Select proper number of shims.

Shim for adjusting height of upper end of lift cylinder

1.0 (0.039)

Select proper number of shims.

Tightening Torque Part name Oil pump

Control valve

Control lever Tilt cylinder

Nm (kg-m, ft/lb) Nm (kg-m, in/lb)*

Oil pump-to-pump motor securing bolts

25 - 31 (2.5 - 3.2, 18 - 23)

Intake connector

92 - 108 (9.3 - 11.0, 68 - 80)

Discharge connector

79 - 88 (8.0 - 9.0, 58 - 65)

Control valve assembly bolt solenoid poppet

49 (5.0, 35-40)

Solenoid valve assembly

49 (5.0, 35-40)

Control valve assembly attaching bolt

20 - 22 (2.0 - 2.2, 168 - 192)*

Striker attaching bolt

13 - 15 (1.3 - 1.6, 120 - 132)*

Lever bracket attaching nut

26 - 33 (2.6 - 3.3, 19 - 24)

Rod head lock nut

108 - 147 (11 - 15, 80 - 108)

Cylinder head Lift cylinder

350 - 400 (36 - 40, 259 - 295)

Cylinder head (Lift Cylinder)

2W, 3F

197 - 245 (20 - 25, 145 - 180)

Cylinder mounting bolt

44 - 54 (4.4 - 5.6, 32 - 40)

U-bolt lock nut

26 - 32 (2.6 - 3.3, 19 - 24)

Adjusting bolt lock nut

Oil tank

47 (4.8, 35-40)

Main relief valve assembly

74 - 94 (7.5 - 9.6, 54 - 69)

Cylinder head (Full-free cylinder)

300 - 370 (31 - 37, 202 - 272)

Full-free cylinder mounting bolt

128 - 156 (13 - 16, 95 - 115)

Oil tank mounting bolt

21 - 26 (2.1 - 2.7, 192 - 228)*

Micron filter unit mounting bolt

21 - 26 (2.1 - 2.7, 192 - 228)*

Connector

79 - 88 (8 - 9, 59 - 64)

HD-4

TROUBLE DIAGNOSES AND CORRECTIONS

! CAUTION • The following table lists only typical examples. To perform an accurate diagnosis, carefully listen to the user’s complaints and check the actual vehicle to fully understand under what conditions the symptoms occur. • For malfunctions closely related to pump motor, refer to MM section for diagnosis. • For malfunctions closely related to control system, refer to ES section for diagnosis.

Oil Pump (Gear Pump) Condition No oil supplied from oil pump Low oil pump pressure

Abnormal noise caused by oil pump

Oil leakage from oil pump

Probable cause

Corrective action

• Low oil level in tank

• Fill up oil to specified level.

• Clogged suction pipe or filter

• Clean. If oil is dirty, replace with new.

• Worn gear shaft bushing or faulty packing ring

• Replace with new one.

• Improperly adjusted relief valve

• Readjust to specified pressure using pressure gauge.

• Air in the system

• Retighten suction side piping. • If oil level in tank is too low, add oil to specified level. • Do not operate pump until air bubbles in tank are removed.

• Cavitation due to crushed suction hose

• Remove foreign matter and repair crushed hose.

• Air sucked from lose suction side joint

• Retighten each joint.

• Excessive viscosity of oil

• Replace with new oil having proper viscosity.

• Air bubbles in hydraulic oil

• Discharge air, remove foreign matter and replace oil.

• Faulty oil seal or body seal

• Replace seal with new one.

• Worn sliding surfaces of gears (Increased inner leakage)

• Replace oil pump with new one.

HD-5

TROUBLE DIAGNOSES AND CORRECTIONS Control Valve Condition

Probable cause

Corrective action

Oil leaking

• Damaged or scratched O-ring

• Replace faulty O-ring.

Pump pressure does not rise.

• Lift lock valve does not operate.

• Disassemble and clean the valve. In case of solenoid operation failure, replace the solenoid.

• Lead wire or solenoid coil is broken.

• Repair or replace the wire or coil.

• Input current of solenoid is small.

• Check if the specified maximum current is applied.

• Foreign matter between sliding surfaces of valve housing and plunger

• Clean valve housing and plunger.

• Deteriorated oil

• Change oil with new.

• Damaged return spring

• Replace.

• Distorted valve housing mounted

• Loosen mounting bolts and check.

• Bent plunger

• Replace valve housing and plunger as an assembly.

• Paint dust or dirt caught in oil seal

• Remove seal and clean.

• Distorted seal plate

• Clean seal plate and retighten bolts.

• Worn or damaged seal

• Replace.

• Damaged plunger

• Replace.

Lowered or tilted forward cylinder without control lever operation (2W5 Only)

• Worn valve housing and plunger

• Replace valve housing and plunger as an assembly.

• Oil leaking from cylinder

• Check cylinder and replace faulty parts.

Load drops when changing control lever from NEUTRAL to RAISE position.

• Foreign matter caught in load check valve

• Disassemble check valve and clean.

• Damaged poppet or check valve seat

• Replace or repair by lapping.

Mast tilts forward when control lever is moved forward and backward while ignition is OFF. (2W5 Only)

• Worn or damaged tilt lock plunger

• Replace plunger and tilt valve housing as an assembly.

• Broken tilt lock plunger spring

• Replace.

• Oil leakage from O-ring in tilt cylinder piston

• Replace.

Cylinder speed is too slow or cylinder does not operate.

• Worn relief valve or damaged seat

• Replace relief valve assembly.

• Foreign matter caught in relief valve

• Clean or replace relief valve.

• Faulty oil pump

• Refer to “OIL PUMP”.

• Stuck or damaged tilt lock plunger (2W5 Only)

• Replace plunger and tilt valve housing as an assembly.

• Foreign matter caught between valve and plunger, making valve inoperative

• Disassemble and clean.

Plunger sticks

Oil leakage from oil seal

Mast is unstable or does not operate when control lever is moved to forward while ignition is ON.

HD-6

TROUBLE DIAGNOSES AND CORRECTIONS Relief Valve Condition Pressure does not rise at all.

Probable cause • Main poppet or pilot poppet is stuck and kept open. • Foreign object is caught in poppet seat.

Relief pressure is unstable.

• Poppet seat is damaged.

• Replace the damaged part. • Clean all the parts thoroughly. • Remove the flaw on the surface.

• Poppet is stuck. Relief pressure is abnormal.

• Wear caused by foreign object • Lock nut or adjusting screw is loosened.

Oil leakage

• Damage to seat

• Replace the damaged part. • Perform readjustment. • Replace the damaged part or the worn part. • Each part should move smoothly.

• Wear of O-ring

Pressure rise is delayed.

Corrective action • Check for foreign objects in the engaged area of the poppet. • The poppet should slide freely. • Clean all the parts thoroughly.

• Each part is stuck due to foreign objects.

• Check for scratch, scoring, and foreign objects.

• Air is trapped in relief valve.

• Bleed air.

Tilt Cylinder (2W5 Only) Condition Oil leakage

Cylinder tilts forward without control lever operation.

Mast swings to and fro when brakes are applied while driving.

Probable cause (Sliding surfaces between cylinder and piston rod) • Foreign matter in U-ring • Damaged U-ring • Foreign matter in lip of wiper ring • Damaged lip of wiper ring • Damaged sliding surface of piston rod

Corrective action

• Flaked hard chromium plate of piston rod

• Remove and clean or replace. • Replace. • Remove and clean or replace. • Replace. • If damage is minor, repair using oilstone. If serious, replace piston rod assembly. • Replace.

(Connected portion of cylinder head and tube) • Damaged O-ring

• Replace.

(Welded portion of cylinder tube) • Damage or cracks

• Replace.

(Others) • Loose connector • Degraded or damaged hose or tube

• Tighten to specified torque. • Replace.

• Damaged sliding surface of cylinder tube

• If damage is minor, repair using oilstone. If serious, replace cylinder tube.

• Damaged sliding surface of piston

• Replace piston rod assembly.

• Damaged O-ring

• Replace.

• Damaged backup ring

• Replace.

• Faulty control valve

• Refer to “CONTROL VALVE”.

• Air in cylinder

• Operate cylinder for about five minutes (10 20 strokes).

• Oil leak from piston seal

• Replace seal or cylinder.

HD-7

TROUBLE DIAGNOSES AND CORRECTIONS Lift / Full-Free Cylinder Condition Oil leakage

Probable cause (Sliding surfaces between cylinder head and piston rod) • Foreign matter in U-ring • Damaged U-ring • Foreign matter in lip of wiper ring • Damaged lip of wiper ring • Damaged sliding surface of piston rod

Corrective action

• Flaked hard chromium plate of piston rod

• Remove and clean or replace. • Replace. • Remove and clean or replace. • Replace wiper ring. • If damage is minor, repair using oilstone. If serious, replace piston rod assembly. • Replace.

Cylinder is lowered without control lever operation or power is insufficient.

• Foreign matter in U-ring on piston side • Damaged lip of U-ring on piston side • Damaged sliding surface of cylinder tube • Damaged sliding surface of piston ring • Faulty down safety valve

• Remove and clean or replace. • Replace U-ring. • Replace cylinder tube. • Replace piston ring. • Replace down safety valve assembly.

Abnormally low lowering speed of cylinder

• Degraded or broken plunger return spring of flow regulator valve • Foreign matter in moving part of flow regulator valve • Faulty down safety valve

• Replace flow regulator valve assembly.

HD-8

• Replace flow regulator valve assembly. • Replace down safety valve assembly

PRECAUTIONS AND PREPARATION • For lift piping, place the fork at the lowest position, turn the ignition off, loosen the shut-off valve and let the remaining pressure escape. • On 2W5, for tilt piping, first place the fork horizontal (tipped slightly forward) and turn the ignition off. Next, loosen the piping and let set while the remaining pressure escapes. • For attachment piping (3rd and 4th) • Union connector Place the attachment in neutral, turn the ignition off, loosen the piping, and let set while the remaining pressure escapes. • Coupling Installing and removing the cup may be difficult if the remaining pressure inside the piping is high. If this is the case, turn the ignition ON and while idling tip the lever (3rd and 4th) backwards or forwards, and one of the cups will come off. Then tip the lever in the other direction and remove the other cup.

! CAUTION • Before removing hydraulic lines or piping, make sure the oil pressure remaining in hydraulic lines is completely bled off. • To prevent foreign matter from entering, always maintain a clean workplace. • When disconnecting pipes, cover the surrounding area with rag and ensure oil does not contaminate other parts. • Never allow foreign matter to enter pipes when connecting. • Put disassembled parts on clean paper or rag and use care not to contaminate, scratch or dent them. • Always assign lifting operations to qualified operators trained in slinging or hoisting procedures. • When handling heavy parts, two people should perform the work. NOTE: • For the removal, installation and service of pump motor, refer to MM section. • For the removal of instrument inner cover, floor mat and floor panel, refer to BF section. • For removal and installation of mast, refer to LM section.

Special Service Tool Purchase locally. Tool number Tool name

Description

Measuring oil pressure

Pressure gauge

HD-9

HYDRAULIC SYSTEM Hydraulic Circuit Diagram

Pump pressure in

Check valve

Relief valve set at psi

Tank return line

Aux valve ports

Switch (valve)

Tilt valve (2W5)

Pump

Lift valve

Pump motor

Valve dump

Tank

Electric lift valve

Return / Fill filter

HD-10

HYDRAULIC SYSTEM Disassembly and Assembly

! CAUTION • Wrap seal tape securely around tapered threads. Never allow pieces of seal tape to enter hydraulic pipes. • O-rings are used in the connectors to connect each hydraulic unit. Before assembling, attach a guide to threads of connector and insert O-ring along with it so as not to damage O-ring. • Tighten connector by hand and after determining connector position, tighten lock nut to the specified torque. • Discharge hydraulic oil before removing suction hose. • During assembling of hydraulic system, be careful not to allow foreign material such as dust in hydraulic line. • When fixing hoses, adjust their rotation direction and position so that the hoses are not twisted and pulled. • Check relief pressure for oil leakage and other malfunctions. • Insert the suction hoses and return hoses until the groove end of pipe or connector.

HD-11

HYDRAULIC SYSTEM Disassembly and Assembly (Cont’d) Hydraulic Piping - Electric (2W6 Standard)

Hydraulic Piping and Fitting (2W5 Standard / 2W6 Optional)

Lift cylinder

Valve assembly (2W6)

Flow valve

Connector SAE-8 to ORFS-8 (2W6)

Filter assembly

Connector SAE-6 to ORFS-4 (2W5)

Pump

Connector SAE-6 to ORFS-4 (2W5)

Suction hose

Connector SAE-6 to ORFS-4 (2W5)

Hose assembly, pump to valve

Connector SAE-6 to ORFS-4 (2W5)

Hose assembly, lift

Connector SAE-8 to ORFS-8 (2W5)

Hose, return

Connector SAE-8 to ORFS-8 (2W5)

Valve assembly (2W5)

Tilt cylinder hose assembly (2W5)

Tilt cylinder (2W5)

Connector SAE-8 to 1/2” hose barb-8 (2W5)

HD-12

HYDRAULIC SYSTEM Disassembly and Assembly (Cont’d) Combo Manual / Electric Valve Assembly

HD-13

HYDRAULIC SYSTEM Disassembly and Assembly (Cont’d) Mast

HD-14

HYDRAULIC SYSTEM Disassembly and Assembly (Cont’d) Mast Piping 2W Mast

HD-15

HYDRAULIC SYSTEM Disassembly and Assembly (Cont’d) Mast Piping (Cont’d) 3F Mast

HD-16

HYDRAULIC SYSTEM Disassembly and Assembly (Cont’d) Mast Piping (Cont’d) 2W Mast

HD-17

HYDRAULIC SYSTEM Disassembly and Assembly (Cont’d) Mast Piping (Cont’d) Mast

HD-18

HYDRAULIC SYSTEM Disassembly and Assembly (Cont’d) Mast Piping (Cont’d) 3F Mast

HD-19

HYDRAULIC SYSTEM Inspection Hoses • Leaking, degraded or damaged hoses should be replaced. • Leaking or damaged connectors should be replaced.

Tubes and Pipes • Leaking, bent, broken or scratched hoses should be replaced. • Leaking or damaged connectors should be replaced.

HD-20

OIL PUMP (GEAR PUMP) Removal

! CAUTION • Clean the area surrounding the pump and remove dust. • Because oil tends to spill, cover the area surrounding the pipes with rag. (Especially opening for pump motor fan) • Never allow foreign matter to enter pump or pipes. 1. Remove battery from the vehicle. 2. Remove front and top cover. 3. On 2W5: Remove counterweight. Refer to BF section. 4. Drain oil from hydraulic tank. 5. Disconnect high-pressure hose from pump at valve. 6. Disconnect suction hose to pump. 7. Remove pump bolts, and then remove pump and motor assembly. 8. Remove pump bolts and remove pump.

Installation

! CAUTION • Apply molybdenum disulfide grease to the pump shaft. • Install new pump and torque bolts to: • Install in the reverse order of removal. • Install pressure hose on pump as shown in figure above.

HD-21

CONTROL VALVE Test Procedures

NOTE: Perform the test under the following conditions. • Heat the hydraulic oil to approximately 50°C After installing oil pump, follow test procedures as follows: 1. Check that oil level in tank is OK and install pressure gauge to control valve at A1 port to lift cylinder. Heat hydraulic oil to 50°C (122°F).

! CAUTION • For installing pressure gauge and adjusting oil pressure, refer to “Hydraulic Test and Adjustment” in “CONTROL VALVE”. 2. With pump running, turn adjusting screw on relief valve to gradually raise pressure from 20.6 MPa (206 bar, 210 kg/cm², 3,000 psi). Place hand on pump body to check for temperature rise. If temperature of pump body is excessively higher than that of hydraulic oil, disassemble oil pump to make sure it is assembled correctly. 3. Reset relief valve to specified pressure. Relief Valve Set Pressure Main relief set pressure

MPa (bar, kg/cm², psi) 20.6 (206, 210, 3,000)

Tilt pressure

same as main

3rd pressure

same as main

HD-22

CONTROL VALVE Test Procedures (Cont’d) 4. Perform pump delivery test. Measure fork lifting speed without load. If the speed is within standard value, pump delivery is correct. Lifting speed without load fpm (mm/s)

Lowering speed without load fpm (mm/s)

50 (254)

2W5

50 (254)

2W6

50 (254)

2W6

50 (254)

Model Mast 2W5

5. Move fork up and down with and without load, and check that it operates correctly.

HD-23

CONTROL VALVE Removal

! CAUTION • Before discharging remaining pressure, lower lift fully and tilt completely forward. 2W5 only: Next, turn control lever toward backward tilt side. • When disconnecting pipes, turn ignition to OFF and discharge remaining pressure in pipes. • Never allow foreign matter to enter pipes or control valve. • Because oil tends to spill, cover the area surrounding the pipes with a shop cloth. (Especially opening for pump motor fan.) 1. Remove front cover and top panel. 2. Remove battery. 3. Disconnect harness connectors inserted into control valve. 4. • Remove high-pressure pipe, low-pressure hose, tilt pipe and lift pipe. (Remove all pipes from control valve.) • For manual valve, remove handles from valve. 5. Loosen control valve attaching bolts to remove control valve assembly with bracket from frame.

! CAUTION • Before removing the control valve attaching bolts, support the control valve using a wooden block to prevent it from dropping. • Be careful not to drop control valve because it is heavy and slippery due to oil.

HD-24

CONTROL VALVE Installation To install, reverse the order of removal. Pay attention to the following points. • Never allow foreign matter to enter pipes or control valve. • After connecting pipes, apply relief pressure to check for any oil leaks.

Combo Valve

Electric Valve - 2W6 Only

HD-25

CONTROL VALVE Combo Valve Disassembly (2W5 Standard / 2W6 Option) 2W6 Electric Valve • There is no disassembly of the electric valve. • Only replace the relief valve if pressure cannot be maintained or adjusted. • The lower valve can be replaced if the unit will not lower. Service Note: Valve spools are not sold separately. O-ring seal kits are available if oil is leaking between valve sections. Relief valve, lower valve and dump valves can also be replaced. 1. Remove bracket containing control valve switch from control valve assembly. (for mechanical) 2. Remove relief valve, lower valve and dump valve from control valve assembly. 3. Remove solenoid from lowering valve.

! CAUTION • Do not disassemble relief valve assemblies because they are replaced as an assembly. • Do not loosen lock nut. If lock nut is loosened, be sure to adjust set pressure after assembling. 4. Remove the cap screws, and disassemble the control valve to each section. Be careful not to lose poppets and poppet springs that are between each section.

Inspection • Clean the disassembled parts with detergent oil, and bleed air to remove foreign objects thoroughly. • Replace the parts with deformation, cracks, or other damage. • Replace the O-ring and wiper ring with new ones.

Assembly • Assemble in the reverse order of disassembly. • Check for smooth operation.

Hydraulic Test

! CAUTION • When performing hydraulic test, wear protective eyeglasses. High pressure oil leaks can cause loss of vision or other eye damage. • Perform the test in an appropriate place to allow lifting of the mast. NOTE: Perform the test under the following conditions. • Heat the hydraulic oil to approximately 50°C

HD-26

CONTROL VALVE Hydraulic Test (Cont’d)

Pressure Test 1. Turn ignition OFF. 2. Remove front cover. 3. Remove plug of high pressure pipe connector at hydraulic control valve. 4. Attach adapter to plug hole, then install pressure gauge. 5. Turn ignition ON and operate control lever and read the pressure referring to table below. Standard pressure Main relief pressure

MPa (bar, kg/cm², psi) 20.6 (206, 210, 3,000)

Tilt pressure

same as main

3rd pressure

same as main

6. If out of specification, adjust the pressure.

HD-27

CONTROL VALVE Hydraulic Test (Cont’d) Pressure Adjustment

• Turn ignition OFF, and then disconnect the battery connection. • Relief valve on control valve right side. 1. Loosen lock nut of relief valve assembly. 2. Connect battery cable, and then turn ignition to ON. 3. Operate control lever. 4. Turn adjusting screw of relief valve to set standard pressure. • If lower than the standard, turn clockwise. • If greater than the standard, turn counterclockwise.

! CAUTION • One rotation of the adjusting screw corresponds to a pressure change of 6.9 - 7.8 MPa (68.6 - 78.5 bar, 70 - 80 kg/ cm², 995 - 1,138 psi), so do not turn carelessly. • Carefully adjust pressure, observing the pressure gauge reading. 5. After completing adjustment, hold adjusting screw in place and tighten lock nut. 6. Implement the pressure test again to check whether the set pressure is correct.

HD-28

TILT CYLINDER - 2W5 ONLY Construction

Piston rod head

Wiper ring

Bush

Cylinder head

U-ring

Grease nipple

O-ring

Lock nut

Bolt

Cylinder tube assembly

Bush

Washer

Backup ring

Rod assembly

O-ring

Piston

Removal

! CAUTION • When removing tilt cylinder, lift mast with wire or nylon string and support cylinder with a block of wood so that it does not fall. • During work, be sure to keep your hands and feet out of danger.

HD-29

TILT CYLINDER - 2W5 ONLY Removal (Cont’d) 1. Lower fork fully. 2. Remove front cover. 3. Remove pivot pin attaching bolt from the joint of outer mast and pull out pivot pin. 4. Turn ignition ON and set tilt cylinder to the maximum backward tilt, then tilt forward to extend cylinder by about 10 mm (0.39 in). Turn ignition OFF and disconnect battery plug. 5. Disconnect two pipes connected to tilt cylinder at pipe connectors.

! CAUTION • Since oil tends to spill when pipes are disconnected, cover the surrounding area with rag. • Stuff stoppers into disconnected pipes to prevent oil spills. 6. Remove pivot pin attaching bolt from joint of body frame and pull out pivot pin to remove tilt cylinder. NOTE: To separate left tilt cylinder on body side, first remove tilt cylinder cover, then go to next step.

Disassembly 1. Hold cylinder in a vise with piping port down and put a plate under port. Apply compressed air alternately to two ports and activate piston rod to discharge oil from cylinder. 2. Loosen head lock nut, then remove rod head from piston rod assembly. 3. Loosen cylinder head, then remove cylinder head from cylinder tube assembly.

! CAUTION • Use care not to damage O-ring. 4. Remove piston rod assembly from cylinder tube assembly.

! CAUTION • Use care not to damage O-ring.

HD-30

TILT CYLINDER - 2W5 ONLY Disassembly (Cont’d) 5. Remove O-ring from piston rod assembly.

! CAUTION • Do not disassemble piston rod assembly. 6. Remove O-ring and backup ring from cylinder head.

! CAUTION • Replace removed O-ring and backup ring with new ones. Do not reuse. 7. Remove U-ring and wiper ring using a screwdriver.

! CAUTION • Replace removed U-ring and wiper ring with new ones. Do not reuse.

Inspection Cylinder Head • Measure inside diameter of cylinder head and outside diameter of piston rod and calculate the clearance. If the clearance is greater than usable limit, replace cylinder head. Standard: 0.05 - 0.15 mm (0.0020 - 0.0059 in) Usable limit: 0.2 mm (0.008 in)

Cylinder Tube • Measure inside diameter of cylinder tube and outside diameter of piston and calculate the clearance. If the clearance is greater than usable limit, replace cylinder tube. Standard: 0.03 - 0.15 mm (0.0012 - 0.0059 in) Usable limit: 0.2 mm (0.008 in) • Check whether the interior is damaged. If damage is minor, repair using oilstone. If serious, replace cylinder tube. • If welded part is damaged, replace cylinder tube.

Piston Rod • Check whether sliding surface is damaged. If damage is minor, repair using oilstone. If serious, replace piston rod. • If hard chromium plate flakes, replate piston rod or replace. • If rod is bent, replace.

HD-31

TILT CYLINDER - 2W5 ONLY Inspection (Cont’d) O-Ring, U-Ring, Wiper Ring and Back-Up Ring Do not reuse. Always replace with new ones.

Assembly To assemble, reverse the order of disassembly. Pay attention to the following points. • Lubricate each part with clean hydraulic oil. • Never allow foreign matter to enter parts. • Use new O-ring, U-rings, backup ring and wiper ring. • Use care not to twist or damage O-ring. • Use care not to damage O-ring and wiper ring with threads of piston rod. Rod head lock nut: : 108 - 147 Nm (11 - 15 kg-m, 80 - 108 ft/lb) Cylinder head: : 350 - 400 Nm (36 - 40 kg-m, 259 - 295 ft/lb) NOTE: To prevent O-ring and wiper ring from being damaged, wrap vinyl tape around threads of piston rod, then attach cylinder head assembly.

Installation To install, reverse the order of removal. Pay attention to the following points. Pivot pin attaching bolt: : 26 - 32 Nm (2.6 - 3.3 kg-m, 18 - 24 ft/lb) • After installing, operate cylinder for about five minutes (10 - 20 strokes).

HD-32

LIFT CYLINDER Construction 2W Mast

Dust seal

Fixing ring

Piston

U-ring

Wear ring

Piston ring

O-ring

Ball

Pull-in wire

Cylinder head

Pull-in wire

Washer

Cylinder tube assembly

Check valve

Piston rod

Spring

HD-33

LIFT CYLINDER Construction 3F Mast

Dust seal

Fixing ring

Piston

U-ring

Wear ring

Piston ring

O-ring

Ball

O-ring

Cylinder head

Pull-in wire

Washer

Cylinder tube assembly

Check valve

Cushion part

Piston rod

Spring

O-ring

HD-34

LIFT CYLINDER Removal

! CAUTION • Be sure to keep hands and feet out of danger.

Preparation 1. Remove from mast carriage assembly with fork. 2. Jack up the front of vehicle to keep about 120 mm (4.72 in) of clearance from lower end of outer mast to floor (refer to GI section). 3. After setting mast vertical and lower lift cylinder at the lower end, turn ignition OFF and disconnect the battery cable.

! CAUTION • Be sure to lower lift cylinder fully to discharge remaining pressure in pipes.

2W Lift Cylinder 1. Remove lift hose from lift cylinder.

! CAUTION • Oil tends to spill if hoses are disconnected, so be sure to block the end with stoppers. 2. Disconnect the hose between the lift cylinders. 3. Remove lock nut on the upper plane of lift cylinder to separate lift cylinder from inner mast. 4. Lift up inner mast with lifting wire/nylon sling.

HD-35

LIFT CYLINDER Removal (Cont’d) 2W Lift Cylinder (Cont’d) 5. Remove lift cylinder attaching bolt and U-bolt, then remove lift cylinder from the front.

! CAUTION • Because lift cylinder is very heavy, two people should perform this task. • When removing U-bolt, support lift cylinder to prevent it from falling.

3F Lift Cylinder 1. Lift up the inner mast until the inner mast lower beam comes to the position of the upper section of the outer mast tilt beam.

! CAUTION • Because the chain and lift hose become saggy, make sure that they are not caught while lifting up the inner mast. 2. Remove the chain anchor on the inner mast side, and remove the mast chain from the inner mast. 3. Remove the hydraulic piping on the lower section of the full-free cylinder. 4. Remove the hose pulley support on the upper section of the middle mast, and remove the chain wheel. 5. Place a square timber of approximately 100 mm (3.94 in) height under the inner mast, and lower the inner mast.

! CAUTION • Make sure that the chain and the lift hose is not caught while lowering the inner mast. 6. Fix the lifting tool to the upper beams of both the inner mast and middle mast. 7. Remove the mounting bolt on the mast cylinder upper surface. 8. Lift up the inner mast and middle mast together, and remove the upper section of the mast cylinder. 9. Disconnect the lift cylinder hose from the mast cylinder, remove the lift hose clamp mounting bolt, and remove the cylinder from the mast.

! CAUTION • Oil tends to spill if hoses are disconnected, so be sure to block the end with stoppers.

HD-36

LIFT CYLINDER Removal (Cont’d) 3F Lift Cylinder (Cont’d) 10. Remove the bolt at the bottom end of the mast cylinder (lower face of the outer mast support).

11. Remove the U-bolt, and remove the mast cylinder toward the front of the vehicle.

! CAUTION • When removing U-bolt, support lift cylinder to prevent it from falling. • Because lift cylinder is heavy, two people should perform this task. 1. Remove the mast assembly from the forklift.

!! WARNING • After removing the mast assembly, the middle and inner rails will easily slide. Use ropes to firmly fasten the outer, middle and inner rail top beams together. 2. Disconnect the high pressure hose at the lower end of the lift cylinder.

3. Remove the lift chain at the chain adjusting bolt.

HD-37

LIFT CYLINDER Removal (Cont’d) 3F Lift Cylinder (Cont’d) 4. Remove the securing bolt from the upper end of the lift cylinder.

!! WARNING • After removing the mast assembly, the middle and inner rails will easily slide. Use ropes to firmly fasten the outer, middle and inner rail top beams together.

5. Slide the middle rail together with the inner rail 250 mm (9.84 in) in the upper direction.

! CAUTION • Record the thickness and location of the adjusting shim used to adjust the lift cylinder height in advance. The adjustment shim is installed to the upper end of the lift cylinder.

!! WARNING • The middle and inner rails easily slide. Use ropes to firmly fasten the outer, middle and inner rail top beams together. 6. Remove the bolt from the lower end of the lift cylinder.

7. Remove the lift cylinder securing U-bolt. 8. Remove the lift cylinder.

HD-38

LIFT CYLINDER Installation (2W, 3F) Installation is in the reverse order of removal. Pay attention to the following points. • Tighten bolt at the lower end of cylinder. : 44 - 54 Nm (4.3 - 5.6 kg-m, 32 - 40 ft/lb)

• Fit the U-bolt into the cylinder, tighten the adjusting nut by hand, and fix with the lock nuts. : 26 - 32 Nm (2.6 - 3.3 kg-m, 19 - 23 ft/lb) • Fit the stopper into the hole at the end of the adjusting bolt. • Tighten the adjusting bolt, and check that the stopper contacts with the cylinder. Then, further tighten for 1/2 to 1 turn and tighten the lock nut. : 74 - 94 Nm (7.5 - 9.6 kg-m, 55 - 69 ft/lb) • When tightening the lock nut, make sure that the adjusting nut does not turn. • For 2W mast, tighten the stud bolts on the set nuts to the bottom of the threads. Apply thread lock to the threads of the stud bolt on the cylinder side. And then tighten and fasten the stud bolt on the top of the lift cylinder. So that the set nut does not become loose, secure the stud bolt with a cotter pin.

• Securely wrap seal tape around tapered threads of pipes. Never allow pieces of seal tape to enter hydraulic pipes. • O-rings are used in the connectors to couple each hydraulic unit. Before assembling, attach a guide to connector threads and insert O-ring along with it so as not to damage O-ring. • Tighten connector by hand and after determining connector position, tighten lock nut to the specified torque.

HD-39

LIFT CYLINDER Disassembly 1. Loosen cylinder head and remove from cylinder tube. 2. Disassemble cylinder head. • Tap out wiper ring/dust seal using a screwdriver.

! CAUTION • Replace removed wiper ring/dust seal with new one. (Never reuse a wiper ring/dust seal after tapping it out because outside diameter is reduced.) • Remove U-ring using a screwdriver.

! CAUTION • Replace removed U-ring with new one. 3. Remove piston rod assembly from cylinder tube.

! CAUTION • Do not disassemble piston rod assembly.

Inspection Cylinder Head Measure inside diameter of cylinder head and outside diameter of piston rod and calculate the clearance. If the clearance is greater than usable limit, replace cylinder head. Standard: 0.05 - 0.15 mm (0.0020 - 0.0059 in) Usable limit: 0.2 mm (0.008 in)

Piston Rod • Check for bent. If excessive, replace with new one. • Check whether sliding surface is damaged. If damage is minor, repair using oilstone. If serious, replace piston rod. • If hard chromium plating flakes, re-plate or replace piston rod.

Cylinder Tube If the interior is damaged, replace cylinder tube.

Dust Seal (Wiper Ring), U-Ring, O-Ring, Wear Ring and Piston Ring (Back-Up Ring) Do not reuse. Always replace with new ones.

HD-40

LIFT CYLINDER Assembly To assemble, reverse the order of disassembly. Pay attention to the following points. • Before assembling, lubricate each part with new hydraulic oil. • Clean packings in petroleum-base hydraulic oil. • During assembly, never allow foreign matter such as dust to enter parts. Cylinder head: 2W, 3F mast: 197 - 245 Nm (20 - 25 kg-m, 145 - 180 ft/lb)

Adjustment Bleeding Air 1. Add hydraulic oil up to the upper limit of level gauge. 2. Raise and lower mast slowly. 3. Lower mast fully and check the hydraulic oil capacity in tank. If hydraulic oil level is reduced, fill up to the upper limit of level gauge. 4. Repeat steps 2 and 3 until the hydraulic oil capacity is not reduced. 5. Check that cylinder moves smoothly up and down.

Adjusting of Cylinder Height NOTE: To prevent mast from being twisted and deformed, adjust the cylinder height. Be sure to adjust, especially when replacing only one cylinder. 1. Check that forklift is placed horizontally. 2. Remove lock nuts/fixing bolts at the upper ends of right and left lift (mast) cylinders. 3. Fully and slowly raise mast without load, then check whether right and left cylinders reach upper ends simultaneously. 4. If one cylinder is delayed, adjust delayed cylinder by inserting shims. Thickness of shim: 1.00 mm (0.039 in) (only one type) 5. Repeat the adjustment above until there is no difference between the right and left cylinders.

6. For 2W mast, tighten the lock nut until it reaches the incomplete thread of the stud bolt. At this time, the difference between the upper beam and the lock nut is 1 mm (0.0394 in) or more.

HD-41

FULL-FREE CYLINDER Construction 3F Mast

Cylinder tube assembly

Washer

Spring

Piston rod

Fuse piston

Cylinder head

Piston

Spring guide

O-ring

Pull-in wire

Wear ring

Backup ring

Ball

U-ring

Check valve

Circlip

Wiper ring

Spring

HD-42

FULL-FREE CYLINDER Removal

! CAUTION • Be sure to keep hands and feet out of danger.

Preparation 1. Remove from mast carriage assembly with fork. 2. Jack up the front of vehicle to keep about 120 mm (4.72 in) of clearance from lower end of outer mast to floor (refer to GI section). 3. After setting mast vertical and lower full-free cylinder at the lower end, turn ignition OFF and disconnect the battery cable.

! CAUTION • Be sure to lower full-free cylinder fully to discharge remaining pressure in pipes.

Procedures 1. Disconnect the hydraulic piping from the full-free cylinder.

! CAUTION • Oil tends to spill if hoses are disconnected, so be sure to block the end with stoppers. 2. Lift up the full-free cylinder using a nylon sling or a lifting wire. 3. Remove the full-free cylinder mounting bolt. Lift up the full-free cylinder, and remove it.

Disassembly 1. Loosen the cylinder head, and remove the cylinder head from the cylinder tube. 2. Disassemble the cylinder head. • Push the wiper ring out by hitting with a screwdriver.

! CAUTION • Replace a removed wiper ring with a new one. (Because the outer diameter of the removed wiper ring has been reduced, it cannot be reused.) • Remove the U-ring by prying with a screwdriver.

HD-43

FULL-FREE CYLINDER Disassembly (Cont’d)

! CAUTION • Replace removed U-rings with new ones. 3. Remove the piston rod assembly from the cylinder tube.

! CAUTION • Do not disassemble the piston rod assembly.

Inspection Cylinder Head Measure the cylinder head inner diameter and piston rod outer diameter, and calculate the clearance. When the clearance exceeds the limit value, replace the cylinder head. Standard: 0.05 - 0.15 mm (0.0020 - 0.0059 in) Limit: 0.2 mm (0.008 in)

Piston Rod • Check the piston rod for bending. When excessive bend is found, replace the piston rod. • Check the sliding face for damage. In case of minor damage, repair with oil stone. In case of severe damage, replace the piston rod. • When the hard chromium plating is peeled off, plate again, or replace the piston rod.

Cylinder Tube When the inner face is damaged, replace the cylinder tube.

Wiper Ring, U-Ring, Back-Up Ring, O-Ring and Wear Ring Do not reuse. Always replace with new ones.

Assembly Assemble in the reverse order of disassembly. Pay attention to the following: • Before assembling, moisten the parts with recommended Hydraulic Oil. • Clean the packing with a petroleum hydraulic fluid. • Prevent foreign objects from entering into the inside during assembly. • Tighten the cylinder head to the specified torque. Cylinder head: 3F mast: 300 - 370 Nm (31 - 37 kg-m, 202 - 272 ft/lb)

HD-44

FULL-FREE CYLINDER Installation Install in the reverse order of removal. Pay attention to the following: • 3F MAST: Adjust with the shim so that the inner mast becomes parallel to the full-free cylinder. Shim thickness: 1.0 mm (0.039 in) Then tighten the mounting bolt. : 128 - 156 Nm (13 - 16 kg-m, 95 - 115 ft/lb)

• Seal the taper threads of the piping with seal tape securely. Prevent chips of the seal tape or other foreign object from entering into the hydraulic piping. • O-rings are used at the connectors which connect the hydraulic units. When assembling, insert the connector with a guide on the threads so that the O-ring is not damaged. • Screw in the connector by hand. When the connector is positioned, tighten the lock nut to the specified torque. (For the tightening torque, refer to “Mast Piping”.)

Adjustment Bleeding Air 1. Add hydraulic fluid to the upper limit of the level gauge. 2. Lift the mast slowly, then lower it slowly. 3. Lower the mast fully, and check the hydraulic fluid amount in the tank. When the hydraulic fluid amount is low, add to the upper limit of the level gauge. 4. Perform the operations mentioned in steps 2 and 3 above repeatedly until the hydraulic fluid amount does not decrease. 5. Move the cylinder up and down, and check for smooth operation.

HD-45

OIL TANK Disassembly

HD-46

LOADING MECHANISM

SECTION

CONTENTS SERVICE DATA AND SPECIFICATIONS . . . LM-2 Inspection and Adjustment . . . . . . . . . . . . . LM-2 Tightening Torque . . . . . . . . . . . . . . . . . . . . LM-3 TROUBLE DIAGNOSES AND CORRECTIONS . . . . . . . . . . . . . . . . . . . . LM-4 PRECAUTIONS AND PREPARATION . . . . LM-5 Precautions . . . . . . . . . . . . . . . . . . . . . . . . LM-5 Removing/Reducing Hydraulic Pressure . . . LM-5 FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LM-6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . LM-6 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . LM-6 Fork Maintenance and Inspection . . . . . . . . LM-7 Inspection of Fork . . . . . . . . . . . . . . . . . . . . LM-12 LIFT CHAINS . . . . . . . . . . . . . . . . . . . . . . . . LM-13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . LM-13 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . LM-17 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . LM-19 CARRIAGE ASSEMBLY . . . . . . . . . . . . . . . LM-20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . LM-20 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . LM-21 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . LM-21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . LM-22 MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LM-23 Mast Assembly . . . . . . . . . . . . . . . . . . . . . . LM-23 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . LM-25 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . LM-27 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . LM-29 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . LM-29 Installation . . . . . . . . . . . . . . . . . . . . . . . . . LM-37 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . LM-38

SERVICE DATA AND SPECIFICATIONS Inspection and Adjustment Adjustment Specifications Applied model

2W5/2W6 series

Outer mast-to-inner mast clearance

mm (in)

0.1 - 0.6 (0.004 - 0.024)

Mast-to-liner clearance

mm (in)

0.1 - 0.6 (0.004 - 0.024)

Mast-to-mast roller rolling surface clearance

mm (in)

0.1 - 0.6 (0.004 - 0.024)

Inner mast-to-carriage roller side face clearance

mm (in)

0.1 - 0.6 (0.004 - 0.024)

Inner mast-to-carriage roller rolling face clearance

mm (in)

0.1 - 0.6 (0.004 - 0.024)

Mast forward/backward tilting angle

2W, 3F

(°)

Carriage lower edge-to-ground distance

mm (in)

Lower end of outer mast-to lower end of inner mast 3F MAST

mm (in)

Mast install angle Chain tension

Lift roller lapping allowance pitch (Dimension “L”)

mm (in) 2W

Lift roller lapping allowance pitch (Dimension “L”)

mm (in) 3F

3°/3° (2W5 only) 2W5: 75 (2.9) / 2W6: 85 (3.3) 0 (0)

(°)

0° ± 30’ (2W6 only)

mm (in)

25 - 30 (0.98 - 1.18)

2,700 (106.30), 3,000 (118.11), 3,300 (129.92)

283 (11.14)

3,500 (137.80)

318 (12.52)

3,850 (151.57), 4,300 (169.29), 4,750 (187.01), 5.150 (202.76)

369 (14.53)

5,500 (216.54)

384 (15.12)

Adjusting Shim / Roller Applied model

2W5/2W6 series

Carriage roller adjustment shim

mm (in)

0.5, 1.0, 2.0 (0.020, 0.039, 0.079)

Carriage side roller and thrust metal adjustment shims

mm (in)

0.5, 1.0, 2.0 (0.020, 0.039, 0.079)

mm (in)

0.5, 1.0 (0.020, 0.039)

Liner adjustment shim

Inner mast roller

mm (in)

3,500 or more (137.80 or more)

3F Middle mast roller

mm (in)

97, 97.5, 98 (3.82, 3.84, 3.86) Upper

97.0 (3.819)

Lower

105, 105.5, 106 (4.13, 4.15, 4.17)

Outer mast roller Carriage roller

mm (in) mm (in)

Upper and lower

Lift cylinder adjustment shim Full-free cylinder adjustment shim

LM-2

97 (3.819) 97, 97.5, 98 (3.819, 3.839, 3.858)

Center

Mast roller adjustment shim

105, 105.5, 106 (4.13, 4.15, 4.17)

97 (3.819) mm (in)

0.5, 1.0, 2.0 (0.0197, 0.0394, 0.0787)

mm (in)

1.0 (0.039)

mm (in)

1.0 (0.039)

SERVICE DATA AND SPECIFICATIONS Tightening Torque Nm (kg/m, ft/lb) Nm (kg/m, in/lb)*

Unit Backrest installation

Backrest securing bolt

177 - 225 (18 - 23, 131 - 165)

Lift chain installation

Lock nut

92 - 124 (9.4 - 13.0, 69 - 93)

Carriage reassembly

Side roller securing bolt

21 - 26 (2.1 - 2.7, 192 - 228)*

Lift cylinder upper side bolt

Lift cylinder lower side bolt Mast reassembly

Full-free cylinder set bolt

Mast installation (2W5)

Mast installation (2W6)

44 - 54 (4.4 - 5.6, 32 - 40)

U-bolt lock nut

78 - 98 (7.9 - 10.0, 58 - 72)

128 - 156 (13 - 16, 95 - 115) 26 - 32 (2.6 - 3.3, 19 - 23)

U-bolt adjusting bolt lock nut

74 - 94 (7.5 - 9.6, 55 - 69)

Lift chain anchor bolt lock nut

92 - 124 (9.4 - 13.0, 69 - 93)

Mast support cap securing bolt

89 - 118 (9.1 - 12.0, 66 - 87)

Tilt cylinder pin retaining bolt

21 - 27 (2.1 - 2.7, 180 - 240)*

Tilt cylinder rod lock nut

108 - 147 (11 - 15, 80 - 108)

Mast support cap

89 - 118 (9.1 - 12.0, 66 - 87)

Main mast mount bracket

LM-3

Stand torques

TROUBLE DIAGNOSES AND CORRECTIONS

! CAUTION • The following table lists only typical examples. To perform an accurate diagnosis carefully listen to the user’s complaints and check the actual vehicle to fully understand under what conditions the symptoms occur. Condition

Probable cause • Improperly adjusted carriage bracket assembly

Forks do not raise or lower smoothly.

Corrective action • Adjust clearances between parts (such as inner mast, side roller, thrust metal, carriage roller). Replace faulty parts with new ones. • Adjust using shim(s) or liner.

• Improperly adjusted inner mast-to-outer mast clearance or roller-to-mast clearance • Insufficient lubrication • Apply grease to contacting/sliding surfaces of parts. • Caught foreign matter in functional parts • Remove foreign matter. • Deformed inner mast • Adjust. • Bent carriage bracket assembly • Adjust or replace.

Forks rising unstable

• Improperly adjusted lift chain(s)

• Adjust lift chain tension. • Clean lift rollers and grease.

Lift rollers fail to rotate.

• Solidified grease on rollers or sliding surfaces or accumulated dirt/dust • Lift roller(s) are improperly installed. • Roller(s) are broken or damaged.

• Apply grease. • Adjust.

Mast assembly emits noise.

• Insufficient lubrication • Improperly adjusted lift rollers, side rollers and/or liners • Worn chain wheels, lift rollers and/or liners • Damaged lift rollers and/or mast rollers

LM-4

• Check and adjust lift rollers. • Replace faulty rollers.

• Replace worn parts. • Replace damaged rollers.

PRECAUTIONS AND PREPARATION Precautions

! CAUTION • Most of the loading mechanism parts such as forks, mast, carriages, etc. are heavy. The hoisting and movement of those objects are inherently dangerous. Therefore, be extremely careful and always employ an assistant when you remove them. • When removing/installing cylinder, always perform the procedure with two persons because of heavy weight, paying attention not to catch hands by components. • Be extremely careful to protect your hands, feet, etc., when performing maintenance work on or moving heavy objects. • Always assign lifting operations to qualified operators trained in slinging or hoisting procedures. • Before removing hydraulic lines or piping, the oil pressure remaining in hydraulic lines must be completely bled off. • Always have container or rags to catch any oil that may leak out.

Removing/Reducing Hydraulic Pressure • For tilt piping (2W5 only), first place the fork horizontal (tipped slightly forward) and turn the ignition off. Next, loosen the piping and let set while the remaining pressure escapes. • For lift piping, place the fork at the lowest position, turn the ignition off, loosen the shut-off valve and let the remaining pressure escape. • For attachment piping (3rd) • Union connector Place the attachment in neutral, turn the ignition off, loosen the piping, and let set while the remaining pressure escapes. • Coupling Installing and removing the cup may be difficult if the remaining pressure inside the piping is high. If this is the case, turn the ignition ON and tip the lever (3rd) backwards or forwards, and one of the cups will come off. Then tip the lever in the other direction and remove the other cup. • Always clean up any hydraulic oil that is on the floor. NOTE: • The fork assembly must be removed as required to make maintenance work easier to perform. • Disassembly of the carriage bracket assembly requires the removal of the forks. Following the removal of forks, remove the carriage bracket assembly from the mast assembly. • If the carriage bracket assembly needs not be disassembled upon removal, remove it with the forks installed to it. This will prevent the carriage assembly from toppling over. • When the mast assembly and carriage bracket assembly are to be removed as a unit, remove the fork assembly beforehand.

LM-5

FORK Removal

! CAUTION • For removal of the fork assembly and carriage assembly as a unit, refer to “CARRIAGE ASSEMBLY”. 1. Raise the forks approximately 100 to 200 mm (3.94 to 7.87 in) above the ground. 2. Turn the lock levers 90° at the upper ends of the forks, then move the forks to the notched portion located in the center of the carriage assembly. 3. While lifting the tips of the forks, disengage the jaws from the carriage (finger bar). Lift the upper portions of the forks up and away from the carriage assembly. Always remove one fork at a time.

Inspection • Check the forks for wear (as shown in the figure). If wear exceeds specifications, replace the forks with new ones. Standard wear limit: More than 3 mm (0.12 in) • Visually check the forks for cracks, deformation or separation of welds. If necessary, replace with new fork assembly. • Check the forks using a dye penetration method. If they are cracked, replace with new ones. • Visually inspect the fork and replace it if cracked or damaged. (To identify minute cracks, use the dye penetrant method.) • If the fork is worn by 3 mm or more compared to a new one, replace it. (The grounding face at the fork base is prone to wear.)

LM-6

FORK Fork Maintenance and Inspection Fork Wear vs Capacity • Forks for counterbalanced and straddle lift trucks are not just bent bars of steel. The manufacturing process is careful and precise with many checks and inspections critical to their safety. Some factors essential to fork manufacture include the steel, the bend thickness of the heel, the welding of the hooks that hold them on the carriage, and the heat treatment of the finished product. • Finished forks are usually painted red, yellow or black when the truck is new. The paint is quickly scraped off once the truck is put into service. The top paint is abraded by the pallet or load and the bottom is worm mostly by contact with the floor. • Lift truck operators are taught to keep their forks low and parallel with the travel surface when traveling empty and tilted back when carrying a load. But some operators go to extremes and travel with the heel of surface of the fork and reduces the capacity of the fork. • Once in service, the bottom of forks may wear badly. This wear may not be noticed, but the consequences are. There are ANSI specifications for User Fork Wear Standards. They are part of the B56 standards by which lift trucks are manufactured and tested. Few operators or fleet managers know of the standards or understand that forks must be inspected. • While the Industrial Truck Association (ITA) recommends that forks be withdrawn from service when fork blade thickness has been reduced by 10%, few users understand that a 10% reduction in blade thickness results in a capacity reduction of 20%. This means that the safety factor for a pair of forks has also been reduced by 20%. • Measuring fork wear is not intuitive. You should make it a part of maintenance or inspection routines.

LM-7

FORK Fork Maintenance and Inspection (Cont’d) Fork Inspection • Forks should be inspected at least once a year (single-shift operation, and more frequently in severe applications) for wear and distortion. The best method is to use a fork caliper, which is a type of adjustable go/no-go gauge. • Each fork consists of two sections: the shank, which is the verical part attached to the carriage, and the blade, which is the portion that picks up the load. • The caliper is first set using the shank of the fork on which there is little or no wear. Then that dimension is used to check the shank back near the heel of the blade. The four contact points of the special fork caliper automatically measure the wear on the blade. • Wear is checked by first measuring the thickness of the verical shank portion of the fork because this part wears little. The interior part of the caliper has two additional points that automatically show a 10% reduction of the shank thickness. These points are slid over the fork blade. If the caliper slides down the blade to the heel, the fork is worn beyond safety and usefulness. It should be replaced. The accompanying chart shows the reduction in capacity as the fork wears.

Using a Caliper Setting a caliper Set the front teeth of the jaws by measuring the thickness of the shank. Ensure that the caliper is held square across the shank for an accurate reading. The caliper is now set to measure the fork arm blade.

Checking blade thickness Position the jaws of the caliper over the flanks of the fork arm blade. Ensure that the measurement is taken at least 1” (25mm) away from the start of the heel radius. If the inside teeth of the caliper hit the fork, it has less than 10% wear and can remain in service. NOTE: Standard Cascade calipers can be used up to and including 100mm, (4” thick). They are not to be used on full or lumber tapered forks where the upright thickness is greater than that of the blade. In these cases 10% reduction must be obtained by measurement, you will need to know the original fork blade thickness.

LM-8

FORK Fork Maintenance and Inspection (Cont’d) Using a Caliper (Cont’d) When to replace forks If a caliper does not pass over freely, the fork arm must be taken out of service. This represents 10% wear and 20% reduction in capacity.

Checking fork heel angle A. Open the calipers to approximately 90° and place the calipers in the top inside heel area of the fork (on top of the blade). B. Ensure that the 2 lower pieces on the horizontal leg are both touching the top of the blade. C. Move the calipers towards the upright. Ensure that the caliper arms are both parallel to the blade and to the upright. D. Open/close the calipers so that the two similar extruding pieces on the vertical leg of the calipers both touch the upright/shank of the fork. E. When you are sure that all 4 points are simultaneously in contact with the fork, gently remove the calipers and look at the indicator line found at the top of the hinge pin. NOTE: If the line on the horizontal leg of the caliper (that points vertically) is found to lie beyond either the 93º or 87º indicator line, the fork should be marked to be checked for either permanent deformation, possible stress cracks or any other defect that could impede the safe use of the fork.

LM-9

FORK Fork Maintenance and Inspection (Cont’d) Using a Caliper (Cont’d) Checking fork hooks Check for wear/straightness of fork hooks. Use the end of the caliper designed for your fork class (Class I, II, or III). If the fork caliper slides entirely into the hook pocket (Diagram B) the fork must be removed from service.

Checking shaft/pin forks Measuring the bore on shaft/pin type forks. The wear caliper can be used as both “outside” and “inside” calipers for general measurements. As an inside caliper they are useful for measuring the bore of the eye or bushing on shaft/pin type fork arms. To convert to an inside caliper just rotate the arms of the caliper until the teeth are on the outside (see Diagram 1). Insert the reversed caliper inside the eye of the tube (see Diagram 1) opening the teeth until both sides of the teeth come in contact with this inside wall of the tube. Pull the caliper out and measure the distance from tip to tip (Diagram 2).

LM-10

FORK Fork Maintenance and Inspection (Cont’d) Fork Use Guidelines Use your forks correctly: 1. Inspect forks regularly. 2. Make sure the fork capacity meets or exceeds truck capacity rating and load weight center. 3. Obtain written approval from fork manufacturer prior to making any fork modifications/repairs. 4. Determine for wear cycle and replacement schedule for your operation. Use of larger forks in demanding applications will extend fork life. 5. All positioning locks must be in place at all times. Forks must be properly seated on the carriage and the positioning locks fully located in the slot before use. What not to do: 1. Do not overload the fork beyond its rated capacity. 2. Do not change fork from one lift truck to another without knowing capacities of each truck and fork. 3. Do not use a fork in an application for which it is not designed. 4. Do not add a fork extension longer than 150% of the supporting fork’s length. 5. Do not try to repair or modify forks in the field, especially by welding. Improper welding destroys heat treat properties and makes the forks brittle. 6. Do not carry full or partial loads on one fork. 7. Do not apply sideways pressure to forks, commonly called “side loading” as they are designed for vertical loading only. (This reprint courtesy of Cascade Corporation)

LM-11

FORK Inspection of Fork Fork Capacities per Pair Full Tapered and Polished Forks, Reduce Capacity by 15% Thickness and Width (inches)

Lbs. at 24" LC

Lbs. at 36" LC

Lbs. at 48" LC

1-1/2 x 2

2100

2x2

3700

2750

2 x 1-1/2

2900

1900

1x4

1950

1-1/4 x 4

3000

2000

1500

1-1/2 x 4

4100

2900

2100

1-3/4 x 4

5800

4000

2900

2x4

7000

5200

3900

1x5

2450

1-1/2 x 5

5400

3800

2700

1-3/4 x 5

7100

5200

3700

2x5

9200

6500

4800 7600

2-1/2 x 5

15000

10500

1-3/4 x 5-1/2

7700

5750

1x6

2900

1-1/2 x 6

6500

4500

1-3/4 x 6

8950

6000

2x6

11000

8200

2-1/4 x 6

17000

12100

8500

3x6

25000

18500

12500

1-1/2 x 7

7600

5000

3800

2x7

13500

9000

6400

2-1/2 x 7

21000

15000

10000

3x7

30000

21000

14500

5500

1-1/2 x 8

8750

6000

4300

2x8

15500

10500

7500

2-1/2 x 8

24000

16000

11500

2-3/4 x 8

28000

20000

13500

3x8

33000

24000

16500

3-1/2 x 8

45000

32000

22500

1-1/2 x 10

10500

7500

5400

2 x 10

18500

13500

9500

2-1/2 x 10

28000

21000

14000

2 x 12

22000

16000

11000

• All fork ratings shown are based on minimum safety factor of 3:1 with static load. • Capacities shown are based on A.I.S.I. 4142 bar heat treated to industry accepted range. • Capacities for fork sizes not shown are available from sales department.

LM-12

LIFT CHAINS Installation To install the lift chains, reverse the removal procedures.

Inspection / Adjustment of Lift Chain Tension Each 50-250 hours of operation (more frequently in severe or extreme environments), chains should be inspected and lubricated. Inspection should involve the following: 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 7-1. 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 7-1. Worn contours and worn surfaces on the outside links or pin heads should not exceed 5% of new height.

Figure 7-1

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 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 7-1.

LM-13

LIFT CHAINS 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.

Figure 7-2 Arc-like cracks in plate are a sign of stress corrosion. Corrosion Fatigue: Corrosion fatigue cracks are very similar (in many cases identical) to normal fatigue cracks in appearance. They generally begin at the pin hole and move perpendicular (90°) to the chain pitch line. Corrosion fatigue is not the same as stress corrosion. Corrosion fatigue is the combined action of an aggressive environment and a cyclic stress (not a static stress alone, as in stress corrosion. Ultimate Strength Failure This type of failure is caused by overloads far in excess of the design load. See Figure 7-3.

Figure 7-3 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.

Fatigue Cracking • Fatigue cracks are a result of repeated cyclic loading beyond the chains endurance limit. The magnitude of the load and frequency of its occurrence are factors which determine when fatigue failure will occur. The loading can be continuous or intermittent (impulse load). • Fatigue cracks almost always start at the link plate pin hole (point of highest stress) and are perpendicular to the chain pitch line. They are often microscopic in their early stage. Unlike a pure tensile failure, there is no noticeable yielding (stretch) of the material. Stress-Corrosion Cracking • The outside link plates which are heavily press fitted to the pins, are particularly susceptible to stress corrosion cracking. Like cracks, these initiate at the point of highest stress (pin hole) but tend to extend in an arch-like pattern between the holes on the plate. • More than one crack can often appear on a link plate. In addition to rusting, this condition can be caused by exposure to an acidic or caustic medium or atmosphere. • 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. • If a plated chain is required, consult factory. Plated chains are assembled from modified, individually plated components which may reduce the chain rating. Cleaning and Routine Maintenance • The chains and related connecting hardware should be cleaned, inspected and lubricated every 200 hours or sooner depending on application. Chains that are exposed to corrosive chemicals or steam cleaning may need to be inspected more frequently. Chains themselves should not be steam cleaned.

LM-14

LIFT CHAINS Cleaning and Routine Maintenance (Cont’d) • *The chains should be wiped off with a cloth or brushed off with a fine brush to remove any build up of grease and dirt to clearly expose the chain elements and joints. A heavy layer of grease remaining on the chain may prevent the lubricant from entering the joint area. The appearance of a heavy grease on the outside of the chain may provide the appearance of proper lubrication; however, the lubricants may not be entering the pivoting joints. • *Each link and connection should be checked for turned pins, cracked links, damage pins, or stiff links. This may require raising and lowering the mast to obtain good visibility of all areas. The evidence of surface rust on the chain may be evidence of insufficient lubrication in the joint area. Any chain or connector with damage should be replaced. Chain with the appearance of stiff links should be replaced. The stiff link is an indication of insufficient lubrication and damage in joint area. Any chain or connector with damage should be replaced. Chain with the appearance of stiff links should be replaced. The stiff link is an indication of insufficient lubrication and damage in joint area. • *The complete chain and connections should be lubricated completely with an oil with a viscosity similar to SAE 20 wt. oil or Chain Oil. A nondetergent oil is recommended: however, synthetic oils with solid lubrication such as molybdenum disulfide may be used. The oil can be applied with a fine brush but must be applied in all area such that the oil can penetrate the joint area. Cycling the mast will help work the lubricate into the joint. The lubricant must penetrate the joint in order to be effective. Measuring Chain Stretch • Chain stretch can be measured with Chain Wear Scale. Measure the chains according to the instruction printed on the scale, without a load on the carriage. If the chains are stretched beyond the recommended amount, they should be replaced in pairs. See page LM-19. • * To check the free lift chains, raise the carriage 1 ft. (30 cm) off the ground to put tension on the chains. • * To check the main lift chains, raise the mast until the inner upright starts to extend to put tension on the chains.

Figure 7-6 Using Chain Wear Scale

LM-15

LIFT CHAINS Chain Length Adjustment

!! WARNING

Figure 7-6 Using Chain Wear Scale

Failure to follow these warnings can result in serious injury. An upright or carriage can move unexpectedly: • The carriage stop must not be allowed to contact the upright stop under any circumstances during normal operations. • 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.

! CAUTION • Threaded chain anchors must be left free to pivot in mounting hole. • Anchor pin heads must be to the inside of the upright. • Make sure chain anchors are secured so that no twist is evident in the chains. • Before installing the chain anchor bolts, ensure that the lift chain is not twisted. • Discard old cotter pins; replace with new ones. Lock nut: : 92 - 124 Nm (9.4 - 13.0 kg/m, 69 - 93 ft/lb)

LM-16

LIFT CHAINS Adjustment

! CAUTION • Before adjusting lift chain tension, park the vehicle on flat and solid ground. • On pneumatic tire models, inflate the tires to the specified pressure. • As for the 3F mast, adjust the mast chain and lift chain. 1. Set the mast assembly in the vertical position and lower the carriage assembly all the way down. 2. Turning the adjustment nut in or out, adjust the carriage assembly until its lower end above the ground is within specifications. Standard clearance: 2W5: 75 mm (2.95 in) 2W6: 85 mm (3.35 in)

3. For the 3F mast, after the adjustment of the lift chain mentioned above, raise the carriage gradually to adjust the adjustment nut of the mast chain so that the difference between the inner mast lower end and the outer mast lower end conforms to the standard value. Standard: 0 mm (0 in)

LM-17

LIFT CHAINS Adjustment (Cont’d) 4. With the fork assembly attached to the carriage, adjust the lift chain adjustment nut so the midpoint of the lift chain can be pulled (2W mast) or pressed (3F mast) 25 to 30 mm (0.98 to 1.18 in). The left and right lift chains must be equally adjusted.

! CAUTION • Check to ensure that the left and right chains are tensioned equally. Lock nut: : 92 - 124 Nm (9.4 - 13 kg/m, 69 - 93 ft/lb) 5. After making the mast and lift chain tension adjustments, move the carriage assembly up and down to ensure it moves smoothly. NOTE: Every 200 hours of operation or once a month, whichever occurs first, apply a coat of recommended motor oil to the lift chains requiring lubrication.

LM-18

LIFT CHAINS Inspection • Visually inspect the lift chains for cracks, breaks or damage. If necessary, replace the left and right lift chains as a unit. • To check the lift chain for elongation, raise the forks approximately 20 to 30 mm (0.79 to 1.18 in) above the ground. NOTE: • Balance the tension between left and right chains. • Cracks or breakages often occur at the ends of the lift chains. If necessary, replace both chains as a unit. • Elongation often occurs in portions of the lift chain which experiences contact with the chain wheel.

How to Inspect the Lift Chain (Reference) 1. Tilt the mast to vertical position. 2. Lift the fork to above 5 cm from the ground. 3. Confirm the chain type. The type of the chain is stamped on the side of the chain. However, special care is needed for the following chain as the number stamped on the chain is different from the chain type number. Stamp on the chain

Chain type

BL5

BL534

BL6

BL634

BL8

BL834

BL10

BL1034

BL12

BL1234

4. Apply the chain gauge and measure the chain length counting the appropriate number of links for the chain type. Replace the fork chain when the length exceeds the limit. BL834 (14 links), RS40 (28 links), RS80 (14 links): Standard length: 355.6 mm (14.000 in) limit length: 364.4 mm (14.346 in) BL534 (22 links), BL1034 (11 links), RS50 (22 links), RS100 (11 links): Standard length: 349.2 mm (13.748 in) limit length: 358.0 mm (14.094 in) BL634 (18 links), BL1234 (9 links), RS60 (18 links), RS120 (9 links): Standard length: 342.9 mm (13.500 in) limit length: 351.4 mm (13.835 in)

LM-19

CARRIAGE ASSEMBLY

Removal NOTE: Removal of the carriage assembly and fork assembly as a unit prevents the carriage assembly from toppling to the ground. 1. Set the mast assembly in the vertical position, then lower the forks to the ground. NOTE: When removing the carriage assembly without forks, attach a lifting wire/nylon sling, then support the carriage assembly using a hoist or crane. 2. Disengage the lift chains at the adjusting bolt and lift chain joint links on the mast side, then drape the lift chains over the backrest. 3. Slowly raise the inner mast, then remove the carriage assembly from the mast assembly.

! CAUTION • Be careful to prevent the mast from catching the removed lifting chain. 4. Back up the vehicle, then remove the carriage assembly from the mast assembly.

! CAUTION • Be sure to lower the inner mast to the ground after backing the vehicle up.

LM-20

CARRIAGE ASSEMBLY Inspection Lift Rollers, Side Rollers and Shims Check for unsmooth rotation, deformation, stepped wear or damage. Replace faulty parts with new ones if necessary.

Carriage Assembly • Visually check for cracks, deformation or separation at welds. If necessary, replace with new ones. • Check the carriage assembly using a dye penetration method. If it is cracked, replace with a new one.

Adjustment 1. Select suitable rollers so that the clearance between the rolling contact surface of the inner mast rail and the carriage roller are within specifications. Standard clearance: 0.1 - 0.6 mm (0.004 - 0.024 in) Available roller sizes: 97.0, 97.5 and 98.0 mm (3.819, 3.839 and 3.858 in) Center mast roller diameter (2W/3F mast): 97.0 mm (3.819 in) 2. Measure the inner wall width (A) of the inner mast at three points (two at upper and lower ends of the inner mast and one in the center of the inner mast at the cross beam location).

LM-21

CARRIAGE ASSEMBLY Adjustment (Cont’d) 3. Measure the pitch of the left and right carriage side rollers, carriage rollers and thrust metals (at points “B”, “B’” and “B””). NOTE: • The upper and middle carriage rollers for 2W/3F mast are used only for lift rollers. The lower carriage roller is guided and rolls to the right and left within the rail race. • Independent side rollers are located on the upper portion of the carriage assembly. 4. Calculate carriage clearances by subtracting the maximum pitch values of the carriage side rollers, carriage rollers and thrust metals (B) from the measured minimum inner wall width of the inner mast (A). 5. Whenever possible, use the same number of adjustment shims to equalize left and right clearances. 6. The difference in shim thickness between right hand side and left hand side shim shall be 0.5 mm (0.020 in) max. Standard carriage clearance: 0.1 - 0.6 mm (0.004 - 0.024 in) Available adjustment shims: For use with carriage side rollers and thrust metals 0.5, 1.0 and 2.0 mm (0.020, 0.039 and 0.079 in) For use with carriage rollers 0.5, 1.0 and 2.0 mm (0.020, 0.039 and 0.079 in)

! CAUTION • Be extremely careful when adjusting carriage clearances. Improper adjustment may cause the carriage bracket to deviate either to the left or right, or tilting of the finger. These conditions will result in unequal heights for the left and right forks. 7. After carriage clearance adjustment, check to ensure that the carriage assembly moves smoothly without binding.

! CAUTION • Apply a coat of grease to the roller rolling contact surfaces and thrust metal contacting surfaces (indicated by arrows in the figure).

Installation To install the carriage assembly, reverse the order of removal. Observe the following:

! CAUTION • Discard old cotter pins; replace with new ones.

LM-22

MAST Mast Assembly 2W Mast

LM-23

MAST Mast Assembly (Cont’d) 3F Mast

LM-24

MAST Removal

! CAUTION • When removing the mast assembly, ensure the forks are removed beforehand. This is a precaution to ensure the safest possible maintenance procedure. NOTE: If the carriage assembly need not be disassembled, remove the carriage assembly together with the forks prior to removing the mast assembly. Refer to “CARRIAGE ASSEMBLY” for instructions.

1. Remove the hoses (lift hose, attachment hoses, etc.), then plug their openings to prevent foreign matter from getting into the hydraulic lines.

! CAUTION • The oil pressure remaining in hydraulic lines must be completely bled off. NOTE: When removing the lift hose together with the carriage assembly, relieve oil pressure in the hydraulic lines beforehand. Attach a lifting wire or nylon sling to the carriage, then suspend it in the air with a hoist to facilitate access to the mast assembly. 2. Attach a lifting wire or nylon sling to the upper beam of the mast assembly, then support the mast assembly using a hoist.

! CAUTION • Be sure to support mast assembly, failure to do so may cause serious injury or costly damage to the mast or other equipment.

3. Remove the mast support cap bolts; remove the mast support cap from the mast support, located at the frame by the inner sides of the front tires (on 2W5) and inside of base legs (on 2W6).

LM-25

MAST 2W5 Only

Removal (Cont’d) 4. (2W5 only): Remove the pivot pin lock bolts, then remove the pivot pins securing the tilt cylinder to the mast assembly. 5. Turn the ignition to the ON position, retract the tilt cylinder all the way (tilting the mast assembly backward).

! CAUTION • Be sure to retract the tilt cylinder all the way, failure to do so may interfere with the tilt bracket when installing the mast assembly. 2W6 Only 6. (2W6 only): Remove pin G.

7. Using a hoist, lift the mast assembly up and away from the vehicle, then lower it horizontally onto blocks.

! CAUTION • Be careful not to damage brake pipes, etc. while lifting or moving the mast assembly away from the vehicle. • When removing the mast assembly and carriage assembly from the vehicle as a unit, securely fasten the tilt beam and carriage assembly (finger bar) with a rope or wire. This prevents carriage assembly movement when mast assembly is transferred to the ground. • Always ensure the mast assembly rests on a flat and solid surface after it has been removed. • When positioning the mast assembly on the block, be careful not to damage the mast support.

LM-26

MAST Removal (Cont’d) 8. When the mast assembly and carriage assembly are removed as a unit, remove the carriage assembly from the mast assembly as follows: • Attach a lifting wire or nylon sling to the carriage assembly and lift using a hoist. • Disengage the lift chains at the lift joint link and adjustment bolt on the mast side, then place the disengaged lift chains on the carriage. • Slide the carriage down and extract it from the lower side of the inner mast.

! CAUTION • Do not allow the mast assembly to snag or catch the lift chain when removing the carriage assembly from the inner mast.

LM-27

MAST Disassembly 2W Mast 1. Remove the hydraulic lines from the lift cylinders. 2. Remove the fixing nuts from the upper ends of the lift cylinders.

3. Draw out the inner masts from the upper end of the outer mast, then remove the bolts from the lower ends of the lift cylinders and the U-bolts. Remove the lift cylinders.

4. Remove the chain wheels, if necessary. 5. Slide the inner mast down. Remove the four mast rollers from the lower end of the inner mast and upper end of the outer mast.

! CAUTION • Be careful not to catch your hands by sliding mast. • Be careful not to catch your hands when roller is being removed from mast. 6. Remove the liners from the outer mast.

7. Attach a lifting wire or nylon sling. Using a hoist, lift the lifting wire or nylon sling until the inner mast is lifted free of the outer mast.

! CAUTION • Be sure to remove the mast rollers in advance, otherwise, inner mast cannot be removed from the outer mast with the mast rollers installed in position.

LM-28

MAST Disassembly (Cont’d) 3F Mast 1. Remove the piping connected to the head block (with the chain wheel) and full-free cylinder. • Remove the chain wheel from the head block if necessary.

2. Remove the full-free cylinder. 3. Remove the mast chain and chain wheel. (3F mast) 4. Remove the piping connected to the mast cylinder. 5. Remove the mast cylinder mounting bolt (upper and lower) and the U-bolt, and remove the mast cylinder. 6. Slide the inner mast and middle mast (3F mast) downward, and remove the mast roller.

! CAUTION • Do not remove the rollers of the 3F mast at one time. Remove the rollers of the inner mast first, then those of the middle mast in this order. • Be careful not to pinch your hand when the mast slides. • Be careful not to pinch your hand when the roller is removed from the mast. 7. Remove the liner from the outer mast and middle mast (3F mast). 8. Pass nylon slings or wires in the mast of the inner mast first, then the middle mast (3F mast) in this order. While lifting them by a hoist, etc., pull them upward over the outer mast.

! CAUTION • Because the inner mast and the middle mast (3F mast) cannot be pulled out if the mast roller has not been removed, special care should be taken.

LM-29

MAST Inspection Lift Rollers Check for unsmooth rotation, deformation, stepped wear or damage. If necessary, replace with new ones.

Liners Check for wear or damage. If necessary, replace with new ones.

Chain Wheels Check for cracks or damage. If necessary, replace with new ones.

Piping Check for cracks, breakage or damage. If necessary, replace with a new one.

Mast Assembly Check for cracks, damage or breakage at welds. If necessary, replace with new one as an assembly.

Assembly

! CAUTION • Assemble the mast assembly while adjusting various parts.

2W Mast 1. Attach a lifting wire or nylon sling to the inner mast. Using a hoist, lift the inner mast and guide it into position for reinstallation to the outer mast. 2. Slide the inner mast down, then install the liner and mast rollers.

! CAUTION • Be sure to install mast rollers in the correct places, since the inner and outer mast rollers are different in diameter. Outer mast roller diameter: 97.0 mm (3.819 in) 3. Select suitable mast rollers so the clearances between the rolling contact surfaces of the inner mast roller and outer mast rail are within specifications. Standard clearance: 0.1 - 0.6 mm (0.004 - 0.024 in) Available roller sizes: Mast height: All (137.80 or more in): 105.0, 105.5, 106.0 mm (4.13, 4.15, 4.17 in) • Apply a coat of grease to the rolling contact surface of the mast rail.

LM-30

MAST Assembly (Cont’d) 2W Mast (Cont’d)

! CAUTION • After adjustment, ensure that the mast assembly moves smooth. 4. According to the following procedures, adjust the liners. • Using a thickness gauge, measure the inner mast-to-liner clearance on each side. • If the clearance is outside specifications, use the same number and thickness of shims on each side to adjust the clearance. Standard clearance: 0.1 - 0.6 mm (0.004 - 0.024 in) Available shims: 0.5 and 1.0 mm (0.020 and 0.039 in)

! CAUTION • When installing the liners after making shim adjustments, apply a coat of bearing grease to the sliding surfaces of the liners and mast assembly. NOTE: The liners are push-in type for easy positioning in the mast assembly. Adjustments with the mast assembly installed to the vehicle. • For removal procedure of carriage assembly, refer to “CARRIAGE ASSEMBLY”. For removal procedure of lift cylinder, refer to HD section. • Lower the inner masts approximately 120 mm (4.72 in), then adjust the shim of liner in the same manner as previously described. 5. To adjust the mast rollers using adjustment shims, proceed as follows: • Extend the mast and adjust the roller pitch (Dimension “L”) for the inner and outer mast rollers according to the forklift model series, as shown in the table below.

Unit: mm (in)

Lifting height

Dimension “L”

2,700 (106.30), 3,000 (118.11), 3,300 (129.92)

283 (11.14)

3,500 (137.80)

318 (12.52)

• Move the inner mast all the way to either side of the inner wall of the outer mast. • Using a thickness gauge, measure the clearance between the mast and mast roller on the opposite side.

LM-31

MAST Assembly (Cont’d) 2W Mast (Cont’d)

! CAUTION • The mast-to-mast roller clearance must be measured at four points (upper, lower, left and right). • Lower the inner mast, then measure the mast-to-mast roller clearance at or near the center cross beam of the outer mast. • Using the same number and type of outer mast roller adjustment shims, equally adjust the outer mast roller-to-inner mast clearance on the left and right sides of the mast assembly until the clearance is within specifications. • Difference between left hand and right hand shim thickness shall be 0.5mm (0.020 in). • Using the minimum clearance value of the measurements obtained from the upper and middle (at cross beam) portions, select suitable inner mast roller adjustment shims. The left and right inner mast roller clearances must be adjusted equally as much as possible. Standard clearance: 0.1 - 0.6 mm (0.004 - 0.024 in) Available adjustment shims: 0.50, 1.00 and 2.00 mm (0.020, 0.039 and 0.079 in) 6. If previously removed, install the chain wheels on the inner masts. 7. Secure the lower ends of the lift cylinders using mounting bolts. : 44 - 54 Nm (4.4 - 5.6 kg/m, 32 - 40 ft/lb) 8. Apply thread lock to the threads of the stud bolt on the cylinder side, then tighten and fasten the stud bolt on the top of the lift cylinder. Install the set nut so that a minimum of 1 mm (.039 in) clearance exists between the nut and mast lift cylinder support.

9. Fit the U-bolt into the cylinder, tighten the nut by hand, and fix with the lock nuts. : 26 - 32 Nm (2.6 - 3.3 kg/m, 19 - 23 ft/lb) 10. Fit the stopper into the hole at the end of the adjusting bolt. 11. Tighten the adjusting bolt, and check that the stopper contacts with the cylinder. Then, further tighten for 1/2 to 1 turn and tighten the lock nut. : 74 - 94 Nm (7.5 - 9.6 kg/m, 55 - 69 ft/lb) • When tightening the lock nut, make sure that the adjusting nut does not turn.

LM-32

MAST Assembly (Cont’d) 2W Mast (Cont’d) 12. Install pipes and tubes to their original positions. 13. For the mast assembly and carriage which were removed as a unit, adjust the carriage lift rollers. After adjusting carriage lift rollers, attach a lifting wire or nylon sling to the carriage, then install it to the inner mast using a hoist. For lift roller adjustments, refer to “CARRIAGE ASSEMBLY”. 14. Place the lift chains on the chain wheels, engage the lift chains at the chain joint links and adjustment bolts, then install to the inner mast.

! CAUTION • Discard the old cotter pins; replace with new ones.

3F Mast

! CAUTION • When adjusting the 3F masts, do not adjust them at one time. Adjust the middle mast first, then the inner mast in this order. 1. Pass nylon slings or wires in the mast of the middle mast (3F mast) first, then the inner mast in this order. While lifting them by a hoist, insert them from over the outer mast. 2. Slide the inner mast and the middle mast (3F mast) toward the bottom of the outer mast, and install the liner, outer mast roller, and middle mast upper roller.

! CAUTION • The roller diameters of the mast rollers differ on the inner mast side, middle mast upper and lower sides (3F mast), and outer mast side. When installing the mast rollers, be sure to install them in the proper positions. Middle mast upper side roller diameter (3F mast): 97.0 mm (3.819 in) Outer mast roller diameter: 97.0 mm (3.819 in) • As for the adjustment of other mast rollers, refer to step 4. on the next page.

LM-33

MAST Assembly (Cont’d) 3F Mast (Cont’d) 3. Adjust the liner using the following procedure. • Measure the clearance between the mast roller and the liner on the inside of the inner mast and middle mast (3F mast) using a thickness gauge. • When the measured value is out of the standard values, perform the shim adjustment to the right and left evenly. Standard: 0.1 - 0.6 mm (0.004 - 0.024 in) Shim: 0.5, 1.0 mm (0.020, 0.039 in)

! CAUTION • When installing the liner after the shim adjustment, apply bearing grease to the mast sliding surface. NOTE: Because the backup metal is designed to be inserted in the mast, it can be installed and removed easily. Adjustment of the mast installed to the vehicle. • Hang the mast using a wire, etc., and remove the carriage assembly. (Refer to “CARRIAGE ASSEMBLY”.) • Remove the mast chain. • Remove the mast cylinder. (Refer to HD section.) • Lower the inner mast by approximately 120 mm (4.72 in), replace the liner of the middle mast side, and then perform the shim adjustment. • Lower the inner mast and middle mast simultaneously for approximately 120 mm (4.72 in), replace the liner of the outer mast side, then perform the shim adjustment. 4. Install the inner mast roller, mast roller of the middle mast lower side, and perform the shim adjustment using the following procedure. • Set the roller pitches (Dimension “L”) of the inner mast, middle mast (3F mast), and outer mast to the dimensions indicated in the table according to the mast lifting height. Unit: mm (in) Lifting height

LM-34

Dimension “L1, L2” 3,850 (151.57) 4,300 (169.29) 4,750 (187.01) 5,150 (202.76)

369 (14.53)

5,500 (216.54)

384 (15.12)

MAST Assembly (Cont’d)

! CAUTION • For the 3F mast, setting the roller pitches of the inner mast, middle mast, and outer mast at one time may cause instability. Adjust in two steps, first for the inner and middle masts, then for the middle and outer masts. • Fix the mast with a rope or a wire to prevent it from sliding. • Select the mast rollers so that the clearances between the mast roller of the inner mast side and the outer mast (middle mast for 3F mast), and between the mast roller of the middle mast lower side and the rail and roller sliding surface of the outer mast (for 3F mast only) conform to the standard values.

• Place the inner mast or the middle mast (for 3F mast only) to the end of the side, and measure the clearance between the mast and the mast roller of the reverse side using a thickness gauge.

! CAUTION • Perform measurement for the mast rollers at four points: upper, lower, right, and left sides (eight points for 3F mast). • Adjust the shim of the mast roller to the right and left as equally as possible, so that the closest clearance between the mast roller of the outer mast side and inner mast (middle mast for 3F mast), and that between the mast roller of the middle mast upper side and the inner mast (for 3F mast only) conform to the standard values. Standard: 0.1 - 0.6 mm (0.004 - 0.024 in) Shim: 0.5, 1.0, 2.0 mm (0.020, 0.039, 0.079 in) • Difference between right hand and left hand shim thickness shall be 0.5 mm (0.020 in) max.

LM-35

MAST Assembly (Cont’d) • Adjust the shim of the mast roller to the right and left as evenly as possible, so that the closest clearance between the mast roller of the inner mast side and outer mast (middle mast for 3F mast), and that between the mast roller of the middle mast lower side and the outer mast (for 3F mast only) conform to the standard valves. Standard: 0.1 - 0.6 mm (0.004 - 0.024 in) Shim: 0.5, 1.0, 2.0 mm (0.020, 0.039, 0.079 in)

• Apply grease to the roller sliding surface of the mast (indicated by arrows in the figure).

! CAUTION • After adjustment, check for smooth operation of the mast.

5. Set the mast cylinder to the hole of the lower beam on the outer mast, and set the piston rod to the cylinder setting bracket on the inner mast. Tighten the mounting bolts at the upper and lower ends of the cylinder. Cylinder upper end: : 78 - 98 Nm (7.9 - 10.0 kg/m, 58 - 72 ft/lb) Cylinder lower end: : 44 - 54 Nm (4.4 - 5.6 kg/m, 32 - 40 ft/lb) 6. Fit the U-bolt into the cylinder, tighten the nut by hand, and fix with the lock nuts. : 26 - 32 Nm (2.6 - 3.3 kg/m, 19 - 23 ft/lb) 7. Fit the stopper into the hole at the end of the adjusting bolt.

LM-36

MAST Assembly (Cont’d) 8. Tighten the adjusting bolt, and check that the stopper contacts with the cylinder. Then, further tighten for 1/2 to 1 turn and tighten the lock nut. : 74 - 94 Nm (7.5 - 9.6 kg/m, 55 - 69 ft/lb) • When tightening the lock nut, make sure that the adjusting nut does not turn. 9. Install the piping to the mast cylinder. 10. Install the chain wheel and mast chain (3F mast). 11. Install the full-free cylinder. At this time, perform the shim adjustment so that the inner mast and full-free cylinder become parallel (3F mast). Shim: 1.0 mm (0.039 in) : 128 - 156 Nm (13 - 16 kg/m, 94 - 115 ft/lb) 12. Install the piping of the head block (with the chain wheel) and full-free cylinder. 13. When the mast assembly is removed with the carriage mounted, adjust the lift roller of the carriage, lift the carriage assembly by a nylon sling or wire, then install to the inner mast. (As for the adjustment of the lift roller, refer to “CARRIAGE ASSEMBLY”.) 14. Pass the lift chain in the chain wheel, connect the adjusting bolt to the chain joint linking section, and then install it to the full-free cylinder.

! CAUTION • Replace the cotter pin with a new one.

LM-37

MAST Installation 1. Attach a lifting wire or nylon sling to the mast assembly, then lift the mast assembly using a hoist.

! CAUTION • Before lifting the mast assembly (if equipped with the carriage assembly), lower the carriage assembly all the way down. Securely fasten the carriage finger bar to the tilt beam. • Make sure the lift chains are placed on the chain wheels. • Make sure the lift chains are not twisted. 2. Apply a coat of multi-purpose grease to the mast mounting shafts. Then install the bushings. 3. Apply a coat of multi-purpose grease to the outer walls of the bushings. Place the mast mounting shaft onto the mast support at the frame, then install the mast support caps. : 89 - 118 Nm (9.1 - 12.0 kg/m, 66 - 87 ft/lb) 4. (2W5 only): Turn the ignition to the ON position. Extend the tilt cylinder using the tilt lever until the pivot pin holes in the tilt cylinders and mast are aligned. Insert the pivot pins into the holes, then secure with the bolts. : 26 - 32 Nm (2.6 - 3.3 kg/m, 19 - 23 ft/lb)

! CAUTION • Be careful not to catch your hands by the tilt cylinder and mast assembly when the tilt lever is operated. 5a. (2W6 only): Lift mast into position on mast support. 5b. (2W6 only): Install cap and torque bolts. : 89 - 118 Nm (9.1 - 12.0 kg/m, 66 - 87 ft/lb) 2W6 Only

5c. (2W6 only): Align tilt bracket and install tilt pin G. Torque bolt. : 26 - 32 Nm (2.6 - 3.3 kg/m, 19 - 23 ft/lb) 5d. (2W6 only): Use the magnetic angle measurement tool to verify the angle of the mast. Use shims “B” to make adjustments: Mast angle should be adjusted to achieve a 90° vertical mast angle +/- 0.5° when measured on both sides of the front of the mast rail mast. Use shims “B” to make adjustments. 6. Install the lift hoses to their connections.

! CAUTION • Ensure that the lift hoses shall not be twisted during installation.

LM-38

MAST Installation (Cont’d) 7. Apply a coat of multi-purpose grease to the mast supports and tilt cylinder pivot pins. 8. Lift and tilt the mast assembly several times. Check that no oil leaks occur at or around the hydraulic lines, and that the mast assembly operates smoothly without binding. 9. Check the lift chains for proper tension. If necessary, adjust the chain tension. For chain tension adjustments, refer to “LIFT CHAINS”.

LM-39

MAST Adjustment Adjusting of Cylinder Height NOTE: To prevent mast from being twisted and deformed, adjust the cylinder height. Be sure to adjust when reassembling the mast assembly, especially when replacing only one cylinder. 1. Check that forklift is placed horizontally. 2. Remove upper mounting nuts/bolts of right and left cylinder. 3. Slowly raise mast without load, and then check that right and left cylinders reach to their stroke end simultaneously. 4. If one cylinder is delayed, adjust delayed cylinder by inserting shims. Thickness of shim: 1.0 mm (0.039 in) 5. Repeat the adjustment above until there is no difference between the right and left cylinders. 6. Ensure that the top of the cylinders are set firmly to the bracket on the inner (middle) mast, and secure by tightening the mounting bolts. 7. Apply Thread Lock to the threads of cylinder mounting bolts. (2W mast only) : 78 - 98 Nm (7.9 - 10.0 kg/m, 58 - 72 ft/lb)

Mast Tilt Angle Adjustment for 2W5 Only 1. Park the vehicle on flat and solid ground. 2. Tilt the mast assembly all the way forward, then check the left and right sides of the mast assembly to ensure that the forward tilt angle is within specifications. Mast tilting angle Forward / Backward 2W, 3F

3°/3°

3. Loosen the lock nuts and turn the tilt cylinder rods using a wrench until their stroke lengths are within specifications.

! CAUTION

2W5 Only

• Adjust the piston rod stroke lengths so the lengths of the piston rod thread portions do not exceed. • Adjust the piston stroke lengths so that the tilt angle of the left and right masts are identical. • Tilt the mast assembly forward and backward. If the left and right masts are improperly adjusted, make fine adjustments of the tilt cylinder stroke lengths as required.

LM-40

MAST Adjustment (Cont’d) Mast Tilt Angle Adjustment for 2W5 Only (Cont’d) NOTE: The backward tilt angle of the mast is automatically set by adjusting the forward tilt angle. 4. After adjusting the forward-backward tilt angle of the mast assembly, tighten the lock nuts on the tilt cylinders. : 108 - 147 Nm (11 - 15 kg/m, 80 - 108 ft/lb) 5. Paint alignment marks on mating areas between the tilt cylinder rod and rod head, and the rod head and lock nut. 6. Operate the mast assembly several times to ensure that it moves smoothly without binding.

2W6 Only

Mast Tilt Angle Adjustment for 2W6 Only 1. Use a magnetic angle measurement tool to verify the angle of the mast. 2. Mast angle should be adjusted to achieve a 90° vertical mast angle +/-0.5° when measured on both sides of the front of the mast rail mast. Use shims “B” to make adjustments.

LM-41

MAST Hi Mast Switch

LM-42

MAINTENANCE

SECTION

CONTENTS LUBRICATION CHART . . . . . . . . . . . . . . . . MA-2 2W5 Lubrication Schedule Chart . . . . . . . . . MA-2 2W5 Grease / Oil Capacity . . . . . . . . . . . . . MA-2 LUBRICATION CHART . . . . . . . . . . . . . . . . MA-2 2W6 Lubrication Schedule Chart . . . . . . . . . MA-2 2W6 Grease / Oil Capacity . . . . . . . . . . . . . MA-2 MAINTENANCE AND RECORD KEEPING . MA-4 MAINTENANCE SCHEDULE . . . . . . . . . . . MA-5 Periodic Maintenance and Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . MA-5 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . MA-8 CONTROL SYSTEM . . . . . . . . . . . . . . . . . . MA-12 PLANNED MAINTENANCE . . . . . . . . . . . . . MA-14 DRIVE WHEEL PRESSING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . MA-16 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . MA-17 Inspection of Hydraulic Fluid Level . . . . . . . . MA-17 Replacement of Hydraulic Fluid . . . . . . . . . . MA-17 Replacement of Micron Filter . . . . . . . . . . . . MA-18 Inspection of Hydraulic Pressure . . . . . . . . . MA-19 LOADING MECHANISM . . . . . . . . . . . . . . . MA-20 Fork Removal and Inspection . . . . . . . . . . . MA-20 Inspection of Fork . . . . . . . . . . . . . . . . . . . . MA-25 Insepction / Adjustment of Lift Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . MA-26 Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . MA-29 Inspection of Carriage Roller . . . . . . . . . . . . MA-32 Inspection of Mast Roller . . . . . . . . . . . . . . . MA-32 Adjustment of Mast Roller Clearance . . . . . . MA-32 Inspection of Mast Operation . . . . . . . . . . . .MA-34 Inspection of Mast Cylinder . . . . . . . . . . . . . MA-34 Inspection of Tilt Cylinder (2W5 Only) . . . . . .MA-34 Greasing Point . . . . . . . . . . . . . . . . . . . . . . . MA-35

LUBRICATION CHART 2W5 Lubrication Schedule Chart

Item #

Description

Lub. Points

Type of Lubricant

Interval

Transmission Fill Plug

(1)

*Chevron SAE 80/90

30 Days; 200 Hours

Transmission Steer Bearing

(2)

*Chevron LC Grease EP #Mobil Grease 28 (synthetic)

30 Days; 200 Hours

Transmission Drain

(1)

*Chevron SAE 80/90

Change after first 200 Hours, then Yearly

Hydraulic Reservoir

(1)

*Daphne Fluid AW32 BH-U #Mobil DTE 13M

90 Days; 600 Hours

Tilt Cylinder Pins

(4)

*Chevron LC Grease EP #Mobil Grease 28 (synthetic)

90 Days; 600 Hours

Wheel Assemblies

(6)

*Chevron LC Grease EP #Mobil Grease 28 (synthetic)

30 Days; 200 Hours

Tiller Arm

(3)

Spray White Lithium

30 Days; 200 Hours

Liner

(1)

N.L.G.I No. 1

90 Days; 600 Hours

Thrust Metal

(1)

N.L.G.I No. 2

90 Days; 600 Hours

Chain

(1)

Sprayon LU202 Moly Chain Lubricant

90 Days; 600 Hours

*Standard Lubrication

#Lubricant used in freezer operation only.

2W5 Grease / Oil Capacity System/component

Oil and grease

Capacity

Transmission

SAE 80W/API GL4

1.7 ℓ (3.5 US pt)

Hydraulic oil tank

Daphne Fluid AW32 BH-U Mobil DTE 13M

13 ℓ (3.5 US gal)

Greasing point

The greasing points and grease type in use are listed in the above lubrication schedule chart.

MA-2

LUBRICATION CHART 2W6 Lubrication Schedule Chart

Item # 1

Description Transmission Fill Plug

Lub. Points

Type of Lubricant

Interval

(1)

*Chevron SAE 80/90

30 Days; 200 Hours 30 Days; 200 Hours

Transmission Steer Bearing

(2)

*Chevron LC Grease EP #Mobil Grease 28 (synthetic)

Transmission Drain

(1)

*Chevron SAE 80/90

Change after first 200 Hours, then Yearly

Hydraulic Reservoir

(1)

*Daphne Fluid AW32 BH-U #Mobil DTE 13M

90 Days; 600 Hours

Wheel Assemblies

(6)

*Chevron LC Grease EP #Mobil Grease 28 (synthetic)

30 Days; 200 Hours

Tiller Arm

(3)

Spray White Lithium

30 Days; 200 Hours

Liner

(1)

N.L.G.I No. 1

90 Days; 600 Hours

Thrust Metal

(1)

N.L.G.I No. 2

90 Days; 600 Hours

(1)

Sprayon LU202 Moly Chain Lubricant

90 Days; 600 Hours

Chain

*Standard Lubrication

#Lubricant used in freezer operation only.

2W6 Grease / Oil Capacity System/component

Oil and grease

Capacity

Transmission

SAE 80W/API GL4

1.7 ℓ (3.5 US pt)

Hydraulic oil tank

Daphne Fluid AW32 BH-U Mobil DTE 13M

13 ℓ (3.5 US gal)

Greasing point

The greasing points and grease type in use are listed in the above lubrication schedule chart.

MA-3

MAINTENANCE AND RECORD KEEPING Record Keeping Model & Serial No.______________________________________________

Stock No._____________________

Date Placed in Service____________________________________________________________ Date

PM Performed

Unit Hours

MA-4

MAINTENANCE SCHEDULE Periodic Maintenance and Lubrication Schedule Before delivery of your new forklift, your dealer provides a predelivery inspection and adjustment service specified by the factory and designed to ensure satisfactory performance. The following tables list the servicing required to keep your forklift operating in good mechanical condition. The forklift should be attended to as indicated, preferably by your Local Authorized Dealer.

!! WARNING • Do not inspect any part of the system while the battery is being charged. • Before checking any part of the system, be sure to disconnect both connectors from the battery. • When it is necessary to check with the battery connected, raise the drive wheels. Be extremely careful to prevent electric shocks. NOTE: • Periodic maintenance should be performed after specified intervals have elapsed in months or hours, whichever comes first. • Under dusty, dirty or heavy operation, more frequent maintenance is necessary. All items listed must be maintained in order to meet and keep control systems operating at design level. Failure to maintain the systems could compromise the warranty. • The inspection/service intervals shown are based on the assumption that the vehicle is operated in a clean and dry environment for 200 hours or less in one month. When determining the inspection/service intervals, consider the actual working conditions of the vehicle

MA-5

MAINTENANCE SCHEDULE Periodic Maintenance and Lubrication Schedule (Cont’d) Interval Months

100s of hours

Motor (dust)

Clean

Wiring, bolts and nuts

Visual

Test

Controller

Drive system

Motor

Inspection Items

Mast

Transmission/ drive unit

Electric system

Amp draw reading for lift pump and drive motor

Resistance between forklift body and +/- terminal of battery/ controller

Measure resistance

Contactor operation

Visual

Contactor tips

Visual

Resistance contactor coil Controller fans

Chassis and body maintenance

How to check

Measure

Visual

Wiring, bolts and nuts

Visual

Controller surface

Clean

Battery: mounting, level and specific gravity

Visual/ Test

Truck harness and connectors

Visual

Switches

Visual/ Test

Lights (option)

Test

Horn/buzzer

Test

Gauge, indicators, warning and safety devices

Test

Check speed of truck and plugging distance (approx. the length of the truck including forks, unloaded)

Test

Crack, damage and leakage

Visual

Differential/drive unit oil level

Visual/ Replace

Drive tire torque nut to 157-196 Nm (116-145 ft/lb)

Test

Function of mast (lift/lower/tilt) 2W5 only Function of mast (lift/lower) 2W6 only

Test

Mast system (damage/cracks/wear)

Visual

I I

Clearance of each stage Mast rail

I I

If necessary

Mast/carriage rollers

Measure Grease Visual/ Test

If necessary

Back-up metals

Grease

Thrust metals

Grease

Abbreviations: I =Inspect (correct or replace if necessary), D: Drain, R: Replacement, A: Adjustment, C: Clean, T: Retighten, L: Lubricate/Grease

MA-6

MAINTENANCE SCHEDULE Periodic Maintenance and Lubrication Schedule (Cont’d) Interval

Hydraulic system Brake system

Steering system

Wheels/ tires

Chassis and body maintenance

Mast

Inspection Items

Months

100s of hours

How to check

Lift chains wear/tension

Visual/ Adjust

Attachments mounting (if equipped)

Visual

Attachments (if equipped)

Grease

Lift chains

Lubricate

Hose pulleys

Visual/ Test

Mast support

Grease

Forks (wearing/damage/cracks)

Visual

Carriage height

Test/ Adjust

Function of hydraulic system

Test

Hydraulic oil level

Visual

Hydraulic oil replacement

Replace

Micron oil filter

Replace

Suction filter

Clean

Visual

Test

Visual

Grease

Visual

Adjust

Grease

Test

Visual

Test

Visual

Control valve mounting (if equipped)

Operation of hydraulic handles (if equipped)

Hydraulic hoses (cracks, damage and fittings)

Lift and tilt cylinder mounting 2W5 only Lift cylinder mounting 2W6 only

Tilt cylinder pins - 2W5 only

Wheels and tires, damage and foreign material

Load wheel adjustment 2W6 only

Wheel bearing grease

Function of steering system

Mounting of steer tiller handle

Steering tiller (movement and play)

Function of brake, tiller return to full up position smoothly (with brake on)

Check return spring linkage for damage

Brake rotor air gap

Test

Brake function/effort, stopping distance (approx. the length of the truck including forks, unloaded)

Test

Abbreviations: I =Inspect (correct or replace if necessary), D: Drain, R: Replacement, A: Adjustment, C: Clean, T: Retighten, L: Lubricate/Grease

MA-7

BATTERY Inspection of Electrolyte Level

! CAUTION • Fill distilled water when battery electrolyte level drops. 1. Open the cap and check the electrolyte level. If electrolyte level is in between - in left figure, it is OK.

! CAUTION • Be careful because battery specifications may vary with each maker. 2. If inspection finds a cell in which electrolyte level is too low, check if there is any leakage and fill with distilled water. Continue filling up with cap opened until electrolyte level rises to position. However, be careful, for it may vary with each maker. NOTE: • Probable causes of leakage are as follows: • Damage to cap • Excessive filling with distilled water • High electrolyte temperature during charging, leading to electrolyte overflow

! CAUTION • Use care not to overfill distilled water. It may cause short or leakage. • Electrolyte lid is pushed into battery cell and needs to be secured to prevent leakage. • If there are any cracks in electrolyte lid, replace with new one. • Be careful because battery specifications may vary with each maker. • Before changing any components (i.e. lamps, fuses, meter panels) or disconnecting any wiring. Always turn OFF ignition and disconnect battery. This will reduce the possibility of damage to the controller system.

Inspection of Electrolyte Temperature Measure electrolyte temperature of each battery cell with a thermometer. NOTE: When battery electrolyte temperature rises, electrolyte and capacity of the battery expand. However, specific gravity decreases because there is no change in weight. Contrary when electrolyte temperature drops, specific gravity increases. Thus, when measuring specific gravity, evaluate result by converting electrolyte temperature at 20°C (68°F). (Refer to “Inspection of Specific Gravity”)

MA-8

BATTERY Inspection of Specific Gravity Specific gravity is very useful for determining battery life and condition. 1. To measure specific gravity of each battery cell by hydrometer.

! CAUTION • Measure with hydrometer placed in battery cell. Use extra care to prevent spilling of battery electrolyte outside when pulling it out of the cell. 2. Keep scale of gravimeter at eye level and read upper end portion of battery electrolyte swollen due to surface tension.

! CAUTION • If there is variance in specific gravity among cells, perform equation charging and measure specific gravity again. (For method of equation charging, refer to CS section). If result shows big variance in specific gravity among cells, battery has reached the end of its life. (Battery life depends on years of use, conditions of use and maintenance; equation charging may be necessary several times depending on cases). • If specific gravity is below 1.250 after charging, battery has reached the end of its life. • Carefully determine the battery life based on the above observation, together with advice by battery maker personnel.

!! WARNING • Always wear personal protective equipment when checking fluid to reduce the risk of coming into contact with fluid. 3. When battery electrolyte temperature is other than 20°C (68°F), convert specific gravity into temperature. Sz0 = St + 0.0007 x t – 0.014 Sz0 : Specific gravity of battery electrolyte at standard temperature [20°C] (68°F) St : Specific gravity of battery electrolyte measured at t°C t : Temperature of battery electrolyte during measuring When specific gravity converted into temperature is below 1.145, immediately perform charging. NOTE: Specific gravity at the time of charging end: 1.280 [electrolyte temperature 20°C (68°F)]

Inspection of Battery Voltage Inspection of battery voltage can be performed in an interactive diagnosis mode without using tester. Refer to CS section.

MA-9

BATTERY Inspection of Cell Voltage Measure the voltage of each cell. NOTE: This is useful for determining battery life and condition.

Inspection of External Leakage (⊕ Leak) Locate leaking cell following the flow chart below. NOTE: • Put tester to paint erased portion (paint is erased by file) when putting the tester to iron box. • White zinc sulfate crystals are most often stuck to  terminal of electrolyte leaking cell.

V 100

Measure voltages by putting tester to terminal of battery connector and tester to iron box.

Remove battery from vehicle body and wash it with water.

Voltage is generated.

OK (no leak)

Yes First time Second time

V 100

Measure voltages in sequence by putting tester to terminal of battery connector and tester to terminal of each cell.

Find cell close to measured value of

Select another cell.

V 100

Measure voltages by putting tester to iron box and tester to terminals of found cell and adjacent cells (in serial direction).

Cell whose voltage value is close to 0V.

Electrolyte nonleaking cell

Yes Electrolyte leaking cell

For inspection of leak, measure in reverse polarity of all leak inspection.

MA-10

and

for

BATTERY Inspection of Body Resistance Check resistance between truck body and negative/positive terminals. Normal: ∞ Ω If resistance value is “no infinity”, check lead wires, controller and motor windings for grounding. Correct or replace faulty parts as necessary.

MA-11

CONTROL SYSTEM Inspection of Main Contactor Contactor Points Make sure each contactor arm moves smoothly when pushed, and that it quickly returns to its original position when released. If it is questionable, disassemble and check the condition of the contactor. If the contactor point is damaged or worn beyond wear limits, replace the contactor base and contactor frame as a unit. Wear limit of movable and stationary contact points: 0.7 mm (0.028 in)

Contactor Coil Using a circuit tester, check continuity in coil circuit. Normal

Abnormal (open circuit)

44 Ω

∞

NOTE: The circuit tester range selector must be set to “x1 Ω”.

Cleaning Controller Clean controller surface. Clean dust with dry compressed air.

Inspection of Low Voltage Detecting Circuit Check operation of low voltage detecting circuit. 1. Raise drive wheels with a jack, placing chocks at rear wheels to prevent truck from moving. 2. Turn all electrical switches and ignition to OFF. (Ex. Lighting switch). 3. Disconnect battery plug. 4. Remove main fuse. 5. Connect power supply (described below) to battery plug (on the chassis harness side). Voltage 18 - 50 (V) ... Variable Ampere About 2 (A) 6. Turn ignition on. 7. Gradually decrease power supply voltage until remaining battery capacity meter moves from 2nd-step to 1st-step position on scale. Check that battery warning mark lamp is flashing. 8. After battery warning mark lamp begins to flash indicating the preset time has elapsed. 9. Further decrease power supply voltage. After the remaining battery capacity meter has moved from 1st-step to 0-step position on the scale, check that battery warning mark is lit.

MA-12

CONTROL SYSTEM Inspection of Low Voltage Detecting Circuit (Cont’d) As an alternative for a quick field test of the low voltage lockout and lift cut out, you can proceed as follows: NOTE: Battery should be charged and the surface charge removed by operating lift and drive controls for ten minutes. Using a jumper cable with alligator clamps on one end and a S.B. 350, or other appropriate battery connector on the other end, connect the red alligator clamp to the negative post of the cell to be tested. Then, plug the connector into the truck. For a 24V battery, drop three (3) cells from battery negative. With ignition on, read the battery discharge indicator. The battery warning mark should be flashing and all systems working. After five to fifteen minutes, the battery indicator should stay on and hydraulics will be interrupted. If you drop 50% of the cells, there should be no hydraulics, drive or power steering. This would effectively test low voltage lock out.

Inspection of Wiring, Bolt and Nut Check wirings, bolts and nuts. 1. Check harness covering of system components for damage or burns. Replace if necessary. 2. Check terminals and nuts of controller, contactors and motor for looseness. Retighten nuts and bolts as required.

MA-13

PLANNED MAINTENANCE The maintenance of this drive assembly is much like any other assembly of this type. The following maintenance checks are required to be performed: Steer Bearing Lubricate the two (2) grease nipples on steer bearing every 30 days or 200 hours.

SERVICE NOTE: Use Chevron LC Grease EP for standard operation and use Mobil 28 (synthetic) for freezer operation.

MA-14

PLANNED MAINTENANCE Transmission Gear Fluid Every 30 days or 200 hours check oil level. After the first 200 hours of operation, and then every 12 months or 2400 hours, drain and replace gear oil (use SAE 80/90) approximately 3.5 pints.

Mount Bolts After the first two days, or 200 hours, check all mounting bolts to frame, should be 57 ft/lb (77 Nm).

MA-15

DRIVE WHEEL PRESSING INSTRUCTIONS NOTE: The drive tire is to be pressed flush +/-0.5mm. This face with the wheel hub (item “A”) as shown. • There are many different sizes and compounds of drive tires used. • Use only standard OEM size 10” x 5” x 6-1/2”.

• Caution must always be exercised when pressing a new tire onto the hub. The dimension from the face of the hub to the edge of the tire is very important in the operation of the truck, to clear the transmission housing. If pressing and dimensions are not maintained and the tire does rub the transmission, this could cause any of the following to occur: • A bond failure from heat. • Transmission housing could be worn beyond repair causing gears to fail. • Drive motor damaged due to excessive amp. draw. • Electrical components fail due to excessive amp. draw and/or heat. There are many different compounds of tires used on our equipment. We have standard components that we use on the various models of trucks. Just because we use something as a standard, it does not necessarily mean that compound is the best for your customer’s application. If your customer is complaining of traction or failures, etc., maybe the application requires another type of tire. Always use only OEM tires and sizes.

Tire Assembly Installation In order to install the tire assembly to the transmission, there are five nuts that are used for mounting to the output shaft. Tighten the five nuts in a pattern of every other nut. This will ensure the assembly is flush with the output shaft. All wheel nuts must be torqued to 135 Nm/100 ft/lb. After the nuts are torqued, look into the center of the wheel hub and make sure the hub is flush against the output shaft.

MA-16

HYDRAULIC SYSTEM Inspection of Hydraulic Fluid Level

! CAUTION • To ensure precise measurement, place the vehicle on level ground, set the mast upright and lower the carriage to the lowest limit. • Only use the authorized genuine hydraulic fluid. Do not mix different types of fluids. 1. Remove the level gauge for hydraulic fluid and clean the level gauge with a shop cloth. 2. Insert the level gauge into the port and pull out the gauge. 3. On the level gauge, check that the fluid level is within the optimum range shown in the figure. Add the specified fluid if necessary.

! CAUTION • Do not overfill the tank. • Do not allow any foreign materials to get into the tank. • If the fluid consumption is too large, there is a possibility of fluid leakage. Inspect the system piping to identify the causal points.

Replacement of Hydraulic Fluid Contaminated or deteriorated hydraulic fluid may lead to malfunctions of the hydraulic pump and control valves. To prevent such symptoms, replace the hydraulic fluid at regular intervals.

! CAUTION • Only use the authorized genuine hydraulic fluid. Do not mix different types of fluids. 2W5 Only 1. Turn ignition to ON and raise the fork slightly by operating the lift (mast) cylinder. (The fork should not touch the ground when the tilt cylinder is fully tilted forward.) 2. Operate the tilt cylinder forward to the full stroke. 3. Return the control lever to the neutral position and turn ignition to OFF. Loosen the connectors in front of the left and right tilt cylinders and disconnect the hoses. 4. With ignition ON, set the control lever in the backward position and tilt the mast fully backward using a crane, in order to return the oil from the tilt cylinder to the oil tank. 5. Return the control lever to the neutral position. Turn OFF ignition switch. 6. Drain the oil from the oil tank and extract the fluid. 7. Flush tank with clean oil and clean inside of tank.

MA-17

HYDRAULIC SYSTEM Replacement of Hydraulic Fluid (Cont’d)

! CAUTION • When cleaning the tank, be careful not to leave any lint or dust inside. These residues may cause filter plugging or hydraulic component malfunctions. • Make sure to replace the micron filter as well, and clean fluid cap. 11. Attach the hoses and fill the oil tank with new hydraulic fluid referring to the table below. Model

2W5/2W6

ℓ (US gal, Imp gal)

17.01 (4-1/2, 4.8)

! CAUTION • The oil level should be between the upper limit and the lower limit on the level gauge when the hydraulic fluid has permeated through the hydraulic system and piping.

Replacement of Micron Filter

! CAUTION • Cover the surrounding areas with shop cloths to catch any fluid overflow. • Do not allow foreign materials to get into the piping. • Wipe away any spilled fluid. • Securely seal the taper thread of HYD pipe with seal tape. 1. Remove the return hose (low pressure hose). 2. Remove micron filter bracket assembly from the tank. 3. Remove micron filter from the micron filter bracket assembly. 4. Install a new micron filter to the micron filter bracket assembly.

MA-18

HYDRAULIC SYSTEM Inspection of Hydraulic Pressure 1. Verify that the fluid level in the hydraulic fluid tank is appropriate and remove the plug from the high-pressure pipe of hydraulic pump. 2. Attach the adapter to the port and connect a pressure gauge to the adapter. 3. Turn ignition to ON and operate control lever for hydraulic system and turn steering wheel fully right or left for power steering system and check the pressure referring to Table below. Standard pressure Main relief pressure

MPa (bar, kg/cm², psi)

20.6 (206.8, 210.9, 3000)

4. If out of specification, adjust the pressure.

MA-19

LOADING MECHANISM Fork Maintenance and Inspection Fork Wear vs Capacity • Forks for counterbalanced and straddle lift trucks are not just bent bars of steel. The manufacturing process is careful and precise with many checks and inspections critical to their safety. Some factors essential to fork manufacture include the steel, the bend thickness of the heel, the welding of the hooks that hold them on the carriage, and the heat treatment of the finished product. • Finished forks are usually painted red, yellow or black when the truck is new. The paint is quickly scraped off once the truck is put into service. The top paint is abraded by the pallet or load and the bottom is worm mostly by contact with the floor. • Lift truck operators are taught to keep their forks low and parallel with the travel surface when traveling empty and tilted back when carrying a load. But some operators go to extremes and travel with the heel of surface of the fork and reduces the capacity of the fork. • Once in service, the bottom of forks may wear badly. This wear may not be noticed, but the consequences are. There are ANSI specifications for User Fork Wear Standards. They are part of the B56 standards by which lift trucks are manufactured and tested. Few operators or fleet managers know of the standards or understand that forks must be inspected. • While the Industrial Truck Association (ITA) recommends that forks be withdrawn from service when fork blade thickness has been reduced by 10%, few users understand that a 10% reduction in blade thickness results in a capacity reduction of 20%. This means that the safety factor for a pair of forks has also been reduced by 20%. • Measuring fork wear is not intuitive. You should make it a part of maintenance or inspection routines.

MA-20

LOADING MECHANISM Fork Maintenance and Inspection (Cont’d) Fork Inspection • Forks should be inspected at least once a year (single-shift operation, and more frequently in severe applications) for wear and distortion. The best method is to use a fork caliper, which is a type of adjustable go/no-go gauge. • Each fork consists of two sections: the shank, which is the vertical part attached to the carriage, and the blade, which is the portion that picks up the load. • The caliper is first set using the shank of the fork on which there is little or no wear. Then that dimension is used to check the shank back near the heel of the blade. The four contact points of the special fork caliper automatically measure the wear on the blade. • Wear is checked by first measuring the thickness of the vertical shank portion of the fork because this part wears little. The interior part of the caliper has two additional points that automatically show a 10% reduction of the shank thickness. These points are slid over the fork blade. If the caliper slides down the blade to the heel, the fork is worn beyond safety and usefulness. It should be replaced. The accompanying chart shows the reduction in capacity as the fork wears.

MA-21

LOADING MECHANISM Fork Maintenance and Inspection (Cont’d) Using a Caliper (Cont’d) When to replace forks If a caliper does not pass over freely, the fork arm must be taken out of service. This represents 10% wear and 20% reduction in capacity.

MA-22

LOADING MECHANISM Fork Maintenance and Inspection (Cont’d) Using a Caliper (Cont’d) Checking fork hooks Check for wear/straightness of fork hooks. Use the end of the caliper designed for your fork class (Class I, II, or III). If the fork caliper slides entirely into the hook pocket (Diagram B) the fork must be removed from service.

MA-23

LOADING MECHANISM Fork Maintenance and Inspection (Cont’d) Fork Use Guidelines Use your forks correctly: 1. Inspect forks regularly. 2. Make sure the fork capacity meets or exceeds truck capacity rating and load weight center. 3. Obtain written approval from fork manufacturer prior to making any fork modifications/repairs. 4. Determine for wear cycle and replacement schedule for your operation. Use of larger forks in demanding applications will extend fork life. 5. All positioning locks must be in place at all times. Forks must be properly seated on the carriage and the positioning locks fully located in the slot before use. What not to do: 1. Do not overload the fork beyond its rated capacity. 2. Do not change fork from one lift truck to another without knowing capacities of each truck and fork. 3. Do not use a fork in an application for which it is not designed. 4. Do not add a fork extension longer than 150% of the supporting fork’s length. 5. Do not try to repair or modify forks in the field, especially by welding. Improper welding destroys heat treat properties and makes the forks brittle. 6. Do not carry full or partial loads on one fork. 7. Do not apply sideways pressure to forks, commonly called “side loading” as they are designed for vertical loading only. (This reprint courtesy of Cascade Corporation)

MA-24

LOADING MECHANISM Inspection of Fork Fork Capacities per Pair Full Tapered and Polished Forks, Reduce Capacity by 15% Thickness and Width (inches)

Lbs. at 24" LC

Lbs. at 36" LC

Lbs. at 48" LC

1-1/2 x 2

2100

2x2

3700

2750

2 x 1-1/2

2900

1900

1x4

1950

1-1/4 x 4

3000

2000

1500

1-1/2 x 4

4100

2900

2100

1-3/4 x 4

5800

4000

2900

2x4

7000

5200

3900

1x5

2450

1-1/2 x 5

5400

3800

2700

1-3/4 x 5

7100

5200

3700

2x5

9200

6500

4800 7600

2-1/2 x 5

15000

10500

1-3/4 x 5-1/2

7700

5750

1x6

2900

1-1/2 x 6

6500

4500

1-3/4 x 6

8950

6000

2x6

11000

8200

2-1/4 x 6

17000

12100

8500

3x6

25000

18500

12500

1-1/2 x 7

7600

5000

3800

2x7

13500

9000

6400

2-1/2 x 7

21000

15000

10000

3x7

30000

21000

14500

5500

1-1/2 x 8

8750

6000

4300

2x8

15500

10500

7500

2-1/2 x 8

24000

16000

11500

2-3/4 x 8

28000

20000

13500

3x8

33000

24000

16500

3-1/2 x 8

45000

32000

22500

1-1/2 x 10

10500

7500

5400

2 x 10

18500

13500

9500

2-1/2 x 10

28000

21000

14000

2 x 12

22000

16000

11000

MA-25

LOADING MECHANISM Inspection / Adjustment of Lift Chain Tension 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. 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. • 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. • 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. • If a plated chain is required, consult factory. Plated chains are assembled from modified, individually plated components which may reduce the chain rating. Cleaning and Routine Maintenance • The chains and related connecting hardware should be cleaned, inspected and lubricated every 200 hours or sooner depending on application. Chains that are exposed to corrosive chemicals or steam cleaning may need to be inspected more frequently. Chains themselves should not be steam cleaned. • The complete chain and connections should be lubricated completely with an oil with a viscosity similar to SAE 20 wt. oil or Chain Oil. A non-detergent oil is recommended: however, synthetic oils with solid lubrication such as molybdenum disulfide maybe used. The oil can be applied with a fine brush but must be applied in all area such that the oil can penetrate the joint area. Cycling the mast will help work the lubricate into the joint. The lubricant must penetrate the joint in order to be effective.

MA-26

LOADING MECHANISM Inspection / Adjustment of Lift Chain Tension (Cont’d) Measuring Chain Stretch • Chain stretch can be measured with Chain Wear Scale. Measure the chains according to the instruction printed on the scale, without a load on the carriage. If the chains are stretched beyond the recommended amount, they should be replaced in pairs. • To check the free lift chains, raise the carriage 1 ft. (30 cm) off the ground to put tension on the chains. • To check the main lift chains, raise the mast until the inner upright starts to extend to put tension on the chains.

Chain Length Adjustment !! WARNING Failure to follow these warnings can result in serious injury. An upright or carriage can move unexpectedly: • The carriage stop must not be allowed to contact the upright stop under any circumstances during normal operations. • 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.

MA-27

LOADING MECHANISM Inspection / Adjustment of Lift Chain Tension (Cont’d) Chain Length Adjustment (Cont’d)

! CAUTION • Before this maintenance work, always ensure that the carriage height is appropriate. 1. Set the mast upright and raise the fork by 20 to 30 mm from the ground level. 2. For the 2W outer chain mast, pull the lift chain at the middle point and check the deflection. For the 2W inner chain, 2H, 2F, 3F and 3V masts, press the lift chain at the middle point and check the deflection. Standard: 25 - 30 mm (0.98 - 1.18 in) 3. If the deflection is outside the specified range, loosen the lock nut and adjust the chain tension with the lift chain adjusting nut.

! CAUTION • Ensure that equivalent tension is applied to the left side and right side of the lift chain. • After adjustment, always check the carriage operation for smoothness.

MA-28

LOADING MECHANISM Lift Chains Installation To install the lift chains, reverse the removal procedures.

Figure 7-1

MA-29

LOADING MECHANISM Lift Chains (Cont’d) 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. Figure 7-2. Arc-like cracks in plate are a sign of stress corrosion. Corrosion Fatigue: Corrosion fatigue cracks are very similar (in many cases identical) to normal fatigue cracks in appearance. They generally begin at the pin hole and move perpendicular (90°) to the chain pitch line. Corrosion fatigue is not the same as stress corrosion. Corrosion fatigue is the combined action of an aggressive environment and a cyclic stress (not a static stress alone, as in stress corrosion. Ultimate Strength Failure This type of failure is caused by overloads far in excess of the design load. See Figure 7-3.

MA-30

LOADING MECHANISM Cleaning and Routine Maintenance (Cont’d) • *The chains should be wiped off with a cloth or brushed off with a fine brush to remove any build up of grease and dirt to clearly expose the chain elements and joints. A heavy layer of grease remaining on the chain may prevent the lubricant from entering the joint area. The appearance of a heavy grease on the outside of the chain may provide the appearance of proper lubrication; however, the lubricants may not be entering the pivoting joints. • *Each link and connection should be checked for turned pins, cracked links, damage pins, or stiff links. This may require raising and lowering the mast to obtain good visibility of all areas. The evidence of surface rust on the chain may be evidence of insufficient lubrication in the joint area. Any chain or connector with damage should be replaced. Chain with the appearance of stiff links should be replaced. The stiff link is an indication of insufficient lubrication and damage in joint area. Any chain or connector with damage should be replaced. Chain with the appearance of stiff links should be replaced. The stiff link is an indication of insufficient lubrication and damage in joint area. • *The complete chain and connections should be lubricated completely with an oil with a viscosity similar to SAE 20 wt. oil or Chain Oil. A nondetergent oil is recommended: however, synthetic oils with solid lubrication such as molybdenum disulfide may be used. The oil can be applied with a fine brush but must be applied in all area such that the oil can penetrate the joint area. Cycling the mast will help work the lubricate into the joint. The lubricant must penetrate the joint in order to be effective.

MA-31

LOADING MECHANISM Inspection of Carriage Roller • If the carriage roller does not operate smoothly or has undergone deformation, stepped wear or damage, replace it. • Check the clearance between the carriage roller rolling face and the inner mast. If the clearance is outside the specified range, replace the carriage roller with a new one with an appropriate size. Standard clearance mm (in): 0.1 - 0.6 (0.004 - 0.024) Available roller sizes mm (in): 97.0, 97.5 and 98.0 (3.819, 3.839 and 3.858) Center mast roller diameter (2W/3F) mm (in): 97.0 (3.819)

Inspection of Mast Roller • If the mast roller does not operate smoothly or has undergone deformation, stepped wear or damage, replace it. • Check the clearance between the mast roller rolling face and the mast rail. If the clearance is outside the specified range, replace the mast roller with a new one with an appropriate size. Standard clearance mm (in): 0.1 - 0.6 (0.004 - 0.024) Roller diameter type mm (in): 2W inner mast: Mast height: 3,500 or more (137.80 or more): 105.0, 105.5, 106.0 (4.13, 4.15, 4.17) Mast height: 2,700 - 3,300 (106.30 - 129.92): 105.0 (4.13) 3F middle mast lower side: 105.0, 105.5, 106.0 (4.13, 4.15, 4.17) 3F inner mast side: 97.0, 97.5, 98.0 (3.82, 3.84, 3.86)

Adjustment of Mast Roller Clearance 1. Preliminarily set the roller pitches (dimension L) of the inner and outer masts referring to the table below.

! CAUTION • For the 3F mast, set the roller pitches in two steps: first for the inner and middle masts, then for the middle and outer masts. Setting the roller pitches of the three masts at once will deteriorate the stability.

2W Mast Unit: mm (in) Lifting height

Dimension “L”

2700 (106.30), 3000 (118.11), 3,300 (129.92)

283 (11.14)

3500 (137.80)

318 (12.52)

3700 (145.67)

343 (13.50)

4000 (157.48)

383 (15.08)

MA-32

LOADING MECHANISM Adjustment of Mast Roller Clearance (Cont’d) 3F Mast

Unit: mm (in) Lifting height

Dimension “L”

3920 (155), 4300 (170), 4756 (188), 5150 (202.76)

369 (14.53)

5500 (216.54)

384 (15.12)

2. Slide the mast to the leftmost or rightmost end. Check the clearance between the mast and the opposite mast roller. If the clearance is outside the specified range, adjust it with the clearance adjusting shims for the roller. Standard: 0.1 - 0.6 mm (0.004 - 0.024 in) Shim type: 0.5, 1.0 and 2.0 mm (0.020, 0.039 and 0.079 in)

! CAUTION • Create an equivalent clearance at both the right and left sides wherever possible.

MA-33

LOADING MECHANISM Adjustment of Mast Roller Clearance (Cont’d) 3. Visually inspect the mast liner. Replace it if worn excessively or damaged. 4. Check the clearance between the mast liner and the inner mast. If not as specified, adjust the clearance using the shims. Standard: 0.1 - 0.6 mm (0.004 - 0.024 in) Shim type: 0.5 and 1.0 mm (0.020 and 0.039 in)

Inspection of Mast Operation • Raise, lower, and tilt forward/backward the mast. The mast should generate no drag feel or unusual noises. • Check that the mast support maintains an appropriate free play and the mast support cap bolt has no looseness.

Inspection of Mast Cylinder • Operate the cylinder and check that no dragging and unusual noises are present. • Check that no oil leaks are present. • The piston rod should be free from scratches. • The cylinder tube should be free from dents and damages.

Inspection of Tilt Cylinder (2W5 Only) Check the following points: • No dragging or unusual noises are present during operation. • No oil leaks are present. • The piston rod should be free from scratches. • The tilt cylinder rod and lock nut are not loose.

MA-34

LOADING MECHANISM Greasing Point Tilt Cylinder Pivot Pin (2W5 Only) • Supply grease to the grease nipple.

Lift Chain • Apply specified oil to the entire surface of the chain.

Mast Support (2W5 Only) • Supply grease to the grease nipple.

Mast Roller and Mast Liner • Apply grease to the roller sliding faces and mast liner.

MA-35

LOADING MECHANISM Greasing Point (Cont’d) • Apply grease to the rolling face of the roller and the rail of the thrust metal contact face.

MA-36

MOTOR (TRACTION)

SECTION

CONTENTS MOTORS GENERAL INFORMATION . . . . . MM-2 Theory of Motor Operation . . . . . . . . . . . . . MM-2 Testing and Repair . . . . . . . . . . . . . . . . . . . . MM-4 AC DRIVE MOTORS . . . . . . . . . . . . . . . . . . MM-5 MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . MM-15 MOTOR INSTALLATION . . . . . . . . . . . . . . . MM-16 DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . MM-17

MOTORS GENERAL INFORMATION Theory of Motor Operation 1. All motors operate because of the way two phenomena react together: magnetism and electricity. a. Magnetism - Let’s begin by looking at the part magnetism plays. As you know, two magnets will attract each other or repel each other, depending on the way the ends, or poles, are pointed. If North is near North (or South near South), the poles will repel each other. This phenomenon of magnetic attraction and repulsion is shown graphically in the figure below.

This diagram shows that a limited degree of motion will occur if you manually bring the North pole of a movable magnet near the South pole of a magnet which has been fixed on a pivot. As it’s been set up in the figure above, the magnet on the pivot would rotate a short distance in a clockwise direction. This motion would continue if you kept moving the magnet on the left in a circle. Another way of achieving rotation and maintaining it would be to give the pivoted magnet a spin, and then keep switching the poles of the magnet in your hand. b. Electricity - This is where the second principle comes in: the principle of electricity. It would help maintain motion if you could change the poles of the magnet in your hand from North to South as the magnet on the pivot swung around. With electricity, this is quite easily accomplished by winding wire around an iron rod and attaching the ends of the wire to the leads of a battery. This creates, by the movement of electricity, a magnet with North and South poles, just as shown in the figure at left. c. Electromagnet - The great advantage of this electromagnet is that you can reverse the poles simply by reversing the leads on the battery. If we could solve the awkward problem of having to manually switch the leads, we could change the poles or polarity of the rod. Then we’d have a primitive model of a simple motor - the kind that a child might construct from a kit. The diagram in the figure below shows how this problem can be solved.

MM-2

MOTORS GENERAL INFORMATION Theory of Motor Operation (Cont’d)

d. DC Motor - Here you see how a rotating electromagnet, or rotor, has been placed between the North and South poles of a permanent magnet, or stator. The ends of the wires from the rotor are attached to a split mechanical ring, called a commutator. The commutator is attached by brushes to the leads of the battery. When the entire rotor assembly turns, the current switches back and forth. This causes the poles of the rotor to continuously change. Another way of saying this is that the commutator “reverses” the current to the rotor, first in one direction, then in the other, thus reversing the poles so that the rotor rotates. Forgetting the problem of how we get a motor to start up in the first place, this explains how it is possible for a motor connected to a direct current (DC) power supply (a battery, rectifier, or generator) to maintain motion. To complete the picture of our DC motor, it would be necessary for both the rotor and the stator to be electromagnets. We’ve already demonstrated an electromagnet rotor. Now we could turn the stator into an electromagnet as well, simply by wrapping wire around a steel core, and attaching the ends to the same power supply, as shown in the figure below.

MM-3

MOTORS GENERAL INFORMATION Testing and Repair Definitions Electrical Terms and Definitions Circuit: A complete path provided by conductors (usually wires) for the electric current to flow. Current only flows when a circuit is complete. Generator: A device that transforms nonelectrical energy (such as mechanical, thermal, etc.) into electrical energy. Voltage: A unit of electromotive force. It is a force which if applied to a circuit will produce a current in the conductor. Volts are generally produced or supplied from storage batteries or electrical generators. Current: The flow of electrons which occurs when a difference in voltage exists between opposite sides (ends) of the circuit. Ampere: The rate at which the electrons flow through a circuit over a given period of time. Amperes can be measured with an ampmeter connected in the circuit. Electric Motor: A device that changes electrical energy into mechanical energy to do work. 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. OHM’s law states that...”Current flow varies directly with voltage and inversely with the resistance in a circuit.”

MM-4

AC DRIVE MOTORS 1 5

7 4

25 24

23 26

28 10 22

3 8

21 9 14

Item

Description

Qty

Item

Drive Motor Assembly

Lock Washer

Rotor

Speed Sensor

Frame

Screw-M6 x 16-8.8

Terminal 3-Pole M10 x 30

Non Drive End Endshield

Hex Nut M10

Screw-M6 x 80

Disk

Lock Washer

Screw-M5 x 16-8.8

Ball Bearing

Dowel Bushing Pin 6 x 25

Wavy Washer

Motor Drive End Endshield

Woodruff Key

Ball Bearing

Connector Kit

Shaft Seal

Connector Kit

Circlip

Target Sensor

Circlip

Thermal Sensor

Screw-M6 x 50

Woodruff key

MM-5

Description

Qty

AC DRIVE MOTORS

MM-6

AC DRIVE MOTORS

MM-7

AC DRIVE MOTORS

MM-8

AC DRIVE MOTORS

MM-9

AC DRIVE MOTORS

MM-10

AC DRIVE MOTORS

MM-11

AC DRIVE MOTORS

MM-12

AC DRIVE MOTORS

MM-13

AC DRIVE MOTORS

MM-14

MOTOR REMOVAL Remove Battery (refer to General Information Section) Remove Hood and Tiller Hinge Cover (refer to Body and Frame section) Remove Tiller Mounting Bracket (refer to Steer Assemble section) Remove Brake optional, but recommended (refer to Brake section)

! CAUTION • The motor is heavy; use a hoist to lift the drive motor out of the transmission using care not to nick the drive gears. Remove and discard the o-ring seal on the drive end of the motor. Required Tools: 8mm Allen wrench or socket

17mm Combination wrench

Wire cutters

Floor jack

½” Impact wrench

½” Drive impact extension 12” long

19mm Impact socket with swivel

(2) 4” x 4” x 6” Long hard wood blocks

Drive gear retaining nut socket p/n 38216-FS001

Lifting sling

Required Parts: O-ring for drive end of motor

Cable ties

Drive motor retaining screws Motor Removal 1. Remove motor power cables to the drive motor using two 17mm wrenches. 2. Remove motor cable ties and cable guides. 3. Disconnect and position cables and harnesses out of the way. 4. Jack up the truck and place on 4”x 4” blocks under the side skids of the power head. 5. Remove the drive tire using a 19mm impact socket. 6. Turn the drive assembly so the 3 motor retaining screws are visible from under the truck, remove the bolts using a 8mm Allen wrench. NOTE: The retaining screws are pretreated with a thread-locking compound and will require replacement.

MM-15

MOTOR INSTALLATION

! CAUTION • The motor is heavy; use a hoist to lower the drive motor into the transmission. Replace the o-ring seal on the drive end of the motor. Use care not to nick the drive gears or o-ring. Required Tools: 8mm Allen wrench or socket

17mm Combination wrench

Torque wrench 0 - 150 ft/lbs

Floor jack

½” Impact wrench

½” Drive impact extension 12” long

19mm Impact socket with swivel

(2) 4” x 4” x 6” Long hard wood blocks

Drive gear retaining nut socket p/n 38216-FS001

Lifting sling

Required Parts: O-ring for drive end of motor

Cable ties

Drive motor retaining screws Motor Installation 1. Set motor onto transmission and secure with three new drive motor retaining screws. Torque screws to 43 Nm (33 ft/lb). 2. Reattach power cables using two-wrench method and torque cable nuts to 21.6 - 26.4 Nm (191 - 233.7 in/lb). 3. Install drive tire and torque to 135 Nm (100 ft/lb) 4. Install removed harnesses, brake, steer tiller, and battery as per the sections referred to for removal.

!! WARNING • Before taking the truck off the supporting blocks, test the truck for proper operation. Once it is determined that all the directional controls, forward/reverse and belly button work properly take the truck off of the supporting blocks and check operation of all functions on the ground. 5. Install all covers.

MM-16

DRIVE MOTOR

Item

Description

Item

Description

Screw - Hex Head M12-1.75 x 25

Transmission Assembly

Washer - Flat M12

Wheel Nut

Drive Seal O-Ring

Key - Woodruff 4 x 16

Screw - SHCS M10-1.5 x 70

Nut

Drive Motor Assembly

Pinion Gear

MM-17

DRIVE MOTOR Drive Motor Diagnostic/Replacement Report Email: ucawty@unicarriersamericas.com Email: service@unicarriersamericas.com REPORT DATE:__________________

1. Contact Information: Customer Name/Location Repairs by: End-User

Dealer Name/Location

2. Equipment Information: Customer Unit #

Model

Purchase Date

3. Application Information: # of Shifts

Serial #

Hours

Date Last PM

Hours Last PM

Floor conditions Clean

Running hours per shift

Smooth

Rough

Operating days per week

4. Previous Failure History:

Drive Motor Replaced Previously? Yes

Fail Date

Serial Number of failed Drive Motor

Hours

Dealer

Dry/Dusty

1-2

3-4

5-6

Wet 6-7

If Yes complete following Repair Date

Fully describe both the nature and cause of the problem with the Drive Motor that required it to be replaced:

Was the replacement of the Drive Motor claimed while under warranty? Yes No If the answer to the above question was ‘Yes’ what was the Claim #

5. Current Failure Information:

Fail Date

Condition of Battery, Voltage Readings:

Repair Date

Hrs

Motor Serial#

Static

Loaded

Fully describe both the nature and cause of the problem with the Drive Motor that required it to be replaced:

(1) Error/Trouble Codes displayed at time motor failed: Provide the following information: (2) Record of Inspection. Condition of following depending on type of Drive Motor, AC Item 1. Brushes 2. Brush Holder 3. Commutator 4. Armature

Good

Worn

UCA Warranty Claim #

Other

If condition is “Other” please describe:

Claim Status: Pending

Serial # of new replacement Motor

Denied

Appealed

Rejected

Replaced by, (Name)

Complete Report in its entirety. Failure to provide all information will result in delays and/or denied claim. UniCarriers® is a registered trademark of UniCarriers Corporation. Revised 08/2014

MM-18

STEER ASSEMBLY

SECTION

CONTENTS STEERING FUNCTION . . . . . . . . . . . . . . . . ST-2 TOP COVER REMOVAL . . . . . . . . . . . . . . . . ST-4 BRAKE INTERLOCK SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .ST-5 STEERHEAD REMOVAL . . . . . . . . . . . . . . . ST-6 TILLER ARM REMOVAL . . . . . . . . . . . . . . . ST-7 STEER ASSEMBLY . . . . . . . . . . . . . . . . . . . ST-8

STEERING FUNCTION The top mounted steer handle for the 2W5/2W6 utilizes the complete motor/drive assembly for steering. A large ball bearing is used to attach the drive assembly to the frame, and allows the motor and drive assembly to turn as a unit for steer control.

The steerhead and tiller are mounted to the top of the drive motor with a mounting bracket. The mounting bracket also incorporates the brake/interlock switch, and coast control mechanism and switch, if equipped with coast control.

ST-2

STEERING FUNCTION Tiller Return Spring The top end of the tiller return (spring) rod attaches to the bottom of the tiller arm as shown:

The bottom end of the tiller return (spring) rod is fixed to a guide bracket which is mounted to the drive motor housing as shown:

Check the condition of the tiller stop bumper and replace if necessary. Do not reuse retaining ring. Install a new one during reassembly. Item

ST-3

Description

Pin, Urethane Spring Mounting

Plate, Urethane Spring Upper

Spring, Urethane

Ring, Push On External

Bushing, Plunger Pin

TOP COVER REMOVAL Required Tools: 4mm Allen wrench 1. With the tiller arm in the full upright position, remove the top 3 screws from the top cover. Slide the top cover up the tiller arm, taking care not to snag the wire harness. Use bungee cord or tape to keep the top cover out of the way. NOTE: Cover can only be removed over hinged end of tiller.

ST-4

BRAKE INTERLOCK SWITCH ADJUSTMENT Interlock Brake Switch Installation

Remove tiller hinge cover with tiller in operating/run position. Measure gap between cam/switch sweep portion of the tiller hinge and brake/interlock proximity switch. The gap should be 2.0mm + 0.25mm (0.079 in. + 0.01 in.)

Interlock Brake Switch Adjustment

ST-5

STEERHEAD REMOVAL Required Tools: 5mm Allen wrench Cord, wire tie to hold control handles secure and out of the way 1. Remove 7 screws using a 5mm allen wrench from the bottom half of the control head.

2. Separate the top half and remove the harness connector from the printed circuit board. 3. Disconnect sidetracker switches, if truck is equipped with sidetracker feature. NOTE: The switch levers for the side tracker option are retained by the top half of the control head and will fall out if turned upside down, recommend using tape to hold in place.

ST-6

TILLER ARM REMOVAL Required Tools: (2) 17mm combination wrenches

3mm allen wrench

1/8” pin punch

Flat blade screwdriver

Brass punch

Roll pin (p/n 48684-FS002)

“E” clip (p/n 48601-FS000)

Nut (p/n 59662-FS004)”

!! WARNING • Support tiller handle during disassembly to prevent unexpected movement/lowering of tiller handle. NOTE: Before performing the Tiller Arm Removal procedure, you will need to perform Top Cover Removal and Control Head Disassembly first. Make sure the main hood is removed, also. NOTE: Make note of harness routings and anchoring positions before disassembly. 1. After the control head wire harness has been disconnected from the Multiplexer, remove pivot cover at the base of the tiller arm using a 3mm allen wrench. Pull control head wire harness down through the tiller arm and lay it off to the side. 2. Support tiller arm and loosen four bolts of the tiller arm mounting bracket using two 17mm combination wrenches. Do not remove the nuts at this time. Loosen until each nut has exposed one or two threads beyond the end of each bolt, to reduce tension on the return spring. Remove the “E” clip from the end of the clevis pin on the return spring rod end. Gently lift up on the tiller arm until pressure on clevis pin is released, so that it can be removed. 3. Use 1/8” pin punch to drive roll pin out from tiller arm pivot shaft. Note the number of shims at the opposite end of tiller arm pivot shaft. Use brass punch to drive out the tiller arm pivot shaft. Before removing the brass punch, support the tiller arm and then slowly remove the brass punch, taking care to retain the shims. 4. Assemble in reverse order using a new “E” clip, roll pin and lock nuts on the tiller arm mounting bracket fixing bolts. Torque: 17.7 - 23.6 ft/lb; 24 - 32 Nm.

ST-7

STEER ASSEMBLY Throttle Spring Replacement Instructions Preparation Park the Pallet Truck in a suitable workspace clear from other traffic. Disconnect the battery prior to working on the truck. Block the truck up to allow the drive wheel to turn freely. Required Tools: 2.5mm Allen wrench

Flat blade screwdriver

5mm Allen socket Figure 1. Disassembly the handle assembly by removing the 12 allen head screws using a 5 mm allen head socket.

Figure 2. Remove the butterfly control knob screws with a 2.5mm allen head socket from both sides.

Figure 3. Remove butterfly control knob from handle assembly from both sides. *(Note tab orientation here for reassembly later.)

ST-8

STEER ASSEMBLY Figure 4. Remove the throttle shaft from the handle assembly by sliding the shaft through the bushings and circuit board. (Remove in direction of arrow.)

Figure 5. Remove the bushings and springs from both sides of the handle, utilizing a flat blade screwdriver.

Figure 6. Note the orientation of the rear leg of spring for proper installation.

Figure 7. Hook rear leg of spring over tab as shown.

Figure 8. Cross front leg of spring over and hook on tab as shown here. Repeat for other side.

ST-9

STEER ASSEMBLY Figure 9. Install a bushing on each side of the handle assembly.

Figure 10. First inspect the shaft for straightness using a straight edge or flat surface. If once you have confirmed the shaft is straight and not bent, install in the below illustrated method. If not followed in this manner the risk of damage to the Cam and MUX Board may occur. Cam Orientation #1, Shaft Orientation #2. (Ensure throttle knob tabs are properly set between the spring legs as illustrated in Figure 3.)

Figure 11. Note bushing is nearly flush with the housing. This confirms proper installation.

Figure 12. Reinstall the butterfly control knobs (please note the tab orientation for return spring Fig. 6-8). Apply Loctite 222 to the threads of the screws. Torque with a 2.5mm allen socket to 6 in/lbs +/- 2 in/lbs.

ST-10

STEER ASSEMBLY Figure 13. Reinstall the top cover to the handles assembly and secure with Allen head screws removed in Step 1. Torque screws to 31-35 in/lbs. And test throttle for proper operation while truck is set atop of the blocks. Please refer to Power Head Cover Maintenance below for more details. This also includes the minimum air gap clearances between the side tracker lever and control head cover, thumb control lever and handle bar. Please inspect the operation of the butterfly control knobs to confirm there is no binding or sticking.

Power Head Cover Maintenance During the monthly planned maintenance service, as outlined in the MA section of this service manual, special attention should be made to the operating clearance of the accelerator thumb actuators.

The minimum air gap clearance between the thumb control and the steer head cover is 1/16” (1.6 mm). If the controls do not operate freely they should be repaired before the unit is allowed to return to operation.

Min. 1/16” air gap between handle bar and thumb control

ST-11

STEER ASSEMBLY Power Head Cover Maintenance (Cont’d) The steer head covers are held together with a series of Allen head socket cap screws. Over tightening of these screws can cause damage to the steer head or create binding of levers or actuators as well as potentially damage other internal components. Therefore, when removal and reinstallation of these screws becomes necessary, it is important to re-torque ALL of these screws to a maximum of 31-35 in/lbs.

! CAUTION • Do not install these screws with electric or air impact devices.

!! WARNING • Once the two sections are assembled together, please inspect the operation of all of the levers and actuators to confirm there is no binding or sticking and that all levers and actuators return to their neutral position on their own and without any resistance. This must be confirmed before allowing the forklift to be put back into service. If the steer head handle actuators or levers bind or stick once everything has been confirmed to have been adjusted and torqued correctly, then the steer head handle must be replaced.

ST-12

SERVICE BULLETIN INDEX - 2W5/2W6 Issue Date

Bulletin No.

April 2015

SB2015-136

Subject Loose Mast Install Procedures

REF NUMBER:

SB2015-136

DATE ISSUED:

April 2015

REVISION:

NEW

TO:

All Dealer Principals, General Managers and Service Managers

FROM:

Customer Quality Service Department

APPLIED MODEL: All Loose Masts SUBJECT:

SERVICE BULLETIN

Loose Mast Install Procedures

CLASS II, III

Loose or Separate Mast Warning and Install Procedures: This Warning and Install Procedure is being issued due to a risk of severe injuries or death if mast installation is not done correctly or in a safe manner. This Warning and Install Procedure is attached to all loose or separate masts being shipped from UniCarriers Americas Corporation to instruct technicians installing the mast to remove all banding and fully lower carriage or attachment before lifting the mast for installation. See full instructions attached. (14MST-INSTALL)

Always use supports to hold mast and carriage up during installation. Never remove the lifting equipment until the mast is completely installed, including all hydraulic hoses. Please ensure that all technicians, whether working in the shop or on the road, receive and understand this important Warning and Installation Procedure. A copy of this bulletin will be added to all current Service Manuals in the LM section. If you have any questions, please call UCA’s Technical Support Team at (815)-568-1487.

This confidential document, “Service Bulletin”, is intended ONLY for the internal use of UniCarriers Americas Corporation, its employees and national Dealer network. All data contained in this bulletin was based on the most current information available at the time of printing, and subject to change without notice.

! WARNING • Remove all banding of any type before installing the mast on the truck. • Carriage must be in lower position on mast and all mast rails should be aligned. • Never get under an unsupported mast or carriage. • Use appropriate jack stands or timbers to support carriage and mast while attaching to truck. • DO NOT remove lifting device or supports until all mast mounting is completed. • Read and follow the enclosed Installation and Lifting Instructions.

! ADVERTENCIA • Retire todo tipo de bandas antes de instalar el mástil en el montacargas. • El tablero porta horquillas debe estar en la posición inferior del mástil y todos los rieles del mástil deberán estar alineados. • Nunca se coloque debajo de un mástil o tablero porta horquillas que no se encuentra soportado. • Utilice torres o maderos de soporte apropiados para sostener el tablero porta horquillas y el mástil cuando lo acopla al montacargas. • NO retire el dispositivo de elevación o los soportes hasta que ha terminado por completo todo el montaje del mástil. • Lea y siga las instrucciones de instalación y montaje adjuntas. November 2014

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14MST-INSTALL

! ADVERTISSEMENT • Retirez tout cerclage de tout type avant d’installer le mât sur le chariot. • Le tablier porte-fourche doit être en position descendue sur le mât et tous les montants du mât devraient être alignés. • Ne jamais vous placer sous un tablier porte-fourche sans soutien. • Utilisez des tréteaux ou des morceaux de bois pour soutenir le tablier porte-fourche et le mât lors de la fixation au chariot. • NE retirez PAS l’appareil de levage ou les supports jusqu’à ce que le montage du mât soit terminé. • Veuillez lire et suivre les instructions d’installation et de levage incluses.

! ATENÇÃO • Remova todas as fitas de fixação antes de instalar o mastro no veículo. • O carrinho de elevação deve estar na posição abaixada e todos os trilhos do mastro devem estar alinhados. • Jamais se posicione embaixo de um mastro ou carrinho de elevação que não esteja apoiado. • Utilize cavaletes ou blocos de madeira adequados para apoiar o carrinho de elevação e o mastro durante sua fixação no veículo. • NÃO remova o dispocitivo de içamento ou os suportes até que toda a montagem do mastro esteja concluída. • Leia e siga as instruções de Instalação e Içamento que acompanham o produto. 14MST-INSTALL

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November 2014

LOOSE MAST INSTALL PROCEDURES FOR UNICARRIERS AMERICAS !! WARNING • Not following these procedures could result in serious injury or death!

Before lifting the mast: • Remove all bands or shipping straps. • Ensure that carriage is at its lowest point. • All mast rail sections are even at the bottom of mast.

• Have supports (i.e. Timbers or Jack Stands) available to support the carriage and mast rails once mast is lifted into position for installing. • Truck should be on a solid level floor

Lifting the Mast: • Only lift mast from designated point with lifting equipment that is rated for the correct capacity. • Check the stability of mast during the lift procedure.

!! WARNING • Do not allow anyone to stand or pass under the elevated portion of the truck, whether empty or loaded. • Never get under an unsupported mast or carriage. • Ensure that team knows all signals that will be used during the lifting procedure.

Installing Mast: • Once mast is installed on drive axle mounting location, DO NOT remove lifting device until mast is fully attached to truck (mast caps and tilt cylinders). • Carefully lift carriage and support with jack stands or timbers before working on attaching mast to the truck.

• Install mast caps around drive axle, then install tilt cylinders. • Have the lift device slowly lowered so all the weight of the mast is on drive axle, torque mast caps bolts to correct torque specification as listed in the service manual for the Forklift Model this mast is being mounted on. • Install all hydraulic connections. • Slowly lift carriage and or mast rails off supports. Once supports are removed then lower carriage. • Start truck up and test all hydraulic functions, DO NOT conduct lift test at this time, check for any leaks. • Shut unit down and remove lift device from mast. • In an area with a clear overhead conduct a full lift test of the mast.

November 2014

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14MST-INSTALL

INSTALACIÓN DE MÁSTIL SUELTO PARA UNICARRIERS AMERICAS !! ADVERTENCIA • ¡No seguir estos procedimientos puede resultar en lesiones graves o muerte!

Antes de levantar el mástil: • Retire todas las bandas o correas de embarque. • Asegúrese que el tablero porta horquillas se encuentra en la posición descendida más baja. • Todas las secciones del riel deben estar parejas en la parte inferior del mástil.

• Tenga soportes disponibles (p. ejem. torres o maderos de soporte) para apoyar el tablero porta horquillas y los rieles del mástil una vez que se ha elevado en la posición de instalación. • El montacargas debe estar sobre un piso solido y nivelado

Al elevar el mástil: • Solo levante el mástil de los puntos designados para este propósito con equipo de elevación de la capacidad correspondiente. • Compruebe la estabilidad del mástil durante el proceso de elevación.

!! ADVERTENCIA • No permita que nadie se coloque o pase por debajo de la parte levantada del montacargas, sin importar si esta vacío o con carga. • Nunca se coloque debajo de un mástil o tablero porta horquillas que no se encuentra soportado. • Asegúrese de que el personal conoce las señales que se usarán durante el procedimiento de elevación.

Instalando el mástil: • Una vez que el mástil está instalado en su posición en el eje motriz, NO retire el dispositivo de elevación hasta que el mástil se encuentre acoplado al montacargas (tapas del mástil y cilindros de inclinación). • Cuidadosamente eleve el tablero porta horquillas y apóyelo sobre torres de soporte o maderos antes de trabajar sobre este acoplando el mástil al montacargas.

Aplicación de grasa Tapa de soporte de mástil

Soporte de mástil

Buje

14MST-INSTALL

• Instale las tapas del mástil alrededor del eje motriz, a continuación instale los cilindros de inclinación. • Haga descender lentamente el dispositivo de elevación de forma que todo el peso del mástil este sobre el eje motriz, apriete con torque los pernos de las tapas del mástil a las especificaciones correctas de torque listadas en el manual de servicio, para el modelo de montacargas en el que se está instalando este mástil. • Instale todas las conexiones hidráulicas. • Lentamente levante de los soportes de apoyo el tablero porta horquillas o el mástil. Una vez que los soportes han sido retirados haga descender el tablero porta horquillas. • Arranque el montacargas y pruebe todas las funciones hidráulicas, NO realice pruebas de elevación todavía, Inspeccione si hay fugas. • Apague la unidad y retire el dispositivo de elevación y retírelo del mástil. • En un área con amplio espacio en la parte superior realice una prueba completa del mástil.

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PROCÉDURES D’INSTALLATION DU MÂT LÂCHE POUR UNICARRIERS AMERICAS !! AVERTISSEMENT! • Le non-respect de ces directives peut entraîner des blessures graves, voire la mort!

Avant de soulever le mât : • Retirez tout le cerclage ou les attaches de transport. • Assurez-vous que le tablier porte-fourche est à son point le plus bas. • Toutes les sections de montant du mât sont de niveau avec l’extrémité inférieure du mât.

• Assurez-vous d’avoir des supports (p. ex. des morceaux de bois ou des tréteaux) disponibles pour soutenir le tablier porte-fourche et les montants du mât lorsque le mât est soulevé en position pour l’installation. • Le chariot doit être sur une surface solide et de niveau

Levage du mât : • Ne levez le mât de son point désigné qu’avec de l’équipement de levage calibré à la bonne capacité. • Vérifiez la stabilité du mât durant la procédure de levage.

!! AVERTISSEMENT! • Ne permettez à personne de se tenir ou de passer sous la portion élevée du chariot, qu’il soit vide ou chargé. • Ne jamais vous placer sous un tablier porte-fourche sans soutien. • Assurez-vous que l’équipe comprenne tous les signaux utilisés durant la procédure de levage.

Installation du mât : • Lorsque le mât est installé sur le moyeu d’essieu moteur, NE retirez PAS l’appareil de levage jusqu’à ce que le mât soit complètement fixé au chariot (condensateurs et vérins d’inclinaison). • Soulevez le tablier porte-fourche avec précaution et soutenez avec les morceaux de bois ou les tréteaux avant de fixer le mât au chariot.

Graissage Capuchon de support de mât

Support du mât

Garnitures d’étanchéité

November 2014

• Installez les condensateurs de mât autour du moyeu d’essieu moteur, puis installez les vérins d’inclinaison. • Descendez doucement l’appareil de levage de sorte que le poids du mât soit sur le moyeu d’essieu moteur, le couple de condensateurs de mât au bon couple selon les exigences du manuel de service du modèle de chariot élévateur supportant le mât. • Installez tous les branchements hydrauliques. • Soulevez lentement le tablier porte-fourche et/ou les montants de mât au-dessus des supports. Lorsque les supports sont retirés, abaissez le tablier porte-fourche. • Démarrez le chariot et effectuez le test de toutes les fonctions hydrauliques, NE PAS effectuer de test de levage à ce moment, vérifiez pour déceler toute fuite. • Éteignez l’unité et retirez l’appareil de levage du mât. • Dans un endroit avec un espace suffisant, effectuez un test de levage complet du mât.

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14MST-INSTALL

PROCEDIMENTOS DE INSTALAÇÃO DE UM MASTRO SOLTO PARA EMPILHADEIRAS UNICARRIERS AMERICAS !! ATENÇÃO • Deixar de seguir esses procedimentos pode acarretar ferimentos graves ou morte!

Antes de erguer o mastro: • Remova todas as fitas de fixação e tirantes de transporte. • Assegure-se de que o carrinho de elevação esteja em seu ponto mais baixo. • Todas as seções dos trilhos do mastro devem estar alinhadas na parte de baixo do mastro.

• Tenha suportes (ou seja, blocos de madeira ou cavaletes) à mão para apoiar o carrinho de elevação e os trilhos do mastro ao erguer o mastro até a posição de instalação. • O veículo deverá estar sobre uma superfície sólida e nivelada

Erguendo o mastro: • Somente erga o mastro pelos pontos designados para tal, com equipamento de içamento de capacidade correta. • Verifique a estabilidade do mastro durante o procedimento de içamento.

!! ATENÇÃO • Não permita que ninguém permaneça ou passe por baixo de uma parte suspensa do veículo, esteja ele vazio ou carregado. • Jamais se posicione embaixo de um mastro ou carrinho de elevação que não esteja apoiado. • Certifique-se de que a equipe conheça os sinais que serão utilizados durante o procedimento de içamento.

Instalando o Mastro: • Após posicionar o mastro no local de montagem sobre o eixo de tração, NÃO remova o dispositivo de içamento até que o mastro esteja totalmente preso à empilhadeira (alças do mastro e cilindros de inclinação). • Erga cuidadosamente o carrinho de elevação e apoie-o com cavaletes ou blocos de madeira antes de trabalhar na fixação do mastro ao veículo.

Aplicando graxa Alça do suporte do mastro

Buchas

14MST-INSTALL

• Instale as alças do mastro em torno do eixo de tração, então instale os cilindros de inclinação. • Abaixe lentamente o dispositivo de içamento, de modo que todo o peso do mastro repouse sobre o eixo de tração, aperte os parafusos das alças do mastro com o torque especificado, conforme informação no manual de manutenção do modelo de empilhadeira em que o mastro está sendo montado. Suporte do mastro • Instale todas as conexões hidráulicas. • Erga lentamente o carrinho de elevação e/ou os trilhos do mastro dos suportes. Após remover os suportes, abaixe o carrinho de elevação. • Dê partida na empilhadeira e teste toda as funções hidráulicas, NÃO realize testes de erguimento de carga nesse momento, verifique a ocorrência de vazamentos. • Desligue a unidade e remova o dispositivo de içamento do mastro. • Em uma área com espaço livre acima da empilhadeira, realize um teste erguendo completamente o mastro.

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November 2014