UTILEV UT15PFE UT35PFE 1.5T-3.5T 4-Wheel Electric Counterbalanced Forklift Truck Maintence Manual

1.5T–3.5T 4-Wheel Electric Counterbalanced Forklift Truck

UT15PFE-UT35PFE

Service Manual

Part 76502794 (R2)

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized UTILEV® distributor. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow the instructions contained in the Service Manual or from your local authorized distributor could result in damage to the products, personal injury, property damage or death.

Ref. Manual Dated (01/2015)

Foreword This manual covers the components, operation, and servicing of the 1.5T-3.5T 4 Wheel Electric forklift truck. To ensure safe operation of this truck, it is important to read and understand the contents of this manual.

Only qualified service personnel should perform maintenance on this truck.

Product specifications in this manual may vary from your actual truck due to periodic improvements in design. Please contact your Utilev dealer if you have any questions or comments regarding this manual.

This electric four-wheel forklift truck has passed the requirements for, and is approved for operation in countries adhering to CE regulations.

MODELS Model

UT15PFE-UT18PFE UT20PFE-UT25PFE UT30PFE UT35PFE

Drive Controller

Pump Controller

Rated Capacity(t)/ Load Center(mm)

Curtis 1234 Curtis 1236 Curtis 1236 Curtis 1238

Curtis 1234 Curtis 1234 Curtis 1236 Curtis 1236

1.5 / 500，1.8 / 500 2.0 / 500，2.5 / 500 3.0 / 500 3.5 / 500

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Contents 1. Drive system................................................................................................................................................ 1 1.1 AC Motor ................................................................................................................................................ 1 1.2 Reduction gearbox ............................................................................................................................... 2 1.3 Drive axle ............................................................................................................................................... 3 2. Steering System ......................................................................................................................................... 9 2.1 Steering column .................................................................................................................................... 9 2.2 Steering axle........................................................................................................................................ 10 3. Brake system............................................................................................................................................. 14 3.1 Brake master cylinder ........................................................................................................................ 14 3.2 Foot brake ........................................................................................................................................... 15 3.3 Parking brake ...................................................................................................................................... 18 4. Hydraulic system ...................................................................................................................................... 19 4.1 Main Pump .......................................................................................................................................... 21 4.2 Control Valve ...................................................................................................................................... 22 5. Lifting System ............................................................................................................................................ 24 5.1 Assembly Data .................................................................................................................................... 24 5.2 Fault...................................................................................................................................................... 25 5.3 Mast...................................................................................................................................................... 26 5.4 Lifting cylinder ..................................................................................................................................... 28 5.5 Tilting cylinder ..................................................................................................................................... 28 5.6. Removal and adjustment ................................................................................................................. 29 5.7 Disassembly and Assembly of lifting cylinder. ................................................................................ 33 5.8 Disassembly and installation of tilt cylinder .................................................................................... 34 6. Electrical System ...................................................................................................................................... 36 6.1 Controller ............................................................................................................................................. 36 6.2 OPS System (Optional) ..................................................................................................................... 42 Electrical Principle Diagram .................................................................................................................... 44

1. Drive system The drive system consists of motor, reduction gearbox, drive axle, brake, tires, rims and other components.

The reduction gearbox is a two stage reduction gearbox, namely a cylindrical helical gear and a planetary hub reduction with a compact structure.

The brakes are shoe type. Please refer to Parts Manual for relevant parts of the braking system for details.

1.1 AC Motor Model

Drive motor

Pump motor

UT15PFE-UT18PFE

See Parts Manual

See Parts Manual

UT20PFE-UT25PFE

See Parts Manual

See Parts Manual

UT30PFE-UT35PFE

See Parts Manual

See Parts Manual

CAUTION AC motors are considered maintenance free with no commutators and brushes. AC motors should be checked daily for dust and debris.

1.2 Reduction gearbox The reduction gearbox is a double reduction gearbox, namely a cylindrical helical gear and a planetary hub reduction, with a compact structure.

Fig. 1-1 Gear Box 1. Transmission Housing 5. Differential housing,R.H. 9.Pinion Gear Shaft 13.Planetary Gear 17.Double Gear Shaft 21.Shim 25.Bolt 29.Bolt 33.Shaft 37.Transmission Housing 41.Locating Plate

2. Bearing Seat 6. Differential Housing,L.H. 10.Pinion Gear Shaft 14.Thrust Washer 18.Bearing 22.O-Ring 26.Locknut 30.Bearing 34.Bearing 38.Washer 42.Bolt

3. Locking Plate 7. Bolt 11.Washer 15.Big Ring Gear 19.Bearing 23.Bearing Seat 27.O-Ring 31.Double gear 35.Pinion 39.Bolt

4.Bolt 8. Pin 12.Half shaft gear 16.Bearing 20.Bushing 24.Washer 28.Bearing cap 32.O-Ring 36.Pin 40.Bolt

Condition

Possible Cause

Loud impact noise when travelling and changing direction

Gear Noise when Travelling

Corrective action

 Excessive gear clearance

Adjust

 High gear wear

Replace

 Low oil level in the gearbox

Add gear oil

 Excessive gear clearance

Adjust

 High gear wear

Replace

1.3 Drive axle 1.3.1 Data Forklift Model

1.5t-1.8t

Rotation starting tension of hub at the hub bolt Axial clearance of wheel bearing Weight

3.0t - 3.5t

Full-floating, drive axle is directly mounted to the frame, front-wheel drive

Drive axle type Tire inflation pressure

2.0t - 2.5t

MPa

0.90

0.79

N

10-29

mm

Less than 0.08

kg

125 - 130

195 - 198

202 - 208

1.3.2 Troubleshooting Possible Cause

Corrective Action

Loose bolts between drive axle and the truck frame.

Tighten

Loose wheel nut.

Tighten

Worn or damaged inner hub bearing.

Replace

Improper adjustment of inner hub bearing.

Adjust

Worn axle shaft spline.

Replace

Inadequate lubrication.

Fill/ lube/ grease

Fault

Abnormal noise

Loose wheel nut.

Tighten

Damaged wheel.

Replace

Inner hub bearing damage.

Replace

Loose bolts between drive axle and the truck frame.

Tighten

Improper adjustment of inner hub bearing.

Adjust

Improper tire pressure.

Adjust

Wheel Wobble

Leaking Fluid

Worn or damaged drive axle oil seal.

Replace Seal

Improperly installed main transmission.

Replace Gasket

Loose oil drain plug.

Tighten

Fig.1-2 Drive Axle (2pc Hub & Drum) 1. Wheel 6. Bolt 11. Axle Shaft 16.Lock Nut 21.Support

2. Brake Drum 7.Brake Assy 12.Bolt 17.Pin

3. Wheel Hub 8. Washer 13.Oil Seal 18.Paper Shim

4.Wheel Nut 9.Bolt 14.Taper Roller Bearing 19.Oil Seal

5. Wheel Hub Bolt 10.Half-Axle Nut 15.Adjusting Nut 20.Axle Housing

Tightening torque: N.m

Item

1.5t-1.8t

2t-3.5t

Axle Shaft Bolt○ A

38-50

58-78

Brake plate Bolt○ B

76-107

118-147

Nut connecting brake drum and hub○ C

260-347

324-373

Bolt and nut connecting support plate and truck body○ D

260-347

324-373

Wheel nut○ E

157-176

363-490

1.3.3 Removal and installation of drive axle assembly WARNING  Be careful during removal and installation of drive axle. The Axle is heavy and can cause serious injury. Use appropriate capacity lifting equipment to avoid injury. （1）Raise front end of forklift truck and support frame with wooden blocks. （2）Remove mast assembles. （3）Slightly raise axle with a hoist and place wooden blacks under differential gear carrier and transmission case. （4）After placing a pan under axle case, loosen oil plug, drain oil from axle case. （5）Disconnect brake nuts from left and right cylinders. (see Figure 1-3).

CAUTION 

Plug brake tube openings to prevent oil from flowing out.

（6）Disconnect brake cable at hand brake lever. （7）Remove front wheels. （8）Remove axle shaft. （9）Support driving axle with wire ropes and lifting device. （10）Remove bolts securing axle mounting bracket to frame. (see Figure 1-4). （11）Remove nuts securing axle case to differential gear carrier. (see Figure1-5). （12）Remove driving axle assembly.

Fig. 1-3 Fig. 1-4 Fig. 1-5 （13）Remove brake drum then remove wheel hub. （14）Remove axle mounting bracket and brake component from axle tube. （15）Remove oil seal from axle tube. （16）To install driving axle assembly in the reverse order of removal. Observe the following: ① When installing axle mounting bracket and brake component, apply a coat of calcium grease to axle tube. ② Apply 1/3-2/3 of volume of calcium grease to wheel hub then install them on axle tube. ③ Install oil seal with its part number facing to the inside of forklift truck. ④ Install drain plug after cleaning it and covering it with seal tape (PVC, white). ⑤ Replenish axle case with gear oil. Tighten vent plug after clearing.** Gear oil GL-5 85W/90

1.5t - 1.8t

4.5 L

2.0t - 3.5t

6.0 L

** Vent plug must be cleaned frequently to prevent the pressure in the axle housing from increasing.

1.3.4 Axle Shaft and Wheel hub Removal process (1) Raise the front end of forklift truck and support frame with solid hardwood blocks.

(2) Remove front wheel and half axle shaft.

(3) Remove lock nuts, lock washers, snap ring, felt ring, adjusting nut. Use special tools.

(4) Remove brake drum (refer to Figure 1-6)； If brake drum is difficult to remove: a. Remove adjusting hole plug. Then with flat-blade screwdriver extend adjusting hole, turn counterclockwise adjusting ratchet wheel by 10 “clicks” to contract brake shoe lining (refer to Figure 1-7). b. Evenly tapping on brake drum with brass bar or wooden mallet.

Fig. 1-6

Fig. 1-7

(5) Remove wheel hub, be careful not to drop bearing inner race.

(6) Remove oil seal and inner bearing as an assembly by evenly tapping on periphery of seal with a wooden mallet and brass bar.

(7) Remove bearing outer race from wheel hub by evenly tapping on its periphery with a wooden mallet.

Caution: Be careful not to damage the oil seal and the outer race.

Inspection

Stepped wear or cracks on axle shaft splines

Replace

Seized, scratched, noisy or rusted bearing or improper rotation of rollers

Replace

Cracked or damage wheel hub

Replace

Damaged oil seal

Replace

Installation

Install in reverse order of removal.

1.3.5 Bearing adjustment (1) Coat the tapered roller bearing with grease; (2) Tighten the lock nut of the inner tapered roller bearing of hub until the hub can no longer be rotated with one hand; (3) Loosen the lock nut in the opposite direction for approx. 60°; (4) Then rotate the hub to the opposite direction for 2-3 rotations to engage the bearing seat; (5) Tighten the lock nut again until it can no longer be rotated with one hand. Then loosen the nut in the opposite direction for approx. 60°; (6) Install the lock washer.

(7) Rotate the hub back and forth for 2-3 rotations respectively to check whether the rotation starting tension is within the specifications; rotation starting tension: 10N-29N. (see Figure 1-8).

(8) Measure the axial clearance of hub, and check it’s within specification. The axial clearance is less than 0.08mm (see Figure 1-9).

Fig. 1-8

Fig. 1-9

2. Steering System The steering system is made up of steering control, steering axle and other components.

2.1 Steering column Being made up of the steering wheel, upper shaft assembly, universal joints, lower shaft assembly, bearings, shaft ring, lower steering tube, steering gear, priority valve, clamp handle, hydraulic switches and other components; the dip angle of the steering wheel can be adjusted forwards and backwards respectively as needed. (See Figure 2-1).

Fig. 2-1 Steering Device 1. Steering Wheel 3. Upper Shaft Assy 8. Gimbal- Universal Joint 10. Lower Shaft Assy 12. Bearing 13. Snap Ring

14. Shaft 17. Steer Control Pump-Orbitrol 18. Priority Valve 19. Bolt 22. Tilt Lever 26. Hydraulic Switch

2.2 Steering axle 2.2.1 General specifications Steering axle type

Steering angle

Centre bearing, rotary type Medial steering angle

1.5t - 1.8t

79.5°

2.0t - 3.5t

80°

Lateral steering angle

1.5t - 1.8t

56°

2.0t-3.5t

55.7°

Axial clearance (mm)

0-1

Thickness of end axle adjusting shim (mm)

0.5, 1.0, 1.6

Part number

See Parts Manual

Main steering pin

Hub bearing

Axial clearance of the main steering pin

Pre-tightening degree

Tighten the nut of steering knuckle until the hub can't be rotated with hands & then loosen the nut for 1/8 to 1/6 turn. Or the tension at the hub bolt is 10 - 29.8 N

Axial clearance

≤0.10 mm

≤0.20mm

Adjusting shim of steering king pin Thickness (mm)

Part number

0.10, 0.30, 0.70

See Parts Manual

Forklift truck type

1.5t - 1.8t

2.0t - 2.5t

3.0t - 3.5t

Weight of steering axle (kg)

66 - 68

96 - 99

98 - 100

2.2.2 Trouble diagnoses corrections Condition

Possible Cause

Corrective action

Loose wheel nut

Tighten

Wheel bearing out of adjustment range.

Adjust

Improperly installed adjustment shims.

Adjust

Wheel Wobble

Steering system failure Inadequate lubrication Loose bolts or nuts Noise

Improperly installed adjustment shim on axle end Shaft.

Joint bearings on both ends of the connecting rod are damaged

Refer to "Steering System" Section Apply and/or inject with calcium-based grease Tighten Adjust Replace

1 2 3 5

9 10 11

1 2

23

24

24 25

6

26 27 28 29

6 4

23

30 7

26 27 29 30

8 12 13 14 21 15

34 35 36 32 37 31 38

16

17

18

9

19

22

20 10

39 43 33

41 2

9

40 31 42 36 35 34

Fig.2-2 Steer Axle 1. Bolt 6. Rubber Mount 11. Cover *16. Bearing 21. Bolt 26. Snap Ring 31. Seal Ring

2. Washer **7. Bolt 12. Axle Housing 17. Lock nut ***22.Nut 27. Bearing 32. Sleeve

3. Plate 8. Washer *13. Oil Seal 18. Washer 23. Grease Fitting 28. Tie Rod 33. Spindle

4. Fitting 9. Bolt *14. Bearing 19. Gasket 24. Pin 29. Nut 34. Grease Fitting

36. Bearing

37. Bearing

38. Dust Seal

39. King Pin

****41. Bolt

42. Sleeve

43. Spindle

5. Shim 10. Washer 15. Hub 20. Hub Cap 25. Tie Rod 30. Cotter Pin 35. Oil Seal 40. Shim (0.10,0.254,0.750)

* Apply Grease ** #7-Torque 137-186 Nm or 101-137 lbf-ft ***#22-Torque (1.5-1.8T) 78-98 NM or 58-72 lbf-ft, (2-3.5T) 137-157 Nm or 101-116 lbf-ft ****#41-Torque 31-42 Nm or 23-31 lbf-ft

2.2.3 Removal process Wheel Hub (1) Jack up the forklift truck with a jack, and support it with solid hardwood blocks; (2) Remove the tires; (3) Remove the wheel hub cover; (4) Remove the steering knuckle nut; (5) Pull out the hub assembly; (6) Remove the bearing inner ring.

 

CAUTION DO NOT drop bearing inner race.

Be careful not to damage oil seal.

2.2.4 Main (Kingpin) steering pin and steering spindle (1) Remove the connecting rod; (2) Loosen the lock bolt (see Figure 2-3); (3) Remove the lube fitting of the steering king pin; (Figure 2-4) (4) Remove the steering king pin;



CAUTION Hold kingpin to prevent it from dropping. (See Figure 2-4).

(5) Remove the spindle, thrust bearing, dust cover and shim.

Fig. 2-3

Fig. 2-4

Inspection （1）Replace spindle if cracked. （2）Replace bearing if its rollers or roller surfaces are rusted or nicked. （3）Replace steel sleeve if it is distorted, out of round, or cracked. （4）Replace thrust bearing and dust cap if they are damaged Installation

To install, reverse the order of removal. Carefully observes the following: (1) The steering spindle must be inserted from the lower end; (2) Install the thrust ball bearing with the backup ring below it and the holder and loose ring above it. Coat the inner wall of dust cover, the loose ring and the backup ring with grease respectively; (3) Increase or decrease the number of shims to obtain required axial clearance of less than 0.20 mm; (4) Install the seal ring with the font face outwards. Coat the roller and holder of the roller bearing with grease, and coat the lip surface and groove of the seal ring with grease; (5) Inject grease into all lube fittings.

2.2.5 Wheel bearing adjustment (1) Rotate the hub slowly, and tighten the steering spindle nut until the hub can not be rotated with one hand; (2) Rotate the steering spindle nut from this position in the opposite direction for 1/6-1/4 circle.

Measure the starting force at the hub bolt; the starting force should be between 10N-30N; (3) Make sure that the rotation of the hub is smooth and stable, and adjust the axial clearance within the specified value range; the axial clearance should be less than 0.10 mm.

2.2.6 Steering cylinder 1

1. Piston Rod 3. O-Ring 5. O-Ring 7. Piston

2

3 4 5

6

7

8

Fig. 2-5 Steering Cylinder 2. LBH wiper 4. ISI seal ring 6. Guide sleeve 8. Housing

3. Brake system The braking system can be divided into the hand-operated parking brake system and footoperated service brake system; the parking brake system is made up of handle and cable, which manually activates the service brakes; the service brake system is made up of brake pedal, brake master cylinder, braking line and brake drum and the brake shoe.

3.1 Brake master cylinder The brake master cylinder consists of a valve seat, a check valve, a return spring, and piston cups and auxiliary cups. With the ends fixed with lock washer, cotter pin and with rubber dust cover or boot, the piston of master cylinder acts through the push rod by pushing on the brake pedal. When the brake pedal is pushed down, the push rod moves the piston forward, and the brake fluid in the cylinder flows back to the storage tank through the return opening until the primary cup blocks the return opening; then the primary cup is pushed through the return opening, after which the brake fluid in the front chamber of master cylinder is compressed and opens the check valve, which flows through the brake line to the brake slave cylinder, so that each brake slave cylinder piston moves outward to make the brake shoe lining contact with the brake drum to achieve the effect of deceleration or braking, and the rear piston chamber is replenished with brake fluid from the return opening and inlet opening.

When the brake pedal is released, the piston is compressed backwards by the return spring, and the brake fluid in each brake slave cylinders is also compressed by the brake shoe return spring to make it reflow to the master cylinder (front piston chamber) through the check valve; the piston returns to the original position, the brake fluid in the master cylinder returns to the reservoir through the return opening, the pressure of check valve is adjusted to be proportional to the residual pressure in the brake lines and brake cylinders, so that the cylinder cup is placed properly to prevent oil leakage and eliminate possible air resistance which occurs during heavy braking.

1. Lock nut 4. Retainer Ring 7. Piston 10. Check valve

Fig. 3-1 Master Cylinder 2. Push Rod 5. Stop Washer 8. Primary cup 11. Valve seat

3. Dust cover 6. Secondary cup 9. Spring 12. Cylinder Housing

3.2 Foot brake 3.2.1 Brake The configuration of the right detent can refer to fig 3-2. (1.5-1.8t), see fig. 3-3 (2-3.5t)

Fig. 3-2 Brake Assy RH 1.5-1.8t

1. Brake Mount Bracket 4. Rubber Cap 7. Push Rod 10. Brake Shoe Assy (front) 13. Adjuster Cable 16. Spring 19. Parking Brake Lever 22. Bolt 25. Anchor Guide 28. Spring 31. Bushing 34. Pin

2. Wheel Cylinder Housing 5. Piston 8. Air Bleeder Cap 11. Brake Shoe Assy (rear) 14. Adjuster 17. Brake Shoe Return Spring 20. Parking Brake Link 23. Washer 26. Spring Support Rod 29. Plug 32. Brake Steel Cable

3. Cylinder Return Spring 6. Cylinder Dust Cover 9. Air Bleeder Screw 12. Cable Guide 15. Actuator Lever 18. Return Spring 21. Brake Link Spring 24. Snap Ring 27. Spring Bracket 30. Oil Fitting 33. Pivot Pin

Fig. 3-3 Brake Assy 2.0-3.5t

1. Brake Assy-LH 4. Brake plate Assy RH 7. Wheel Cylinder LH 10. Piston Cup 13. Washer 16. Spring 19. Lever Pin 22. Brake Lever LH 25. Spring 28. Brake Shoe (LH & RH) 31. Spring 34. Lever LH

2. Brake Assy-RH 5. Cable LH 8. Wheel Cylinder RH 11. Pin 14. Rubber Plug 17. Washer 20. Shim 23. Brake Lever RH 26. Link 29. Spring 32. Adjuster LH 35. Lever RH

3. Brake plate Assy LH 6. Cable RH 9. Dust Cover 12. Bolt 15. Washer 18. Washer 21. Lock washer 24. Toggle-Shoe Guide 27. Link Actuator 30. Strut 33. Adjuster RH

3.2.2 Replacing brake shoe Method of replacing brake shoes: – Place the forklift truck on a flat level concrete floor.

– Start the forklift truck and raise the forks about 100 mm.

– Place solid hardwood blocks or chocks behind rear wheels to prevent the forklift truck from moving backwards.

– Loosen the wheel nuts by 2-3 turns respectively.

– Tilt the mast backward fully, and put solid hardwood blocks under each side of the outer mast.

 –

WARNING Do not allow wooden blocks to touch front tires.

Tilt the mast forward until the tires are lifted off the floor.



CAUTION Remove the wheel nuts when the front wheels are lifted off the ground.

– – – – – – – –

Increase the block height on both sides of the mast front end to support the forklift truck.

Switch off the forklift truck.

Remove the wheel nuts and wheels. Remove the axle shaft, lock nuts and lock washers.

Remove the hub and brake drum.

Replace the brake shoe with new set.

Reinstall the hub and brake drum, lock nuts and lock washers.

Adjust the bearing clearance.

Adjust shoe to brake drum clearance: – Remove adjusting hole plug on the bottom of the brake assemble.

– Insert a flat-blade screwdriver to adjusting hole, turn adjusting ratchet wheel downward to expand the brake shoes until wheel hub cannot be turned by hand.

– Move the ratchet wheel 2-3 notches to loosen allowing the wheel hub to be turned freely, slight friction is allowed between the brake drum and shoe lining.

– Replace the plug.

– Install wheels.

– Properly adjusting pedal stroke.

– Rotate the wheel in the opposite direction; at the same time depress the brake pedal several times.

– Remove all wooden blocks: in the reverse order when removing the insertion of each block.

– After confirming that nobody and no obstacles are nearby, back the forklift truck with a speed of 2-3 km/h (1-2 mph) and step on the brake pedal. Repeat 2-3 times.

3.2.3 Brake Adjustment: 1. Follow the Gap adjustment procedure items 1-8 in the Replacing brake shoe section item (9).

Note: Adjuster nut (wheel) adjustment step is very important, if ratchet adjustment is over tighten, it can cause the brake drum to heat up and cause premature wear on the brake drum.

2. Get back in the seat, start in forklift, and tilt the mast forward, lifting forklift drive wheels off the surface. Using both hands turn the drive wheels both forward and backwards to check for rotation, wheel should turn freely. Otherwise, re-adjust nut (wheel) until it meets the requirements.

3.3 Parking brake The hand operated parking brake manually activates the brake shoe / brake drum assembly on the front wheels through a cable connected to the parking brake handle and the service brakes. The parking brake is primarily used to park the forklift. The parking brake, when in good condition and correctly adjusted, will hold the forklift with full capacity on a 15% grade (a slope that increases 1.5 meters in 10 meters (1.5 feet increases in 10 feet)). If parking brake requires adjustment, notify trained service personnel to adjust the parking brake.

Condition

Insufficient braking force

Dragging Brakes

Possible Cause

Corrective action

 Brake line leaks fluid

Correct and refill oil

 Air in the brake lines

Exhaust (Bleed) the air

 Brake master cylinder or wheel cylinder is malfunctioning

Correct or replace the cylinder

 Blocked or clogged brake lines

Clean

 Improperly adjusted parking brake

Notify Trained Service Personnel

 No free play at the brake pedal

Adjust

 Damaged piston cup

Replace

 Weak or broken return spring

Replace

 Clogged master cylinder return port

Clean

 Blocked or clogged lines

Clean

4. Hydraulic system The high-pressure oil flows from the main hydraulic pumpto the priority valve, through which the oil is divided into two lines, and one line flows to the multi-way valve, where it is sent to the lifting cylinder or tilting cylinder by multi-way valve high-pressure oil, and the priority valve does not supply oil when the lifting and tilting valves are in the neutral position. When the lifting valve is pulled, the high-pressure oil flows to the lifting cylinder piston to push up the piston rod. When the lifting valve is pushed, the lower part of the lifting cylinder piston connects with the low pressure to lower the piston rod by gravity, then the oil from the lifting cylinder flows through the one-way flow control valve to control the descending speed, and the priority valve does not supply oil at this time; when the tilting valve is operated, the high-pressure oil flows to one chamber of the tilting cylinder with the other side connecting with the low pressure to complete the backward or forward tilting of the mast. The other line of oil flows to the steering gear to give priority to the operation of steering system.

Fig.4-1 Hydraulic System Diagram

4.1 Main Pump Condition Hydraulic pump not pumping out fluid

Possible Cause Low fluid reservoir level

Top up to specified fluid level

Clogged suction hose or strainer.

Flush fluid lines and fluid reservoir.

Change hydraulic fluid if dirty

Worn bearing damaged backup ring and O-ring.

Replace defective parts.

Misadjusted relief valve

Adjust the pressure measuring with a pressure gauge Retighten suction side hose and connections.

Low discharge pressure on hydraulic pump

Add hydraulic fluid to the fluid reservoir Air in hydraulic pump.

Cavitation generated by kinked suction-side hose or clogged filter Air entering from loosened suction-side fittings Noisy hydraulic pump

Cavitation caused by high viscosity of hydraulic fluid

Air bubbles in hydraulic fluid.

Oil leaking from hydraulic pump

Corrective action

The oil seal on the hydraulic pump is damaged; the O-ring is damaged, or the sliding surface of the hydraulic pump is worn.

Check the hydraulic pump seal for damage and leaks.

Do not operate pump until bubbles in tank have disappear.

Adjust or replace hose and clean or replace filter Retighten each joint connection.

Replace hydraulic fluid with new hydraulic fluid with viscosity suitable for the hydraulic pump operating speed.

Do not operate until fluid temperature is normal Check cause of bubbles, then take appropriate steps Replace damaged parts.

4.2 Control Valve Condition

Possible Cause Pressure adjusting screw loose

Relief valve pressure erratic or cannot be adjusted up

With the fork truck off, masts tilt forward when control lever is used.

Pressure adjusting spring deformed or damaged Relief valve spool worn, stuck or blocked

Corrective action Readjust pressure and tighten screw Replace Replace or remove, clean and reassemble

Pump malfunctioning

Repair or Replace

Worn or damaged tilt lock valve.

Replace valve core and tilt lock valve as an assembly.

Broken tilting lock spring.

Replace spring.

Damaged tilt valve plunger O-ring.

Replace O-ring.

Mast is erratic when Malfunctioning tilt relief valve. tilting forward.

Excessive wear gap between valve housing and valve stem.

When the lift control Spool valve is not centered. lever is in neutral position, the fork carriage is obviously Cylinder seal defective too high

Replace tilt relief valve assembly.

Replace spool valve with specified clearance.

Keep being in the center.

Examine and repair cylinder.

Taper valve is worn or blocked by dirt. Replace or clean taper valve.

Damaged or distorted repositionReplace spring. spring.

Fails to reset (Spool Dirt exists between valve housing and Clean. spool valve. valve is not returning to neutral Blocked control device.

Adjusted. position) Reset parts are not coaxial

Reinstall, MUST be coaxial.

Damaged O-ring.

Replace.

Faulty seal of joint.

Check and retighten.

Loose seal plate.

Clean seal plate and retighten bolts.

Loosed lock-nut of relief valve and connect-nut between plate and plate.

Tighten.

Leakage

Adjusting the pressure of the main relieve valve The relief valve pressure has been preadjusted before delivery, and adjustments performed by users are not allowed in general case. The following is an example of 3t truck to specify how to adjust the pressure: – –

–

Place 125% of the rated load, or 3750 kg, on the forks smoothly and steadily.

With the brake pedal fully pressed, operate the lift lever, the main relief valve pressure is set properly, if the forks/load can be lifted to a height of 300 mm range.

Otherwise, make adjustment according to Step (3).

The main relief valve pressure shall be increased if the forks/load cannot be lifted (that is cannot move off the ground); remove the front base plate, loosen the lock nut of main relief valve, and turn the adjusting screw clockwise to increase the main relief valve pressure. If the lifting height of the fork is greater than 300 mm, then turn the adjusting screw counterclockwise to reduce the main relief valve pressure.

WARNING 

The load must be placed in a stable and secure position to avoid tip over of the truck; once the pressure has been adjusted, it should not be readjusted unnecessarily. Poor pressure adjustments could cause truck damage.

Tonnage Item

Main Relief Valve Pressure (Working Pressure)

1.5 T

1.8T

2.0T

2.5T

3.0T

3.5T

15.5 MPa

17.4 MPa

17.5 MPa

17.6 MPa

17.7 MPa

17.8 MPa

5. Lifting System 5.1 Assembly Data Inspection and Adjustment Place

Between Mast and Rollers

Assy clearance (mm)

Repair clearance (mm)

0.1-0.8

0.2-1.0

Between Spacers - Shims

0.5-2.0

Between Mast and Support Guide Plate

0.1-0.8

Between Spacers-Shims

0.2-1.0 0.5-1.0

Inner Mast and Fork Carriage Side Rollers

0.1-0.6

Lift Chain Slack

0.2-1.0 25-30 mm

Tightening Torque of Main Parts Place

N·m

Lift Chain Lock Nuts

127-157 (M16), 176-216(M18) ; 245-314(M20)

The Bearing Cover Between the Mast and the Drive Axle

89-118 (M14), 176-216 (M18)

Tilt Cylinder Lock Nuts

89-118 (M12)

Lift Cylinder Bolts (Top)

76-107 (M12)

Lift Cylinder Bolts(Bottom)

22-29 (M8), 44-58 (M10)

Lift Cylinder Mounting Bolts (UShaped Bolts)

14-18 (M8), 29-39 (M10)

Weight of Basic 3M Mast Tonnage

1.5t

2.0t

2.5t

3.0t

3.5t

Mast Weight (kg)

531

930

1000

1100

1200

5.2 Fault Condition

Possible Cause Tilt Cylinder And Ring Abraded Excessively Fork Arm Carrier Or The Hydraulic Control Valve Spring Is Mast Tilt By Itself.

Inoperative.

Caused By Piston Jamming Or Bent Piston The Fork Arms Rod. Carrier Moves Up And Down Too Much Dirt Is Accumulated In The Sluggishly.

Cylinder.

Carriage Bracket Assembly Out Of Adjustment.

Insufficient Clearance Between Inner And Outer Masts Or Rollers And Mast.

Unable To Lift Or Lower Forks Biting Foreign Backing Materials Between Smoothly.

Moving Parts.

Replace The Faulty Parts.

Strip It Down And Clean.

Adjust Clearance With Thrust Metal And Carriage Side Roller.

Adjust Clearance With Rollers.

Bent Carriage Bracket Assembly.

Lift Chains Out Of Adjustment.

Adjust Lift Chains.

Grease Stiffened Or Dirt Accumulated On Lift Roller Does Not Lift Roller And Mast Sliding Surfaces.

Rotate Improperly Adjusted Lift Roller.

Insufficient Lubrication.

Improperly Adjusted Lift Roller, Side Roller And Back-Up Metal.

Excessive Mast Noise Rubber Pad On Lower Of Outer Mast Is Useless For Container Fork Lift Truck.

Excessive Wear Occurs Between The Hydraulic pumpBody And Gears, Causing Too Much Clearance.

The Lifting Jack Piston Yx-Ring Is Worn, Resulting In Excessive Inner Leaks.

Springs Of The Multiple Control Valve And Its Relief Valve Are Inoperative Oil Leaks.

Excessive Wear On The Hydraulic Control Valve, Resulting In Excessive Oil Leaks.

Insufficient Lift Power Or No Lift Movement.

Replace.

Remove Foreign Backing Materials.

Apply Grease On Contact Surfaces Of Sliding Parts.

Repair Or Replace.

Insufficient Lubrication.

Forks Are Lifted Unevenly

Corrective Action Replace Piston Ring Tilt Cylinder.

Clean And Lubricate Lift Rollers.

Adjust.

Lubricate.

Adjust.

By Adjusting Shims And Rubber Pad, Piston Rod Is In Touch With Bottom Of Cylinder Body After Inner Mast Is In Touch With Rubber Pad. Replace The Worn Parts Or The Oil Pump.

Replace Yx-Ring.

Replace.

Replace.

Dismantle For Regrinding The Joint Surfaces And Reassemble The Valve.

Tighten The Joint Nuts And Leakage Occurs In The Hydraulic Pipe.

Inspect The Seal For Damage.

Change The Wrong Hydraulic Oil The Hydraulic Oil Temperature Is Too High. Or Stop Operation For Reducing Oil Viscosity Is Too Low And The Rate Is The Oil Temperature. Find Out The Insufficient.

Reasons For High Oil Temperature And Eliminate The Trouble.

The Load Carried Is Beyond The Designed Observe The Lifting Capacity Limit.

Capacity.

Oil Leaks Occur Between The Hydraulic Control Valve Sections.

5.3 Mast Standard 2 stage LFL mast is 3m high, composed of inner and outer mast, carriage, load backrest, chain and roller, etc.

Fig. 5-1 Simplex 2 Stg. LFL

1.Outer Mast 5.Fork 9.Tilting Cylinder

2.Inner Mast 6.Chain 10.Idler Wheel

3.Load Backrest 7.Lifting Cylinder-LH

1. Outer Mast 5. Carriage 9. Load Backrest

Fig. 5-2 Duplex 2Stg. FFL 2. Inner Mast 3. Chain- FFL 6. Fork 7. Lifting Cylinder-LH 10.Tilt Cylinder

4. Carriage 8.Lifting Cylinder-RH

4. Free Lift Cylinder 8.Lifting Cylinder-RH

Fig. 5-2 Triplex 3 Stg. FFL

1. Outer mast 5. Carriage 9. Lifting Cylinder-RH

2.Inner mast 6.Fork 10. Load Backrest

3. Chain-RH/LH 7. Sideway cylinder 11.Tilt Cylinder

4. Free Lifting Cylinder 8. Lifting Cylinder-LH

5.4 Lifting cylinder Plunger feeder lifting cylinder has dash control, configuration see fig 5-3.

1. LBH Dust Proof 5. Piston 9. Cylinder Housing 13. Support Ring 17.Snap Ring

Fig. 5-3 Lift Cylinder 2. ISI Ring 3. Plug Screw 6. Bolt 7. Guide Sleeve 10. Piston 11. Snap Ring 14. Backup Rings 15. OSI Ring 18. Bearing 19. Pipe Joint

4. O-Ring 8. Bushing 12. Piston 16. Valve Guide 20. Adjusting Washer

5.5 Tilting cylinder

Fig. 5-5 Tilt Cylinder 1. Retaining Ring 2. Knuckle Bearing 3. Support 4. Grease Fitting 6. Bolt 7. Dust Proof 8. Cylinder 9. Guide 11. O-Ring 12. Piston Rod 13. O-Ring 14.Backup Ring 16. Piston 17. Cylinder Housing 18. Washer 19.Nut 21. Bolt 22. Nylon Spacer 23. Snap Ring 24.Snap Ring

5. Nut 10.U ring 15.U ring 20.Pin 25.Spacer

5.6. Removal and adjustment Warning: Be careful when removing and installing the forks, carriage and mast as they are heavy. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage.

5.6.1 Remove forks and mast assembly （1）Unlock fork lock pins by pulling them and moving forks to cutout portion in the middle of carriage bracket assembly. （2）Pull on lower portion of fork to remove its lower jaw and lift it out.

Warning: a. Keep hands and feet away from forks when removing and installing forks. b. Do not remove forks from the end of the fork bar. Severe injury can result if the forks are dropped.

（7）Support mast assembly with wire ropes.

（8）Pull out tilt cylinder pivot pin.

（3 ）Attach wire ropes to carriage bracket assembly and lift carriage bracket assembly up with a lifting device. （4）Remove chain attaching nuts, and detach chains from carriage bracket assembly. （9）Remove mast support caps.

（5）Remove carriage bracket assembly from inner mast. （6）Detach high pressure hose, lift hose and low pressure hose.

（10）Remove mast assembly. （11）To install mast assembly, reverse order of disassembly.

5.6.2 Disassembly

Warning： The mast is very heavy. Be extra careful when detaching it.

Remove lifting jack （1）Place mast flat on ground. Remove lifting jack attaching bolts-bolts and tightening screw.

Inspection: （1 ）Check lift rollers, roller shafts, and associated parts for wear or damage. （2）Replace damaged parts as required.

5.6.3 Assembly and adjustment Warning: Be careful when assembling the masts as they are heavy.

Lift roller Slide inner mast into outer mast and securely attach lift rollers.

（2 ）Slide inner mast, then remove lifting cylinders.

Remove roller （ 1） Slide inner mast out until rollers are exposed and remove little rollers with bearing puller. Make two pieces of round board about 10mm thick with a diameter are Ø53 and Ø58, covered on the seat of roller. Then remove the compound roller and main roller with bearing puller. （2）Unclench rollers carefully so no bearing puller or rollers are smashed.

Lift roller-to-mast clearance adjustment Set roller pitch of inner and outer masts to “L” dimension. Then proceed with the following adjustment.

Dimension “L” Unit: mm Model 3.0t-3.5t

2.0t-2.5t

1t-1.8t

2500-3300

368

328

288

3600

388

348

308

4000

418

378

338

4500

443

403

363

Max.lift height(mm)

Remove inner mast Attach wire rope to middle of inner mast and slide it out with a lifting device.

（1）Adjustable range “A” with shims: a. Dimension:0.1mm-0.6mm.(≤2 t)

Clearance of back up metal and mast steel Adjust clearance “B” to 0.1-0.8mm with shims, if needed. Thickness of shim is 0.5mm or 1mm.

b. Dimension:0-0.5mm (2.5t-3t). One or two may not have rubber pad; Dimension: 0.1mm-0.6mm without rubber pad.

Orientation pin ensures that side roller is vertical to inner mast track.

（2）It is recommended that clearance of roller and outer mast is about 0.8-1mm. Clearance cannot be adjusted. Replace roller if roller wear is excessive. （3）Apply lubrication to interface of inner mast and outer mast, interface of roller and mast. Be careful when applying lubrication in areas with a lot of wind or sand.

Apply a coat of grease to back-up metals.

Install mast and lifting jack on forklift truck.

Connect circle tube and high-pressure tube.

5.6.4 Left and right cylinder height adjustment. （1）Install left and right lifting jack on mast, pin must be installed into orientation hole of outer mast lower cross beam. （2）Install upper of piston rod on inner mast.

Inner mast lay evenly in the direction of left, right, upper and lower. If it is not even, please adjust by putting washer between hole of cylinder support and upper end of piston rod. （3）Install U-bolt onto cylinder, hand-tighten nuts and lock it with two tightening nuts. Screws down tighten bolt and nuts to avoiding them becoming loose.

5.6.5 Lifting chain adjustment Install fork arm carrier on inner mast, and install lifting chain, then install two nuts on end of every side. With mast sitting straight up, lower carriage completely. Temporarily adjust clearance of carriage to 74mm-76mm above ground. If necessary, adjust with chain adjusting nut.

To adjust tension of the lift chain, lower lifting jack until forks are on the ground ,and adjust chain adjusting nut (three each side) so that dimension C appears below when the middle portion of chain is pressed by a finger.

Dimension C: 25mm-30mm

5.6.6 Clearance of fork arm carrier assembly and rollers adjustment （1）Measure inside width “A” between inner masts. Take measurements at the top, bottom and center (cross beam) sections. （2）Measure right and left pitches, B,B’,B” of carriage side roller, carriage roller and thrust metal. （3）Calculate A-B, A-B and A- B". Each result shows clearances between each roller and inner mast. Adjust shims of each roller evenly on the left and right and make clearances, between smallest part of inner mast and carriage side roller.

A- B = 0.2mm-1.0 mm A-B’ = 0.1mm-0.8 mm A-B"= 0.1mm-0.8 mm

Shims 0.5 mm, 1mm Number of shims must be the same on the right and left sides, when using shims.

After clearance adjustment, push carriage assembly to see if it operates properly.

5.7 Disassembly and Assembly of lifting cylinder.

Remove tighten skew and nylon stopper, then remove cylinder head. （1）Remove dust gasket ring. （2）Remove Y-ring with screwdriver.

Warning： Keep your body away from equipment. （1）Turn off engine, put lifting cylinders falling into lowest position so that piston rod touches bottom of cylinder body so the oil flows back in the tank completely. （2）Unscrew piston rod and bolt. （3）Disconnect circle oil pipe, remove high pressure tubes. （4 ）Remove U-bolt of outer mast fixation board and tighten skew of other side. （5）Remove chain of outer mast. （6） Attach wire rope to inner mast and remove left and right lifting jack with a lifting device.

Caution： Do not re-use dust gasket ring, O-ring or Y-ring.

Replace with new. （3）Draw out piston rod, remove Y-ring on end of piston.

5.7.2 Install and replace faulty parts. （ 1 ） Coat parts with clean oil before installing. （2 ）Coat guiding bush and piston with hydraulic oil of the same brand as used in oil box. （3）Avoid letting dust or dirt from falling into lifting jack. （4）Assembly is the reverse of disassembly. （5）Install Y-ring on piston. （6 ）Install piston rod assembly into clean cylinder body.

Caution: Make sure the end of cylinder body mast is slick and clean, installation must set center, avoid scratching Y-ring. （7 ）Install replacing dust gasket ring and Y-ring in guiding bush and cylinder head.

5.7.1 Disassembly Rated capacity is less than 2.5 t Remove cylinder head and guiding bush. Rated capacity is more than 3 t

Caution: The guide sleeve with the installed Seal Ring needs to be lubricated with hydraulic fluid having the same brand and specification number as in the operating fluid reservoir.

（8）Place cylinder head into piston rod, screw

5.8 Disassembly and installation of tilt cylinder Warning: When detaching a cylinder used for tilting, pay attention to the following:  Secure the outer mast with a steel cable or chain from a crane to prevent the mast from falling down after the cylinder is detached.  Keep your housing as far away as possible from the equipment. Do not stand on a fork carriage that is equipped with a fork. （1）Lay down fork arm carrier completely. （2）Remove the bolt on the left and right bracket of outer mast, pull axis out. （3）Remove oil pipe to the inlet of tilt cylinder. （4 ）Remove the bolt on the bracket of frame, pull pin out, then move tilt cylinder. （ 5 ） To install, reverse the disassembly procedures.

down cylinder body.

5.8.1 Disassembly （1）Squeeze tilt cylinder with pliers, then pull piston rod out from the tilt cylinder, so remaining oil is discharged from the tilt cylinder. （2）Unscrew earring bolts (#2) until loos and unscrew and remove earring (#1). （3）Remove cylinder head guiding bush(# 3); （4）Draw out piston rod assembly (#4) (see figure). （5）Remove all dust gasket rings, O-ring and Y-ring.

（6 ）Remove dust gasket ring from the cylinder head using the same process for removing dust gasket ring from the cylinder head of lifting jack (see disassembly and installation of lifting jack). （7）Remove O-ring outside in the guiding bush. （8）Remove O-ring and Y-ring in the inner hole of guiding bush (see Fig. disassembly and installation of lifting jack).

（9）Remove the O-ring and the Y-Seal Ring from the hole in the guide sleeve. (See the lift cylinder dis-assembly figure above.)

Caution： Throw away and do not re-use the dust ring and the Y Seal Ring

5.8.2 Install tilt cylinder after replacing ring The order of installation is the reverse of disassembly, but observe the following: （1）Lubricate parts with clean hydraulic oil. （2） Avoid dust and dirt from falling into tilt cylinder. （3）Avoid scratching the end of cylinder body, and oil inlet and outlet. （4）Push piston rod into cylinder body when setting center, especially avoid scratching Yring. （5 ）Before installing guiding bush, wipe hydraulic oil backing boarded with employment oil trademark in the middle of O-ring and Y-ring in the inner hole of guiding bush. （6）Don’t scratch O-ring outside in the guiding bush when installing. （7）Remember to install nylon stopper and tighten screw after screw cylinder head.

5.9 Noticing proceeding of debugging （1）Adjust the mast Forward and Backward of the mast Place fork lift truck on level ground, operate control lever to move the mast forward or backward fully. As assembly debugging data required, adjust combined screw thread length until according with data of Backward. Then lock earring ring close. (see foregoing table for torque specifications of M10 bolt) （2）Adjust installation position of left and right lifting jack again. a. Adjust washer in the middle of piston rod and inner mast bracket if one lifting jack is not synchronized with the others when rising or falling, and if one lifting jack is a different height from the others. b. Loosen two nuts on the U-bolt. Mast will not rise or lower until relative position of U-bolt and lifting jack is suitable. Then screw down nuts and tightening screw on the U-bolt. Thus lifting jack can be used longer and wear of piston rod can be reduced. （3） See foregoing table for torque specifications of bolt or screw. Please refer to common bolt tightening torque prescribed in our company if you want know other torque specifications of bolt or screw. (refer to OPERATION AND MAINTAIN MANUAL backing boarded with it).

6. Electrical System 6.1 Controller Controller Summarize The controller Company adopts the internationally advanced closed-loop AC system and vector control technology. The design of large-screen dash display clearly shows common information such as the battery level, speed, and total runtime. Faults are indicated with codes to improve repair efficiency. Four operating modes can be set via the dash display to adapt to different conditions. （1）Actuating motor The actuating motor adopts a three-phase alternating current frequency conversion electric motor increasing conversion efficiency without a commutator or brushes in order to be maintenance-free. （2）Lift motor The Lift motor is direct current motor and adopts three-phase alternating electric motor, increasing conversion efficiency, without a commutator or brushes in order to be maintenancefree.

(3) Features related to Security and Protection – – – – – –

Battery polarity protection Circuit connection protection All around input connection error protection Circuit overload protection The circuit monitoring component limits the maximum current Heat protection ① When the controller temperature exceeds 85℃, overheating protection starts. The maximum current decreases as the temperature increases. When the electrically controlled temperature exceeds 95℃; the vehicle automatically stops and reports an alarm. ② When the motor temperature exceeds 145℃, heat protection starts. The maximum current decreases as the temperature increases. When the motor temperature exceeds 160℃, the vehicle automatically stops and reports an alarm.

–

–

–

–

Battery over-discharge protection When the battery capacity is too low, the maximum speed and current are greatly decreased.

External protection The electric controller is characterized by hermetic design, which effectively avoids ingress of external dust and liquid.

Starting sequence protection The vehicle starts only with correct operation sequences. The driving request must be sent to start the vehicle electric lock switch is closed.

Electronic self-protection is on when electrical components are damaged

(4) Operation Features – – –

The closed-loop control system makes the vehicle speed follow the accelerator, easier to control the speed no matter high or low.

The design of two speeds and acceleration is applicable to more scenarios.

The regeneration-to-zero technology makes the forklift truck change directions more smoothly.

–

Three regenerative braking modes: ① Regenerative braking when the accelerator pedal is partially released. ② Regenerative braking during reverse direction. ③ Regenerative braking during downslope process.

Besides improving drive security, it reclaims part of electrical energy and extends the working time of each shift.

– Downslope speed control: The motor speed depends on the accelerator. If the motor speed exceeds the setting value of accelerator, the controller will automatically brake, which provides the best slope protection function.

Precautions: –

–

To repair the electric controller, cut off the power first and short circuit the residual voltage on the capacitor by connecting the 10-100 ohm resistance to the positive and negative poles of controller. Failure of doing so may cause electric shock.

The magnetic field and electromagnetic radiation in the environment may influence the work of inverter, or damage the controller if such influence continues. Therefore, the magnetic field and electromagnetic radiation shall be kept off.

Controller Failure Code There are two LEDs including a yellow LED and a red LED. The two LEDs have four different display modes, indicating the type of information they are providing.

The Controller’s Two Leads Will Display This Repeating Pattern RED

YELLOW

RED

YELLOW

✱

✲✲

✱✱

✲✲✲

(first digit)

(2)

(second digit)

(3)

The numerical codes used by the yellow LED are listed in the Troubleshooting Chart below, which also lists possible fault causes and describes the conditions that set and clear each fault.

SUMMARY OF LED DISPLAY FORMATS The two LEDs have four different display modes, indicating the type of information they are providing.

DISPLAY

STATUS

Neither LED illuminated

Controller is not powered on, has a dead battery, or is severely damaged.

Yellow LED flashing

Controller is operating normally.

Yellow and red LEDs both on solid

Controller is in Flash program mode.

Red LED and yellow LED flashing alternately

Controller has detected a fault.

TROUBLESHOOTING The troubleshooting chart, below, provides the following information on all the controller faults:  Fault Code  Fault Name as displayed on the programmer’s LCD  The Effect of the Fault  Possible Causes of the Fault  Fault Set Conditions  Fault Clear Conditions Whenever a fault is encountered and no wiring or vehicle fault can be found, shut off KSI (Key Switch) and turn it back on to see if the fault clears. If not, shut off KSI and remove the 35-pin connector. Check the connector for corrosion or damage, make sure pins are engaged, clean it if necessary, and re-insert it.

CODE 1,2 1,3 1,4 1,5

1,6

1,7

1,8

2,1

2,2

2,3

2,4

2,5 2,6 2,7

2,8

2,9

PROGRAMMER LCD DISPLAY

POSSIBLE CAUSE

1. External short of phase U, V, or W motor connections.

2. Motor parameters are miss-tuned.

3. Controller defective.

1. Leakage to vehicle frame from phase U, V, or W (short in motor stator).

Current Sensor Fault 2. Controller defective.

1. External load on capacitor bank (B+ connection stud) that prevents the Recharged Failed capacitor bank from charging.

2. See 1311 menu Monitor » Battery: Capacitor Voltage.

Controller Severe Under 1. Controller is operating in an extreme environment. temperature 2. See 1311 menu Monitor » Controller: Temperature.

1. Controller is operating in an extreme environment.

Controller Severe Over 2. Excessive load on vehicle. temperature 3. Improper mounting of controller.

4. See 1311 menu Monitor » Controller: Temperature.

1. Battery Menu parameters are misadjusted.

2. Non-controller system drains on battery.

3. Battery resistance too high.

Severe Under voltage 4. Battery disconnected while driving.

5. See 1311 menu Monitor » Battery: Capacitor Voltage.

6. Blown B+ fuse or main contactor did not close.

1. Battery Menu parameters are misadjusted.

2. Battery resistance too high for given regen current.

Severe Overvoltage 3. Battery disconnected while regen braking.

4. See 1311 menu Monitor » Battery: Capacitor Voltage.

1. Controller is performance-limited at this temperature.

Controller Under 2. Controller is operating in an extreme environment. temperature Cutback 3. See 1311 menu Monitor » Controller: Temperature.

1. Controller is performance-limited at this temperature.

2. Controller is operating in an extreme environment.

Controller Over 3. Excessive load on vehicle. temperature Cutback 4. Improper mounting of controller.

5. See 1311 menu Monitor » Controller: Temperature.

1. Normal operation. Fault shows that the batteries need recharging.

Controller is performance limited at this voltage.

2. Battery parameters are misadjusted.

3. Non-controller system drain on battery Under voltage Cutback 4. Battery resistance too high.

5. Battery disconnected while driving.

6. See 1311 menu Monitor » Battery: Capacitor Voltage.

7. Blown B+ fuse or main contactor did not close.

1. Normal operation. Fault shows that regen braking currents elevated the battery voltage during regen braking Controller is performance limited at this voltage.

Overvoltage Cutback 2. Battery parameters are misadjusted.

3. Battery resistance too high for given regen current.

4. Battery disconnected while regen braking 5. See 1311 menu Monitor » Battery: Capacitor Voltage.

1. External load impedance on the +5V supply (pin 26) is too low. +5V Supply Failure 2. See 1311 menu Monitor » outputs: 5 Volts and Ext Supply Current.

Digital Out 6 Overcurrent 1. External load impedance on Digital Output 6 driver (pin 19) is too low.

Digital Out 7 Overcurrent 1. External load impedance on Digital Output 7 driver (pin 20) is too low.

1. Motor temperature is at or above the programmed Temperature Hot setting, and the requested current is being cut back.

2. Motor Temperature Control Menu parameters are mistuned.

Motor Temp Hot Cutback 3. See 1311 menus Monitor » Motor: Temperature and Monitor » Inputs: Analog2.

4. If the application doesn’t use a motor thermistor, Temp Compensation and Temp Cutback should be programmed Off. 1. Motor thermistor is not connected properly.

2. If the application doesn’t use a motor thermistor, Temp Compensation Motor Temp Sensor Fault and Temp Cutback should be programmed Off. 3. See 1311 menus Monitor » Motor: Temperature and Monitor » Inputs: Analog2.

Controller Overcurrent

CODE

PROGRAMMER LCD DISPLAY

3,1

Coil 1 Driver Open/Short

3,1

3,2

3,2

3,3

3,4

3,5

3,6 3,7

3,8

3,9

4,1 4,2 4,3 4,4 4,5 4,6

4,7

4,7

4,9

6,8

POSSIBLE CAUSE

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

1. Open or short on driver load.

Main Open/Short 2. Dirty connector pins.

3. Bad crimps or faulty wiring.

1. Open or short on driver load.

Coil2 Driver Open/Short 2. Dirty connector pins.

3. Bad crimps or faulty wiring.

1. Open or short on driver load.

EM Brake Open/Short 2. Dirty connector pins.

3. Bad crimps or faulty wiring.

1. Open or short on driver load.

Coil3 Driver Open/Short 2. Dirty connector pins.

3. Bad crimps or faulty wiring.

1. Open or short on driver load.

Coil4 Driver 2. Dirty connector pins.

Open/Short 3. Bad crimps or faulty wiring.

1. Open or short on driver load.

PD Open/Short 2. Dirty connector pins.

3. Bad crimps or faulty wiring.

1. Motor encoder failure.

Encoder Fault 2. Bad crimps or faulty wiring.

3. See 1311 menu Monitor » Motor: Motor RPM. 1. Motor phase is open.

Motor Open 2. Bad crimps or faulty wiring.

1. Main contactor tips are welded closed.

2. Motor phase U is disconnected or open.

Main Contactor Welded 3. An alternate voltage path (such as an external recharged resistor) is providing a current to the capacitor bank (B+ connection stud).

1. Main contactor did not close.

2. Main contactor tips are oxidized, burned, or not making good contact.

Main Contactor Did Not 3. External load on capacitor bank (B+ connection stud) that prevents Close capacitor bank from charging.

4. Blown B+ fuse.

1. Throttle pot wiper voltage too high.

Throttle Wiper High 2. See 1311 menu Monitor » Inputs: Throttle Pot. 1. Throttle pot wiper voltage too low.

Throttle Wiper Low 2. See 1311 menu Monitor » Inputs: Throttle Pot. 1. Brake pot wiper voltage too high.

Brake Wiper High 2. See 1311 menu Monitor » Inputs: Brake Pot. 1. Brake pot wiper voltage too low.

Brake Wiper Low 2. See 1311 menu Monitor » Inputs: Brake Pot. 1. Combined pot resistance connected to pot low is too low.

Pot Low Overcurrent 2. See 1311 menu Monitor » Outputs: Pot Low. 1. Failure to write to EEPROM memory. This can be caused by EEPROM EEPROM Failure memory writes initiated by VCL, by the CAN bus, by adjusting parameters with the 1311, or by loading new software into the controller.

1. KSI, interlock, direction, and throttle inputs applied in incorrect sequence.

HPD/Sequencing Fault 2. Faulty wiring, crimps, or switches at KSI, interlock, direction, or throttle inputs.

3. See 1311 menu Monitor » Inputs.

1. Emergency Reverse operation has concluded, but the throttle, forward Emer Rev HPD and reverse inputs, and interlock have not been returned to neutral.

1. This is a safety fault caused by a change in certain 1311 parameter settings so that the vehicle will not operate until KSI is cycled. For Parameter Change Fault example, if a user changes the Throttle Type this fault will appear and require cycling KSI before the vehicle can operate.

1. VCL code encountered a runtime VCL error.

2. See 1311 menu Monitor » Controller: VCL Error Module and VCL Error.

VCL Runtime Error This error can then be compared to the runtime VCL module ID and error code definitions found in the specific OS system information file.

CODE

6,9

7,1 7,2

7,3

PROGRAMMER LCD DISPLAY

POSSIBLE CAUSE

1. External load on the 5V and 12V supplies draws either too much or too little current.

External Supply Out of 2. Fault Checking Menu parameters Ext Supply Max and Ext Supply Min Range are mistuned.

3. See 1311 menu Monitor » Outputs: Ext Supply Current.

OS General 1. Internal controller fault.

1. Time between CAN PDO messages received exceeded the PDO PDO Timeout Timeout Period.

1. Stalled motor.

2. Motor encoder failure.

3. Bad crimps or faulty wiring.

Stall Detect 4. Problems with power supply for the motor encoder.

5. See 1311 menu Monitor » Motor: Motor RPM.

8,7

Motor Characterization Fault

8,8

Encoder Characterization Fault

8,9

Motor Type Fault

9,2

EM Brake Failed to Set

9,3

Limited Operating Strategy (LOS)

9,4

Emer Rev Timeout

1. Motor characterization failed during the motor characterization process.

1. Encoder characterization failed during the motor characterization process.

2. Motor encoder pulse rate is not a standard value (32, 48, 64, 80 ppr).

1. The Motor type parameter value is out of range.

1. Vehicle movement sensed after the EM Brake has been commanded to set.

2. EM Brake will not hold the motor from rotating.

1. Limited Operating Strategy (LOS) control mode has been activated, as a result of either an Encoder Fault (Code 36) or a Stall Detect Fault (Code 73).

2. Motor encoder failure.

3. Bad crimps or faulty wiring.

4. Vehicle is stalled.

1. Emergency Reverse was activated and concluded because the EMR Timeout timer has expired.

2. The emergency reverse input is stuck On.

6.2 OPS System (Optional)

The Operator Presence Sensing (OPS) system is a program (Software) that senses whether the driver is seated in correct posture through a seat sensor. If the driver is not properly seated, all the hydraulic operations will be stopped and powered travel is cut off. This system helps prevent unintended operation when operators leave the seat. Operators cannot perform driving, loading and unloading operations without sitting on the correct driving position.

Driving Protection Function If the driver leaves the seat or the seat belt is unfastened (optional seat belt switch is installed) for more than 3 second when the vehicle is in driving status, the vehicle will automatically stop. The seat switch indicator “ ” on the instrument will light up and the buzzer will make a continuous alarm sound. Only when the driver sets the parking brake or correctly sits on the seat and the direction switch is shifted to neutral, the seat switch indicator “ will go out and the driving OPS intervention will be released.

” on the instrument

Working Protection Function If the driver leaves the seat or the seat belt is unfastened (optional seat belt switch is installed) for more than 3 second when the vehicle is in working status, the hydraulics and traction will automatically stop. The seat switch indicator “ ” on the instrument will be lighted and the buzzer will make a continuous alarm sound. The automatic OPS indicator is lighted, the buzzer warns, and the hydraulics and traction operation automatically stops. Only when the driver sits on the seat correctly, the seat switch indicator “ OPS status will be released.

” on the instrument will go out and the working

Alarm Function When the seat sensor detects that the seat switch is turned off, the buzzer will make a continuous alarm sound within 1 second and the seat switch indicator “

” will be lighted. The

seat switch indicator “ ” is always on when the seat switch is off, which indicates that OPS of the vehicle is in enabled status.

Neutral Recovery Function If the direction switch is not restored to neutral and the seat switch is turned on, the buzzer will make a continuous alarm sound, reminding the operator that OPS is in enabled status.

OPS Exception Handling For the cases mentioned below, stop the vehicle at a safe place and contact your dealer.



a. After the driver leaves the seat, the seat switch indicator “

” cannot be lighted.

b. When the driver returns to the seat, the seat switch indicator “

” cannot go out.

Caution For the forklift truck with a seat belt protection switch, the driver needs to correctly sit on the seat and fasten the seat belt before properly operating the vehicle. If the OPS system is enabled when the operator drives upslope, the driving power supply will be interrupted and thus the vehicle will roll downslope. To prevent this situation, the driver must correctly sit on the seat when driving for upslope.

Fork Lock Function after Power Failure This function indicates that the fork will not lower when the ignition switch is turned off or the power is cut off. The fork will not move downward even if the downward control lever is operated.

Electrical Principle Diagram

Electrical Principle Diagram Overview 37

Maintenance Records Date

Maintenance Content

Maintenance Personnel

UTILEV TECHNICAL PUBLICATIONS “UTILEV” is a registered trademark. THE UTILITY LIFT TRUCK and UTILITY YOU CAN TRUST are trademarks in the United States and certain other jurisdictions.

P/N 76502794

06/2017

(04/2017)