PDF DOWNLOAD: Yale A861 (NDR GA) Forklift Service Manual

Sheet 1: Operating Instructions OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS-GENERAL Before attempting to operate this truck, carefully read and understand these operating procedures.

Make sure the truck is in proper operating condition. Visually inspect the entire truck for any damage that may have occurred during shipment.

NOTE: Throughout this manual the terms right, left, front and rear relate to the viewpoint of an operator riding on the truck facing the forks.

Familiarize yourself with the information contained on the capacity plate which is located on the battery compartment cover. Information on this capacity plate is shown in Figure 1-1 and as follows: A. Serial Number This is an identification number assigned to this particulartruck and should be used when ordering service parts or when requesting any information from your Yale industrial truck dealer. The serial number is a six digit number preceded by a letter and is stamped on the lift truck frame and on the nameplate.

B. Model Code The model number and the serial number should be used when requesting information. An explanation of the model code is located on Page B of this manual.

C. Truck Weight This is the approximate weight of the truck without a load on the forks. This weight plus the weight of the load to be moved must be considered when operating on elevated floors or elevators.

D. Capacity Rating This rating shows the maximum load capacity of this truck. Personal injury and damage to the truck can occur if the capacity rating is exceeded.

This truck meets all applicable mandatory requirements of ANSI B56.1 Safety Standard for Powered Industrial Trucks at the time of manufacture. In addition, these trucks are classified by Underwriters' Laboratories, Inc. and/or approved by Factory Mutual Engineering Corporation for the type designation. Consult UL Index of Classified Products and FM Approval Guide.

No additions, omissions or modifications should be made that will affect compliance to the previously stated requirements or in any way minimize the effectiveness of the safety devices.

Safety and informational labels are located in conspicuous locations on this truck and should be strictly followed.

Check the capacity plate of each truck before operation. These safety and informational labels must be replaced immediately if missing or defaced. Labels will vary with type of truck and equipment installed. Refer to the Parts Manual for part number and location for all labels.

NOTICE TO USER The U.S.A. Occupational Safety and Health Act of 1970 and other national safety codes require a new plate if this unit is equipped other than as stated on plate. Obtain the correct plate from your authorized dealer.

If a truck is shipped incomplete from the factory, the capacity plate will be covered by the label shown above. Do not operate the lift truck until you obtain a complete capacity plate from your Yale industrial truck dealer.

Sheet 1: Operating Instructions

Capacities and cautions contained on this capacity plate must be strictly followed.

Figure 1-1 -Capacity Plate Information SAFETY LABELS A definition of the safety labels used on the motorized lift trucks is listed below.

DANGER DANGER: Identified by a Red Label, immediate hazards which WILL result in severe personal injury or death.

WARNING WARNING: Identified by an Orange Label, hazards or unsafe practices which MAY result in personal injury or death.

CAUTION CAUTION: Identified by a Yellow Label, hazards or unsafe practices which may result in minor personal injury, product or property damage.

THE READER MAY FIND ANY OR ALL OF THE FOLLOWING LABELS USED IN THIS PUBLICATION. AN UNDERSTANDING OF THEIR USE, AS GIVEN BELOW WILL AID THE READER. DANGER Directs attention to unsafe practices and/or existing hazards which WILL result in severe personal injury or death if proper precautions are not taken.

WARNING Directs attention to unsafe practices which could result in personal injury or death if proper precautions are not taken.

CAUTION Directs attention to hazards or unsafe practices which may result in minor personal injury, product or property damage if the proper precautions are not taken.

NOTE An advisory procedure, practice, condition, etc., which is essential to emphasize.

OPERATING INSTRUCTIONS OPERATOR PRE-CHECKS AND INSPECTION Before each shift, every 8 hours, or before beginning truck operation it is the operator's responsibility to carry out the following checks and inspections. Do not operate the truck if it is in need of repair, if it is in an unsafe condition, or might contribute to an unsafe condition. Remove the key and report the condition to the proper authority. If the truck becomes unsafe in any way while you are operating it, STOP operating the lift truck and report the matter immediately to the proper authority.

Basic maintenance information and the Recommended Schedule of Maintenance are in the Operating Manual, Part Number 520371745, located in the document holder on the mast screen. Also refer to Section 2 of this manual.

1. Make sure overhead guard, load backrest extension, wire screens and all other safety devices are attached.

2. Make sure all capacity, safety and informational plates or labels are attached. This truck is not considered safe

Sheet 1: Operating Instructions to use without a legible, properly filled out nameplate.

Contact Yale Materials Handling Corporation or your local dealer for Yale industrial trucks if the nameplate is not present and legible. See parts manual for label page with label and plate locations.

3. Inspect truck for any damage that might have occurred during the previous shift.

4. Inspect truck for any signs of external leaking of the battery, steering system or hydraulic system.

5. Check hydraulic hoses for leaking, chafing, cuts, or reinforcement showing through the outside of the hose.

6. Make sure chains are not damaged or kinked. Check for excess slack or mistracking on the sheaves.

7. Make sure all latches are adjusted (if necessary) and fastened.

8. Operate brake, hydraulic controls, lift, auxiliary functions and steering. Make sure all controls operate correctly and return to their proper positions. See section on Operating Controls for detailed descriptions.

9. Inspect condition of wheels and tires.

10. Inspect forks for damage. Make sure they are correctly attached and locking clips are in their proper position.

11. Test horn, lights, gauges, and meters. Make sure they work correctly.

12. Make sure any unusual noises are investigated immediately.

OPERATING PROCEDURE-GENERAL •

Read and understand the Operating Manual supplied with the lift truck. Notify your supervisor if the manual is not available.

•

Keep hands, feet, and other parts of your body inside the designated operator's compartment. Parts of your body outside the truck can be injured when passing obstructions.

•

Do not permit passengers to ride on the truck.

•

Observe and comply with instructions concerning floor loadings. Know the weight of your truck and load combined. Truck weight information is located on the capacity plate.

•

Travel with the load lowered and, where possible, tilted back. Do not elevate the load except during stacking.

•

The operator can change the direction of travel while the lift truck is moving, by moving the direction control handle in the opposite direction. The truck will come to a stop and then accelerate in the opposite direction, unless the control lever is released. This is called "plugging".

•

Look in the direction of travel and keep a clear view of the path of travel.

•

If visibility is impaired by the load, operate truck with the forks trailing and always look in the direction of travel.

•

Start, stop, travel, steer, and brake smoothly. Slow down for turns and on uneven or slippery surfaces that could cause truck to overturn or slide.

•

Watch clearances around forks. The driver must be aware that the forks can sometimes extend beyond the load. This may cause the forks to hit an object or lift another load.

•

Watch out for any obstructions, especially those overhead. Check clearances.

•

Do not run over objects on the roadway surface as truck stability and steering may be adversely affected.

•

When approaching cross aisles, slow down, sound horn, and keep to the right side of aisle.

•

Operate truck under all conditions at a speed that will permit it to be brought to a stop in a safe manner.

•

Narrow Aisle trucks are designed for use on smooth, hard floors with minimal grades.

OPERATING INSTRUCTIONS

Sheet 1: Operating Instructions •

Operate a loaded truck with the load upgrade. Operate an unloaded truck with the lifting mechanism downgrade.

•

Do not push loads with the truck.

•

Watch out for pedestrians at all times. Do not drive up to anyone standing in front of an object..

•

Observe all traffic regulations, including authorized plant speed limits. Under normal traffic conditions, keep to the right. Maintain a safe distance from the truck ahead (approximately three truck lengths), and keep the truck under control at all times.

•

Yale lift trucks are not intended for use on public roads.

•

When leaving truck unattended, lower the lifting mechanism, shut off power, and remove key. Chock wheels if truck is parked on an incline.

•

Report all accidents involving personnel, building structures and equipment to the proper authority.

•

Check all gauges and indicator lights for correct operation. Frequent reading of the instrument panel should become a habit.

•

Avoid any abrupt moves. Be a professional. "HANDLE WITH CARE."

•

Follow the Recommended Schedules of Maintenance. Maintain your lift truck for dependable and economical operation.

SHUT DOWN PROCEDURE When leaving truck unattended, fully lower forks, shut off power, set brake, set coast control to off (when equipped), neutralize controls, and remove key. If you park the truck on an incline, chock the wheels.

FORK ADJUSTMENT Forks should be spaced as far apart on the fork carriage as the load being moved will allow. Both forks should always be the same distance from the center of the fork carriage.

Check for the presence and condition of studs at each end of the carriage upper fork clip slide. If studs are damaged or missing they should be repaired or replaced before the forks are adjusted.

To adjust the forks, raise them a few inches off the floor. Lift up on the keeper pin and slide the forks along the carriage by pushing them away from you. Do not pull the forks toward you. When the forks are set to the desired position, make sure the keeper pin is down in a slot on the top of the fork carriage plate.

SAFETY AND OPERATIONAL CHECK LIST A "Daily Check List" similar to the one shown on the next page should be used every day before operating the truck.

The check lists are available in tablet form with 50 sheets per tablet and can be obtained from your local Yale Industrial Truck Dealer for a nominal fee.

Both this manual and the Operating Manual contain the Recommended Schedules of Maintenance which should be used as a guide along with the Lubrication Instructions.

A professional operator should also be familiar with the information contained in the American National Safety Standard for Powered Trucks -ANSI B56.1, Part I I.

Sheet 1: Operating Instructions

Figure 1-2 -Typical Narrow Aisle Electric Lift Truck NOTE: This Daily Check List is available for the Operator. Some items on this list may not be applicable to your truck. This convenient check list is in tablet form and can be ordered through your Yale Industrial Truck Dealer.

Form Number 944-6418-A.

Sheet 1: Operating Instructions

MODEL AND OPERATING INFORMATION The NR-CA/NR-GA (reach) and NDR-CA/NDR-GA (double reach) narrow aisle electric lift trucks have lifting capacities of 1362 kg (3,000 Ibs) to 2043 kg (4,500 Ibs) with a 609.6 mm (24 in) load center.

These trucks feature operator comfort, low noise and vibration levels, and ease of brake and control handle efforts.

The large operator compartment is designed for flexible side stance position. Yale Hi-Vis Triplex masts provide excellent visibility for these models.

Before attempting to operate this truck, carefully read and understand these operating procedures. Make sure the truck is in proper operating condition. Be sure all safety devices, such as the overhead guard, mast screen, and the load backrest extension are in place and properly secured.

Sheet 1: Operating Instructions

Figure 1-3 -Narrow Aisle Electric Lift Truck

Figure 1-4 -Operating Controls 1. The Instrument Display is mounted on the mast, within easy sight, and has the following features: A. The Battery Indicator has a 10-bar green, yellow, and red light emitting diode (LED) to indicate battery charge status. As power is used, the LEDs will turn off, starting with green. The red LED, second from the bottom, will flash indicating a nearly discharged battery. The bottom red LED will alternately flash with the LO-Batt indicator LED (a crossed battery symbol), indicating a discharged battery. The lift function will be locked out at this point.

B. The Message Center is a 16 character, dot matrix, liquid crystal display (LCD) with green back light. There are four yellow and one red/yellow LED indicators. The 16 character, alphanumeric display shows the hourmeter readings, truck performance status, and a warning or fault condition. When a warning message is received, the warning/fault indicator will blink as a yellow light. When a fault message is received, the warning/fault indicator will blink as a red light.

Sheet 1: Operating Instructions

Figure 1-5 -Instrument Display C. The Instrument Display Hourmeter switch is operator controlled and is used for on-demand display of hourmeter information. The hourmeter data can be displayed at any time by pressing the hourmeter switch.

The switch is marked with an hour glass symbol. Press once to display truck hours to 1 /10 of an hour. Press twice to display drive motor hours. Press three times to display the hoist motor hours. Press four times to return to the normal display. After 30 seconds the display will return to the normal display mode, which indicates the current operational status of the truck.

D. The Drive Mode switch allows the operator to select the level of traction motor controller speed best suited to the application. Operation of the drive mode switch will cause the green indicators and corresponding drive modes to increase from Turtle (mode 1) to Mid (mode 2) to Rabbit (mode 4). Turtle mode provides slower acceleration and reduced top speed. It is also a valuable setting when training new operators. Mid mode reduces acceleration with full travel speed. Rabbit mode provides maximum acceleration and travel speed. When the key switch is turned to off, the selected drive mode is retained. When the battery is disconnected the drive mode defaults to the Rabbit mode. Mode 4 is entered when the brake pedal is released part way, opening the first of two switches. The brake signal to the MIB goes low, causing the MIB to stop transmitting a throttle signal to the PMC, which applies a braking force. If the pedal is released all the way it will open the second switch, activating the electric brake and caster brake, stopping the truck. The rates of acceleration and travel speeds are programmable and can be adjusted by a qualified service technician.

E. The LED Function Selection Lights are for the display of Status, Warning and Fault conditions. Status messages will be displayed for Lift, Reach, Tilt and Sideshift. The indicators will display up-to-date status conditions, independent of the present LCD display. There are four yellow and one red/yellow LED indicators.

The Instrument Display is powered even when the vehicle is not being operated. When the battery is disconnected, the dashboard contains an internal back-up battery, capable of memory retention of the battery Indicator, hourmeter, and drive mode data. This internal battery is not serviceable and is designed to last for the life of the instrument display.

2. Control Handle -The multi-function control handle is used for hydraulic and traction operation. Each auxiliary function, Reach, Tilt and Sideshift (optional) has a separate switch. There is also a switch for the horn. For location of the functions see Figure 1-6 and Table 1-1.

The handle is moved horizontally for forward and reverse travel. Up and down movement while pressing an auxiliary function switch, controls the auxiliary hydraulic functions. Up and down movement without pressing an auxiliary function switch operates the lift function, up for lift, down for lower. Once the handle is moved from the neutral position the switch can be released. Thefunction will be locked until the handle is returned to the neutral position.

NOTE: Diagonal movement of the handle will control both travel and a hydraulic function simultaneously.

Sheet 1: Operating Instructions

Figure 1-6 -Control Handle Table 1-1 -Control Handle Switch Locations

If the operator wants to perform an auxiliary function in one direction, immediately followed by the reverse direction, (example: extend then retract), the reach auxiliary function switch should be pressed and held until the handle is moved from the extend (up) position, through the neutral position into the retract (down) position. If the switch is not held while moving through the neutral position, the control will select the lowering function and mast lowering will occur.

WARNING: Unintentional mast lowering can cause damage or injury.

The operator can change the direction of travel while the lift truck is moving by moving the control handle in the opposite direction of travel. The lift truck will come to a stop and then accelerate in the opposite direction. This action is called "plugging".

3. Steering Disc -The steering disc controls truck direction with 5 turns lock to lock.

WARNING: Reverse steering is available for this truck. Operator should check steering direction before operating truck.

Figure 1-7 -Steering Disc 4. Key Switch -The key switch is a three-position switch. The first position is OFF (marked O). The second position is RUN (marked I). The third position is START (marked II). The key automatically returns to the second position, after it is released in the third position. The key switch is located to the right side of the control handle.

Sheet 1: Operating Instructions

Figure 1-8 -Key Switch 5. Battery Power Disconnect - A red battery power disconnect knob is located next to the key switch. When pressed, battery power is shut off to all circuits in the truck. When the battery power disconnect switch is activated, power is still supplied to the battery indicator. Power is restored by turning the key switch to the start position.

Figure 1-9 -Battery Power Disconnect 6. Brake Pedal - The brake is applied when the pedal is released. The brake is released when the pedal is depressed. Braking force can be controlled by the operator. The brake pedal works with the "Operator Sensing Switch". The operator's right heel must be on the Operator Sensing Switch and the left foot must depress the brake pedal before any truck functions will work. After the operator is in the correct position, the hydraulics can be operated with the left foot raised (brake applied). The right foot can be lifted while traveling with the brake pedal depressed (brake released). When the operator leaves the truck, the parking brake is automatically applied and power steering is turned off.

2.

1.

BRAKE PEDAL OPERATOR SENSING SWITCH Figure 1-10 -Brake Pedal

7. The Operating Manual is sent with the truck and is located in the container on the mast screen. The Operating Manual is a permanent reference and must be available for the operator's use at all times. Read and understand this manual before operating the lift truck.

Sheet 1: Operating Instructions

Figure 1-11 -Operating Manual SAFE MAINTENANCE PROCEDURES Your Yale industrial truck, as manufactured, meets all the applicable mandatory requirements of the American National Safety Standard for Powered Trucks -ANSI B56.1, Part I I. All standard trucks conform to the Underwriters Laboratories requirements forthe type designation shown on the nameplate. The truck is also equipped with certain safety devices as standard equipment. For example, all high lift trucks are equipped with a load backrest extension and high lift rider trucks with an operator's overhead guard.

No additions, omissions, or modifications should be made that will affect compliance to the above requirements or in any way reduce the effectiveness of the safety devices.

The following instructions have been prepared for your safety and the safety of your fellow workers during maintenance operations and should be strictly followed. Carefully read and understand the maintenance procedures before attempting to repair the truck. When in doubt of any maintenance procedure, contact your local Yale industrial truck dealer.

1. When necessary to work with mast in a raised position, install a safety chain to restrain moving parts. Connect moving parts to a part that does not move.

2. The Recommended Schedules of Maintenance should be used as a guide for inspection of the truck.

3. Only qualified and authorized personnel should be permitted to maintain, repair, adjust, and inspect the truck.

4. The work area should be properly ventilated. Keep shop clean and floor dry.

5. Avoid fire hazards and have fire protection equipment present. Do not use an open flame to check level of electrolyte. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts.

6. Raise the lift truck only if it is on a solid level floor. Disconnect the battery. Use solid, one-piece blocks or other positive truck positioning devices to support the truck. Chock the wheels to prevent movement of the truck.

7. Before removing any component from the truck, such as counterweights, mast assembly, drive unit, etc., make surethat the lifting mechanism and slings are of the proper capacity and in good condition.

8. When working on the hydraulic system, be sure the truck is turned off, battery is disconnected, mast is lowered, and the hydraulic pressure is relieved in hoses and tubes.

9. Brakes, steering mechanisms, control mechanisms, warning devices, guards, and safety devices should be inspected regularly and maintained in a safe operating condition.

10. All parts of lift and tilt mechanisms and frame members should be carefully and regularly inspected and maintained in a safe operating condition.

11. All hydraulic systems should be regularly inspected and maintained in conformance with the maintenance schedules. Lift cylinders, valves, and other similar parts should be checked to assure that "drift" has not developed to the extent that it would create a hazard.

12. Special trucks or devices designed and approved for hazardous area operation should receive special attention to ensure that maintenance preserves the original approved safe operating features.

13. Modifications and additions which affect capacity and safe truck operation should not be performed by the customer or user without the manufacturer's prior written approval. Operation and maintenance instruction plates

Sheet 1: Operating Instructions and capacity tags or labels should be changed accordingly.

14. Operation and maintenance instruction plates and capacity tags, and labels should be maintained in legible condition.

15. The truck should be kept in clean condition to minimize fire hazards and facilitate detection of loose or damaged parts.

16. Checking the performance of the truck or attachments should be conducted in an authorized safe clearance area.

17. Always use Yale replacement parts to be sure they are interchangeable with the original parts and are of a quality equal to that provided in the original equipment.

You should also be familiar with additional maintenance safety instructions contained in the following publications: 1. ANSI B56.1 -Safety Standard for Powered Industrial Trucks This booklet can be obtained from: Society of Mechanical Engineers 345 E. 47th Street New York, NY 10017 2. ANSI/NFPA 505 -Type Designations, Area of Use, Maintenance and Operation of Powered Industrial Trucks This booklet can be obtained from: National Fire Protection Assoc.

Batterymarch Park Quincy, MA 02269 3. Code of Federal Regulations Title 29, Chapter XVII, Section 1910.178 (OSHA) Powered Industrial Trucks This booklet can be obtained from: Superintendent of Documents U.S. Government Printing Office Washington, DC MOVING A DISABLED LIFT TRUCK WARNING: Use extra care when towing a lift truck if there is a problem with any of the following: 1. Brakes do not operate correctly.

2. Steering does not operate correctly.

3. Tires are damaged.

4. Traction conditions are bad.

5. If the lift truck must be towed on a steep grade.

Remember! There may be problems with more than one of the above areas of the truck. Do not tow the lift truck if you have not identified all problem areas.

If the steering pump motor does not operate steering the lift truck can be difficult. Poor traction can cause the disabled lift truck or towing vehicle to slide. Steep grades will increase the required brake effort.

HOW TO TOW A LIFT TRUCK 1. The towed lift truck must have an operator.

2. If another lift truck is used to tow the disabled lift truck, that lift truck must have an equal or lager capacity than the disabled lift truck. Install an approximate half capacity load on the forks of the lift truck being used to tow the disabled lift truck. This half capacity load will increase the traction of the lift truck. Keep the load as low as possible. If the lift truck must be moved without electrical power, the brake can be manually released. There are two holes with 1 /4-20 UNC threads in the back plate. Install capscrews in the holes. Use the capscrews to push the armature plate away from the friction disc.

Sheet 1: Operating Instructions 3. Tow the lift truck slowly.

4. Raise the carriage and forks approximately 12 inches (30 cm) from the surface. Install a chain to prevent the carriage and mast from moving.

5. If another lift truck is used to tow the disabled lift truck, that lift truck must have an equal or larger capacity than the disabled lift truck. If a counterbalanced lift truck is being used for towing, place a half capacity load on its forks. This half capacity load will increase the traction of the lift truck. Keep the load as low as possible.

Never lift a disabled lift truck unless the lift truck must be moved and cannot be towed. The lift truck used for lifting the disabled truck must have a rated capacity equal to or greater than the weight of the disabled lift truck. The capacity must be for a load center equal to half the width of the disabled lift truck. See the nameplate of the disabled lift truck for the approximate total weight. The forks must extend the full width of the disabled lift truck. Center the weight of the disabled lifttruck on the forks and be careful not to damage the underside of the lift truck.

HOW TO PUT A LIFT TRUCK ON BLOCKS WARNING: The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity, mast, drive axle and battery.

WARNING: Put the lift truck on blocks only if the surface is solid, even and level. Make surethatany blocks used to support the lift truck are solid, one piece units. Put blocks in front and back of the tires to prevent movement of the lift truck.

CAUTION: To prevent damage, make sure the reach mechanism is fully retracted before lifting the rear of the lift truck.

Figure 1-12 -Putting a Lift Truck on Blocks HOW TO RAISE THE LOAD WHEELS 1. Release the brake pedal to apply the brake. Put blocks on both sides (front and back) of the drive/steer tire and the caster wheels to prevent movement of the lift truck.

2. Use an overhead crane and web sling under the outriggers at the mast, to raise the load wheels. Another lift truck can also be used to raise the outriggers. Make sure that the crane and sling or other lift truck has a capacity of at least 2/3 the total weight of the lift truck as shown on the nameplate.

3. Raise the outriggers only enough to suspend the wheels. Install blocks under the outriggers at the rear of the wheels to support the lift truck.

HOW TO RAISE THE DRIVE/STEER TIRE AND CASTER WHEELS 1. Put a block on each side (front and back) of the load wheels to prevent movement of the lift truck.

Sheet 1: Operating Instructions 2. Use a special low clearance hydraulic jack under the rear frame to raise the drive/steer tire and caster wheels.

Another lift truck can also be used to raise the lift truck. Make sure that the jack or other lift truck has a capacity of at least 2/3 the total weight of the lift truck as shown on the nameplate.

3. Raise the lift truck only enough to suspend the drive/steer tire and the caster wheels. Install blocks under the rear of the frame to support the lift truck.

PRECAUTIONS FOR TRUCKS IN STORAGE Complications can arise as a result of improper handling of trucks during periods of storage.The main areas of concern are electric motors, hydraulic components and electric truck batteries. Electric powered trucks can best be protected by being operated for a short exercise period each month.

Before placing any truck in storage, you must choose an area which is clean, dry and free from airborne contaminants.

When parking the truck, chock the wheels. The forks should be fully lowered and tilted forward. For safety and increased usable floor area, remove the forks and tag them with the truck serial number. Coat all exposed portions of cylinder rods and lift chains with fresh high grade SAE 30 or 40 weight engine oil.

Electric trucks should be stored without batteries, therefore you will have to provide a fully charged battery for the exercise period.

Operate the truck for a short period of time each month. Electric drive motors must be exercised to keep them free of rust and contamination caused by condensation built up over periods of inactivity. Operate the truck with the motor at its normal temperature for at least five minutes.

All hydraulic cylinders should be cycled several times each month to keep the seals active and to coat the interior walls with oil. Actuate each cylinder, in both directions, until the stops are reached. With the power off, actuate each control button to relieve hydraulic pressure.

Prior to operating the truck, make a visual inspection for leaks or signs of deterioration. Check the fluid level in the hydraulic tank and brake master cylinder. Take corrective action if necessary.

When a truck is returned to service, it should be given the 350 hour inspection shown in the Recommended Schedule of Maintenance found in Section 2.

PRECAUTIONS FOR BATTERIES IN STORAGE Batteries should be placed on a wooden pallet and stored in a dry, moderately cool area. Lead acid batteries will slowly "self discharge" overa period of time. This "self discharge" is dueto a chemical reaction. This chemical reaction can be accelerated by heat, resulting in a more rapid "self discharge". The average rate of discharge results in a 0.001 drop in specific gravity per day. If the self discharge is left uncontrolled, excessive sulfating can occur which is difficult to reduce and may damage the plates.

A discharged battery with a specific gravity of 1.100 will freeze at -8 °C (+18 °F) . A fully charged battery with a specific gravity of 1.280 will freeze at -67°C (-87°F).

OPERATING INSTRUCTIONS The following procedure should be followed when placing a battery in storage or when not in operation for more than 30 days.

1. Give equalizing charge prior to placing new batteries in storage. Used batteries are to be fully charged and allowed to balance for approximately three more hours.

2. Neutralize and clean the battery with a solution of 16 ounces of baking soda in one (1) gallon of water.

3. Store in a cool, dry location.

4. Check each cell in the battery at least once every 30 days and boost charge when specific gravity falls below 1.240.

5. Protect batteries from ambient contamination.

If a greasy film forms on the top of a battery, it is acid and must be neutralized with a solution of 16 ounces of baking soda in one (1) gallon of water.

Sheet 1: Operating Instructions

Sheet 2: General Truck and Lubrication GENERAL This manual covers the repair and maintenance of the NR-CA/ NR-GA (reach) and NDR-CA/ NDR-GA (double reach) narrow aisle electric lift trucks having lifting capacities of 1362 kg (3,000Ibs) to 2043 kg (4,5001bs), with a 609.6 mm (24 in) load center.

The manual has been subdivided into various sections which contain instructions for removal, disassembly, inspection, assembly, installation, and adjustment of the major components. Additionally, this manual includes, within this section, the recommended schedules of maintenance and lubrication schedule. Troubleshooting charts and recommended specifications are also included within the sections.

Various components that are not covered in specific sections are covered in this section. Some of these components must be opened or removed to complete maintenance or repairs covered in other sections.

Figure 2-1 -NR/NDR Lift Truck FRAME The lift truck frame is a one-piece structure fabricated from steel incorporating mounting points for the mast, hydraulic controls, electrical controls, pumps, and motors.

LOAD BACKREST AND FORKS Two different arrangements are used on these lift trucks for attaching the load backrest and forks. One arrangement is for units supplied with shaft-type forks (standard) while the other arrangement has hook-type forks. The removal and assembly will depend upon the type of forks used. See Section 8, MAST AND REACH ASSEMBLY for the recommended removal and assembly for the LOAD BACKRESTS AND FORKS. WIRE GUARD A wire guard is provided to prevent fingers or hands from being placed into the mast area. The lift truck should never be operated without the wire guard. The wire guard may be removed for servicing the lift truck by removing the four attaching capscrews. Two of the capscrews retain the top of the wire guard to the overhead guard, while the bottom two capscrews retain the wire guard to the lift truck frame. The operating manual holder is located on the wire guard.

ACCESS DOOR AND COVERS The drive unit access door is mounted on a hinge and secured by two capscrews at the rear of the lift truck.

The battery compartment cover is made of molded plastic. It covers the compartment above the battery compartment. The cover is furnished in five sizes, depending on the size of the battery compartment. To remove the cover, unsnap from spring clips.

The drive unit compartment cover is located over the drive unit compartment and adjacent to the steering disc. The cover is attached with spring clips. To remove the drive unit compartment cover, snap off the cover from its mounting points. To install the drive unit compartment cover, position the cover under the battery compartment cover, align the

Sheet 2: General Truck and Lubrication cover, and snap in place.

The floor plate located in the operator's compartment is not attached. To remove the floor plate, liftthe plate up offtheframe and disconnect the connector for the operator sensing switch connector, then remove the floor plate from the lift truck. To install the floor plate, connect the connector to the main harness and position the floor plate in the frame of the operator's compartment.

OVERHEAD GUARD The overhead guard consists of the overhead guard weldment and one supporting post. The overhead guard weldment is attached to the mast with six capscrews and hardened washers. The rear post is attached to the lift truck frame with a capscrew and washer in the drive unit compartment, while the top slides into the overhead guard weldment.

The overhead guard is furnished in two different sizes, depending upon the battery compartment size.

To remove the overhead guard from the truck, open the drive unit compartment and remove the capscrew and lockwasher retaining the postto the frame. Hold the postwhile removing the hardware so that the post does not slide out of the slot in the overhead guard weldment. Attach a sling and lifting device to the overhead guard weldment.

Remove the six capscrews and hardened washers retaining the overhead guard weldment to the mast and lower the overhead guard weldment to the floor.

To replace the overhead guard weldment, use a sling and lifting device to raise the overhead guard weldment. Align the weldment and the mast and install the six capscrews and hardened washers. Tighten the capscrews to 149 Nm (110 lb ft). Align the rear post with the slot in the overhead weldment and slide the post into the opening. Align the lower portion ofthe post with the frame in the drive unit compartment and install the capscrew and washer to retain the rear post.

BATTERY COMPARTMENT The battery compartment is furnished in two sizes. Refer to Table 2-1.

Battery retainers are located on both sides of the lift truck. They can be removed by raising them up using the hand opening and moving them away from the frame weldment. A battery may be installed or removed by moving the battery on the rollers provided in the bottom of the battery compartment.

WARNING: To prevent personnel injury, keep clear of battery. Battery may roll out of battery !M compartment.

NOTE: It is recommended that the battery be removed from the right hand side of the lift truck to reduce the possibility of damaging the battery cables and the connector.

WARNING: Never operate the lift truck without both battery retainers in place. Spacers must also be used, as required, to maintain a maximum of 12.7 mm (0.50 in) between the battery and the side plates or retainers.

Table 2-1-Battery Compartment CHANGING THE BATTERY WARNING: If a different size battery is installed in the lift truck, the battery spacers must be changed. See the parts manual for the correct battery spacer arrangement.

Sheet 2: General Truck and Lubrication WARNING: To prevent personal injury and unexpected battery movement, the battery must be level when it is moving. Make sure the battery stand is on a level surface and is aligned and adjusted as described in the following procedure.

WARNING: Batteries are heavy. Use care to avoid injury 1. Make sure the key is in the OFF position. Disconnect the battery. Move the connector and cables so that they will not be damaged when the battery is moved.

2. Remove the battery panel.

3. Align the battery stand with the battery so that the end of the stand is against the roller frame of the lift truck.

Adjust the capscrew legs of the battery stand so that the tops of the rollers are level and at the same height as the bottom of the battery. Attach the puller cable to the battery case. Stand on the base of the battery puller and pull the battery onto the battery stand.

4. If the battery is lifted use a spreader bar and crane to lift the battery from the battery stand.

Figure 2-2 -Changing the Battery 1.

2.

3.

4.

5.

6.

BATTERY BATTERY DISCONNECT ROLLERS BATTERY STAND RATCHET LOCK LEVER BATTERY PULLER

WARNING: Make sure the capacity of the crane and the spreader bar is greater than the weight of the battery. The weight of the battery is normally shown on the battery case. The maximum battery weight is shown on the lift truck capacity plate. The spreader bar must not be made of metal or it must have insulated straps.

WARNING: If the lift truck has been operated with a low battery, check the contactors for welded contacts before a charged battery is connected. The circuit will not reset and lift truck operation cannot be controlled if the contacts are welded. To check the contacts, see the Maintenance Manual for this truck.

5. Before installing the battery, make sure the battery is cleaned and painted. Refer to BATTERY AND CHARGING, Section 9.

6. When a replacement battery is installed, make sure the battery fits the battery compartment. Use spacers to prevent the battery from moving more than 0.5 in. (13 mm) in any horizontal direction.

7. Make sure the weight of the replacement battery is within the maximum and minimum weights shown on the capacity plate.

8. The battery must be installed so that the battery connector will connect to the lift truck connector without pulling on the cables.

NOTE: Complete information relating to the care and maintenance of batteries can be found in the literature shipped with the battery.

Sheet 2: General Truck and Lubrication NOTE: Your company, industry and government safety regulations should be reviewed to help reduce accidents and damage to equipment.

TIRES AND WHEELS 1. Check the tires for damage. Inspect the tread and remove any objects that will cause damage.

2. Smooth any cuts or tears to prevent further damage. Check for bent or damaged rims. Check for loose or missing parts. Remove any wire, straps or other material that may have wrapped around the axle.

Figure 2-3 -Inspecting Tires Standard tire sizes are listed in Table 2-2 for both drive/steer, caster and load wheels. For lift trucks equipped with special tires consult your nearest authorized Yale industrial truck dealer.

Table 2-2 -Articulation Chart 2. Tire sizes listed in Table 2-2 are for both drive and steer tires.

3. Position the new tire in the press. See Figure 2-4. Align the wheel and tire assembly removed from the truck on top of the newtire. Make certain the wheels are aligned. Make certain the tires are level. Position a press ring on top of the wheel hub.

SOLID TIRES Remove the One-Piece Wheel and Tire WARNING: Wheels must be changed and tires replaced by trained personnel only. Always wear safety glasses.

NOTE: To change cushion tires, the wheel must be pressed out of the rim. The propertools, equipment, and press ring must be used. Do not attempt to change tires, rims, or wheels unless you have the proper tools, equipment, and experience.

1. Loosen the wheel lug nuts. Put the lift truck on blocks as described in HOW TO PUT THE LIFT TRUCK ON BLOCKS, Section 1, this manual.

Sheet 2: General Truck and Lubrication WARNING: The lifting and carrying of solid tires is not recommended because their weight could be in excess of 45 kg (100 lb). Where applicable, use a wheel or tire dolly to assist in the removal and installation of the wheel.

2. Remove the wheel nuts and remove the wheel from the lift truck.

3. The correct tools, equipment, and a press ring must be used for each size of wheel. Use a press to push the wheel hub from the tire.

Install the Tire on the One-Piece Wheel 1. Make sure the wheel hub is the correct size for the tire. Do not mix types of tires, types of tire treads, or wheels of different manufacturers on any one lift truck.

Figure 2-4 -Position Tire on Wheel 1.

2.

3.

4.

PRESS RING OLD TIRE NEW TIRE WHEEL HUB

4. Carefully apply hydraulic pressure until the wheel hub is forced from the old tire into the new tire. The new tire, when properly seated, will be flush to the inner or outer edge of the wheel hub. See Figure 2-5.

Figure 2-5 -13.5 x 5.5 Solid Tire Pressed onto Wheel INSTALL THE WHEELS ON THE LIFT TRUCK 1. Install the tire and wheel on the hub. Tighten the lug nuts to 136 Nm (100 Ibf ft) torque.

2. Raise the lift truck high enough to remove the blocks. Lower the lift truck to the floor.

CAUTION: Check all wheel nuts after 2 to 5 hours of operation: when new lift trucks begin operation and on all lift trucks when the wheels have been removed and installed. Tighten the nuts in a cross pattern to 136 Nm (100 Ibf ft) torque. When the nuts stay tight for eight hours, the interval for checking the torque can be extended to 350 hours.

Sheet 2: General Truck and Lubrication TANDEM LOAD WHEELS Removal-Tandem Load Wheels NOTE: The load wheels are held in place by the load wheel brackets. For easier installation, remove and install one load wheel before removing the next load wheel.

1. Put the lift truck on blocks as described in HOW TO PUT THE LIFT TRUCK ON BLOCKS, Section 1, this manual.

2. Remove the axle nut, axle shaft, washers, bearings, and load wheel. Remove the axle sleeve from the load wheel.

Installation-Tandem Load Wheels 1. Pack the new load wheel with the recommended grease listed in the LUBRICATION SCHEDULE, this section.

Install the new load wheel, axle shaft, axle sleeve, bearings, washers and axle nut. See Figure 2-6.

NOTE: On lift trucks used in freezer applications, apply the recommended Anti-Seize Lubricant listed in the LUBRICATION SCHEDULE, this section, to the load wheel axle shaft.

2. Remove the blocks from under the lift truck.

Figure 2-6 -Tandem Load Wheels 1.

2.

3.

4.

5.

6.

7.

AXLE SHAFT WASHER BRACKET AXLE SLEEVE BEARING LOAD WHEEL NUT

CASTER AND CASTER WHEELS Description The caster is installed on the right hand end of the articulating axle weldment. The caster is one support for the rear of the lift truck. The drive wheel on the master drive unit is the other support at the left hand end of the articulating axle weldment. The axle of the caster is an articulated axle. The articulation of the axle permits both wheels of the caster to always have equal weight on each wheel. Caster operation and wheel wear are improved with this design.

The caster is attached to the articulating axle weldment with a bearing locknut and lockwasher. The complete caster can be replaced as a unit or the wheels can be replaced. Always replace the wheels as a set for better caster operation and wheel wear. A single new wheel will wear rapidly.

Removal-Caster 1. Put the rear of the lift truck on blocks. See HOW TO RAISE THE DRIVE/STEER TI RE AND CASTER WHEELS, Section 1. Make sure the blocks are in a location to permit removal of the caster from the right hand side of the lift truck.

2. Remove two screws (1), lockwashers (2), retainer (3), and live swivel (4) from articulating axle (7).

Sheet 2: General Truck and Lubrication 3. Remove bearing locknut (5) and bearing lockwasher (6) from caster assembly (8).

4. Remove caster assembly (8) from articulating axle (7).

Installation-Caster 1. Install caster assembly (8) onto articulating axle (7) with bearing lockwasher (6) and bearing locknut (5).

2. Install live swivel (4) and retainer (3) onto articulating axle (5) with two lockwashers (2) and screws (1).

3. Remove the blocks from under the lift truck.

Removal-Caster Wheels NOTE: Always replace the wheels as a set. Replacing only one wheel causes more wear on the new wheel. The caster also will not operate correctly when a single wheel is replaced, causing more wear or caster damage.

1. Put the rear of the lift truck on blocks. See HOW TO RAISE THE DRIVE/STEER TI RE AND CASTER WHEELS, Section 1. Make sure the blocks are in a location to permit removal of the caster wheels from the right hand side of the lift truck.

2. Remove four lug nuts (16) and caster wheel (15) from caster assembly (8).

Installation-Caster Wheels 1. Completely fill the new bearings with the recommended grease listed in the LUBRICATION SCHEDULE, Section 2. Install the bearings in the replacement wheels.

2. Install caster wheel (15) onto caster assembly (8) using four lug nuts (16) 3. Remove blocks from under lift truck.

Figure 2-7 -Caster Wheels 1. CAPSCREW 2. LOCKWASHER 3. RETAINER 4. LIVE SWIVEL 5. LOCKWASHER, BEARING 6. LOCKNUT, BEARING 7. AXLE-ARTICULATING 8. CASTER ASSEMBLY 9. STUD 10. BEARING 11. BRAKE DRUM

Sheet 2: General Truck and Lubrication 12. SNAP RING 13. LOCKWASHER 14. NUT 15. WHEEL 16. LUG NUT ARTICULATION STOP ADJUSTMENT Stability and traction will be affected if the drive unit articulation stops are not adjusted properly.

The articulation stop screws must be adjusted to the proper setting as listed in the ARTICULATION CHART, atthefollowing times: 1. Every 350 hours during routine maintenance.

2. When a drive and/or caster wheel is changed.

3. When any repairs are carried out on the articulation axle.

Figure 2-8 -Drive Unit Articulation Stops Nameplate Table 2-3 -Articulation Chart

NOTE: The articulation stop settings are also listed on the capacity plate.

ADJUSTMENT PROCEDURE 1. Position the truck on a flat, level floor.

2. Disconnect the battery.

3. Open the drive unit compartment door, after turning the latch capscrew one-half of a turn to unlock the door.

4. Check the articulation stop clearance on both the drive and caster stop screws. If the clearance between the stops are not within the range listed in the ARTICULATION CHART, loosen the lock nuts and adjust the stop screws to the correct setting.

5. Tighten the lock nuts and torque to 108 Nm (80 Ibf ft).

6. Close and lock the compartment door.

Sheet 2: General Truck and Lubrication

Figure 2-9 -Articulation Stop Location YALE WARRANTY INFORMATION A Yale Warranty Statement is provided with each new Yale industrial truck. To maintain your Yale Warranty in good standing you must follow the Recommended Schedules of Maintenance and perform the daily operational and safety checks and maintenance functions described in this manual.

If you require a warranty repair you must contact your Yale industrial truck dealer for warranty service during the periods outlined in the Warranty Statement. Your Yale industrial truck dealer has complete details on which components are covered and the types of repairs that are warrantable. When in doubt about your warranty coverage, be sure to contact your Yale industrial truck dealer. If you have a warranty problem that cannot be resolved with your Yale industrial truck dealer, you may request a review of your problem by contacting the Yale Regional Service Representative.

All new Yale trucks will be shipped with an Operating Manual and an optional Parts Manual through yourYale industrial truck dealer. Additional Standard Manuals, Special Parts Manuals and Maintenance Manuals are also available from your Yale industrial truck dealer for a nominal charge.

For the optimum in professional repair and maintenance, we recommend your Yale industrial truck dealer's factory trained mechanics for Yale service and a Yale Maintenance Agreement.

RECOMMENDED SCHEDULES OF MAINTENANCE (ALL MODELS) Although the following Recommended Schedules of Maintenance are intended for use with all Electric Narrow Aisle lift truck models, not all models are equipped with all the items listed in this schedule.

Be certain this schedule is read thoroughly and all operations are followed. If in doubt of any procedure or component to be inspected, adjusted and lubricated, or if the truck is specially equipped and used for special applications, consult your nearest authorized Yale industrial truck dealer for assistance.

THE OCCUPATIONAL SAFETY AND HEALTH ACT (OSHA) REQUIRES THAT THE USER EXAMINE THE TRUCK BEFORE EACH SHIFT TO BE SURE IT IS IN SAFE WORKING ORDER. LUBRICATION INSTRUCTIONS WARNING: Yale Industrial Trucks are equipped with certain safety devices as standard equipment, for example: overhead guards, load backrest extensions, and mast screens. If for any reason these safety devices are removed when the truck is being serviced, adjusted, repaired or overhauled, these safetydevices must be properly installed before testing or operation of the truck. Failure to complywith this warning could result in serious injury to the mechanic and/or the operator.

Sheet 2: General Truck and Lubrication CAUTION: Never use steam to clean the electronic control or electrical parts. In dustyareas, use low pressure air to blow the dust off the control. In oily or greasy areas, use a mild solution of detergent and water, or denatured alcohol to wash off the control. Then blow the control completely dry with low pressure air.

The following maintenance instructions are for standard models. Trucks used for special applications may be equipped with extra lubrication fittings, covers, special oils, etc. Consult your nearest authorized Yale industrial truck dealer when servicing these models.

IMPORTANT: The interval of time referred to in the maintenance chart is based on normal operating conditions. If the vehicle is operated in areas of high contamination such as dust, corrosive vapors, etc., the interval of time should be adjusted accordingly.

Refer to both the Recommended Schedules of Maintenance and these Lubrication Instructions when inspecting, lubricating and servicing these models. Read and observe all safety and operational precautions described in this manual before performing any work on this truck.

Refer to the appropriate charts in this section for the oils and grease that are recommended for use on these models.

Perform all 8 hour safety and operational checks as described in the Recommended Schedules of Maintenance located in this section.

Check all fluid levels. Hydraulic oil, brake fluid and battery levels should be at their full marks. Add recommended fluids and oils as required. A certain amount of water loss in battery cells is normal. Always replace water at the end of a charge. Use approved tap or distilled water.

EVERY 350 HOURS WARNING: The articulation stops must be adjusted every 350 hours or whenever a drive wheel tire or caster wheel tire is replaced. Failure to adjust these stops properly can reduce stability as well as traction. Refer to the Articulation Stop Adjustment in Section 2 of this manual for the adjustment procedure and proper clearance settings.

Apply lithium base, multi-purpose No. 2 grease with a high pressure gun to the following fittings. Clean lube fittings before and after lubricating Location of Lube Fittings

No. of Fittings

1. Master Drive Unit Bearing

2

2. Articulation Shaft

1

3. Thrust Rollers -Reach Frame/Fork Carriage 2 4. Reach Cylinder Pivot Pins -Upper and Lower 4 5. Reach Arms -NR

6

6. Reach Arms -NDR 12 Apply lithium base, multi-purpose No. 2 grease to the following surfaces: 7. Mast Load Roller Wear Plugs Sliding Surfaces 8. Reach Load Roller Radial and Thrust Wear Surfaces Apply silicone spray lubricant to all of the following friction points: 9. Lift Chain Sheaves Apply engine oil (SAE 30) to all friction points of the following: 10. Master Drive Unit Chain Assembly 11. Lift Chains -Wipe off all old oil using a clean cloth, then use compressed air to blow off chains. With a clean brush, apply SAE 30 weight oil to the full length of chain. Oil must penetrate chain joints.

Apply anti-seize lubricating compound to all friction points of the following:

Sheet 2: General Truck and Lubrication 12. Articulation Stop Hardware 13. Articulation Shaft Retaining Bolt and Ends of Shaft 14. Drive Wheel Lug Nuts 15. Caster Wheel Lug Nuts 16. Load Wheel Axle Bolts 17. Brake Rods and Brake Drum Splines 18. Caster Brake Linkage 19. Brake Liners, Shoulder Bolts, Adjusting Rod and Spring Retainers 20. Door Hinge Hardware 21. Control Handle Torsion Springs WARNING: The articulation stops must be adjusted every 350 hours or whenever a drive wheel tire or caster wheel tire is replaced. Failure to adjust these stops properly can reduce stability as well as traction. Refer to the ARTICULATION ADJUSTMENT, Section 4, this manual for the adjustment procedure and proper clearance dimensions.

22. Brake Master Cylinder - The brake fluid reservoir is mounted to the inside of the drive unit compartment door.

Remove cap from reservoir and check fluid level. Correct level is 6.35 mm (0.25 in) from top of reservoir. Add brake fluid if necessary. Use SAE J1703 hydraulic brake fluid, Federal Motor Vehicle Safety Standard -FMVSS 116 (DOT 3). The capacity of the reservoir is 0.45 litre (0.12 gal.).

23. Hydraulic OiILevel-Remove and wipe dipstick. With forks fully lowered and oil at normal operating temperature, (above 100°F), measure oil level with dipstick. Add hydraulic oil, if necessary, to the "full" mark on the dipstick.

Remove and clean breather assembly and the breather with solvent. Blow dry with compressed air, replace and tighten. Replace the breather/filler assembly and breather if they cannot be cleaned or they are damaged. DO NOT OVERFILL. 24. Drive Unit Oil Level -Park truck on a level floor. Remove oil level/fill plug. Oil level should beat the bottom edge of the hole. If low, fill with SAE 80W-90 weight gear oil until oil runs out of the oil level/fill hole. Replace plug. DO NOT OVERFILL. NOTE: The manufacturer recommends draining and refilling the drive unit oil after the first 500 hours of use on all new trucks. Park truck on a level floor. Remove drain plug. Drain gear oil into a suitable container and discard in accordance with local regulations. Replace drain plug and fill with gear oil through level/fill hole. Drive truck slowly to circulate oil. Drive Unit Capacity 3.7 litres (0.98 gallons) for all models.

EVERY 2000 HOURS 25. Brake Master Cylinder - Drain and flush system. Fill the system with new hydraulic brake fluid. After filling, bleed the brake system. Brake System Capacity 0.45 litres (0.12 gallons).

26. Hydraulic Oil Strainer - Remove dipstick and filler cap. Remove hydraulic oil strainer. Clean strainer with solvent and blow dry with compressed air. Replace strainer if dirt cannot be removed. Replace the breather/filler assembly.

27. Hydraulic Oil Filter -Lower mast. Replace hydraulic oil filter, located in drive unit compartment, at each oil change.

Sheet 2: General Truck and Lubrication

Figure 2-10 -Lubrication Points 28. Hydraulic System - Lower mast. There is no drain plug in this hydraulic tank. The hydraulic tank is drained at the supply hose. (The hose and tubing between the bottom of the hydraulic tank and the main hydraulic pump.) Put a shallow pan with a capacity equal to the hydraulic system of the truck under the end of the hose. See hydraulic tank capacities below. Disconnect the hose at the pump and drain the oil. Pour the oil into a suitable container and discard in accordance with local regulations.

Table 2-4 -Hydraulic Oil Tank Capacities

Clean hydraulic tank with solvent and dry with compressed air. Connect the hose to the tube and tighten the hose clamp. Remove the breather cap and fill the tank with hydraulic oil. Raise and lower mast, operate tilt control and reach mechanism (if equipped), to expel air from hydraulic system.

NOTE: If hydraulic system is contaminated contact your authorized Yale industrial truck dealer for assistance.

29. Drive Unit -Park truck on a level floor. Remove drain plug. Drain gear oil into a suitable container and discard in accordance with local regulations. Replace drain plug and fill with gear oil through level/fill hole. Drive truck slowly to circulate oil. Drive Unit Capacity 3.7 litres (0.98 gallons) for all models.

NOTE: Do not expose bearings or hydraulic system to foreign particles.

Sheet 2: General Truck and Lubrication

NOTE: The following inspections and necessary corrections are the responsibility of the user.

Sheet 2: General Truck and Lubrication

Sheet 2: General Truck and Lubrication

Sheet 2: General Truck and Lubrication NOTES: 1. Tires -Condition affects Stability, Safety and Load Capacity that can be handled safely.

2. Use MagnagloorequivalentFatigueCrackDetectortotest forks. Refer to Service News Bulletin SE-643 for Procedure on Field Testing Load Forks. The Bulletin also defines minimum acceptable fork tine thickness due to wear.

3. With the mast vertical and with a rated load at 609.6 mm (24in) load center, check lift cylinder drift. Lift drift must not exceed 25.4 mm (1 .0 in) in 2 minutes, oil at 26°C (79°F). Refer to Service Bulletin SE-1077 for Procedure to Measure Hydraulic Drift.

4. With a rated load at 609.6 mm (24 in) load center, check tilt cylinder, if equipped, for drift. Tilt drift must not exceed 25.4 mm (1 .0 in) in 2 minutes, oil at 26°C (79°F). Referto Service Bulletin SE-1077 for procedure to measure hydraulic drift.

5. The presence of hydraulic fluid on cylinder rods and fittings does not necessarily indicate a leak.

6. Recycle all waste oils.

To obtain more information on the above reference Service Bulletin, contact your nearest authorized Yale industrial truck dealer.

HYDRAULIC OILS

Sheet 2: General Truck and Lubrication

GEAR OILS

Sheet 2: General Truck and Lubrication

BRAKE FLUID

GREASE

Sheet 2: General Truck and Lubrication

ANTI-SEIZE LUBRICATING COMPOUND

FASTENERS-INTRODUCTION Threaded fasteners like bolts, nuts, capscrews, and studs are made to specifications that describe the mechanical strength and hardness of the fastener. A fastener used in a design application is selected according to its specifications. Yale Materials Handling Corporation buys parts from many countries. Parts that are purchased must be to Yale standards. There are several standards used by these countries in the manufacture of threaded fasteners. Many of these fasteners are similar, but cannot be used as a direct replacement. To make sure that you have the correct fastener, order fasteners and parts through the Yale Parts Distribution Center, Danville, IL. Service persons must use replacement fasteners that have the same specifications. Fasteners made to each specification have identification marks for that specification. This specification is commonly called "Grade" for SAE standards and "property class" for metric standards. This section describes the identification of some common fasteners.

The metric system used by Yale Materials Handling Corporation is described as SI (Le Systeme d'Unites or the International System of Units, also called SI in all languages). The SI system of measurement is described in ISO Standard 1000, 1973. A conversion table of common measurements is shown in Table 2-8.

Threads, Nomenclature The thread design is specified by a series of numbers and letters for inch and metric fasteners. See Figure 2-11. The diameter of the shank of the fastener is shown first in the series [M12 = 12 mm, M20 = 20 mm (1 /2 = 1/2 inch, 3/4 = 3/4 inch)].

Sheet 2: General Truck and Lubrication The length of the shank is often indicated as part of the description of a fastener. This length is shown in inches for inch fasteners and in millimetres for metric fasteners.

The number of threads per inch for inch fasteners may either be shown as UNC (Unified National Coarse) or UNF (Unified National Fine). Metric fasteners show the thread pitch.

A capscrew will have the following description: Table 2-5 -Capscrew Description

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 capscrew 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 any marks. The following tables show the marks that identify the grades and property classes for different fasteners.

CAUTION: When fasteners must be replaced, the new fasteners must be of the same strength or greater than the original fasteners. The new fasteners must also be the correct size.

NOTE: Identification marks are according to bolt strength. The higher the number or the increase in the number of marks indicates increased bolt strength.

Figure 2-11 -Thread Design Table 2-6 -Bolts and Screws

Sheet 2: General Truck and Lubrication

Table 2-7 -Studs and Nuts

Sheet 2: General Truck and Lubrication

Table 2-3 -Torque Nuts

Sheet 2: General Truck and Lubrication

Table 2-4 -Torque Nuts with Nylon Inserts

Sheet 2: General Truck and Lubrication

Table 2-5 -General Guide to Torque Values

Sheet 2: General Truck and Lubrication

Table 2-7 -Recommended Maximum Torque Values for Hydraulic Fittings*

Sheet 2: General Truck and Lubrication

Table 2-8 -Conversion Table for Metric and English Units

Sheet 2: General Truck and Lubrication

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting DASH DISPLAY ASSEMBLY Description/Features The dash display is a rectangular front mounted display unit that interfaces with both the MIB and the traction controller. It is located on the left side of the front wire guard.

Two versions of the dash display are available dependant on ambient temperature: Standard -25°to 70°C (-13°to 158°F) Freezer -40°to 70°C ( -40°to 158°F) The dash display contains the following features: •

Four hydraulic function indicator lights

•

Three "button selectable" hourmeters (Traction, Lift and Total Hours)

•

Ten bar LED battery state of charge indication

•

Low battery lift interrupt indication and permissive output

•

Sixteen character English messages for status, warnings and faults

•

Three "button selectable" drive modes

Figure 3-18 -Dash Display Assembly Operation 1. The Battery Indicator has a 10 bar green, yellow and red light emitting diode (LED) to indicate battery charge status. As power is used the LEDs will turn off, starting with green. The red LED second from the bottom will flash indicating a nearly discharged battery. The bottom red LED will alternately flash with the LO-Battery indicator LED (a crossed battery symbol), indicating a discharged battery. The hoist function will be disallowed out at this point.

2. The Message Center is a 16 character, dot matrix, liquid crystal display (LCD), with green back lighting. The 16 character, alpha numeric display shows the hourmeter readings, truck performance status, and warning or fault conditions. When a warning message is received, the warning/fault indicator (6) will blink as a yellow light. When a fault message is received, the warning/fault indicator (6) will blink as a red light.

3. The Instrument Display Hourmeter switch is operator controlled and is used for on-demand display of hourmeter information. The hourmeter data can be displayed at any time by pressing the hourmeter switch. The switch is marked with an hour glass symbol. Press once to display truck hours to 1 /10 of an hour. Press twice to display drive motor hours. Press three times to display the lift motor hours. Press four times to return to the normal display. After 30 seconds the display will return to the normal display mode, which indicates the current operational status of the truck.

4. The Drive Mode Display allows the operator to select the level of traction motor controller performance most suited to the application. Operation of the drive mode switch will cause the green indicators and corresponding drive modes to increase from Turtle (Mode 1) to Mid (Mode 2) to Rabbit (Mode 3). *Turtle mode provides slower acceleration, reduced top speed and maximized energy efficiency. It is also a valuable setting when training new operators. *Mid mode reduces acceleration with full travel speed. *Rabbit mode provides maximum acceleration

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting and travel speed. When the key switch is turned to off, the selected drive mode is retained. When the battery is disconnected the drive mode returns to the Rabbit mode. The rates of acceleration and travel speeds are programmable and can be adjusted by a qualified service technician. See PROGRAMMING THE TRACTION MOTOR CONTROLLER. *As programmed from the factory.

Mode 4 is entered when the brake pedal is released part way, opening the first of two switches. The brake signal to the MIB goes low, causing the MI B to stop transmitting a throttle signal to the PMC, which applies a braking force. If the pedal is released all the way it will open the second switch, activating the electric brake and caster brake, stopping the truck.

5. The LED Function Selection Lights are for the display of Status, Warning and Fault conditions. Status messages will be displayed for Lift, Reach, Tilt and Sideshift. The indicators will display up-to-date status conditions, independent of the present LCD display. There are four yellow and one red/yellow (6) LED indicators.

The Dash Display is energized when the key switch is on and the main contactor is energized. An internal back-up battery provides memory retention of the battery indicator and hourmeter readings when the battery is disconnected from the truck.

Testing Inoperative Dash Display Assembly If the dash display is blank (no display, LEDs etc.) with the key switch on and the main contactor energized, see BLANK DASH DISPLAY, MIB FAULT CODES, Page 7 for troubleshooting procedures.

Inoperative Drive Mode Selection Communication FROM the dash display TO the traction motor controller occurs through two wires, DM1 and DM2.

Wires DM1 and DM2 are located in the X-6 connector of the dash display and in the X-19 connector at the traction motor controller. A digital signal is carried to tell the traction motor controller to operate in one of the three drive modes (turtle, mid or rabbit).

If pressing the mode selection button causes the green LED mode indicators to change, but truck performance appears unchanged, check the communication FROM the dash display TO the traction motor controller as follows: Troubleshooting with a Programmer Hand Set Using the Programmer Handset, enter the TEST MENU. See HAND SET, TEST MENU. While depressing brake, check the MODE A INPUT and the MODE B INPUT. See Table 3-19 for the correct inputs.

Table 3-19 -Dash Display Drive Mode Inputs

If the communication is occurring as shown in Table 3-19, but correct operation is still suspect, program the traction motor controller using the hand set as follows: 1. Enter the PROGRAM MENU on the hand set. See PROGRAMMING THE TRACTION MOTOR CONTROLLER.

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting 2. Program M1 (turtle mode) MAX SPEED to 40%.

3. Program M2 (mid mode) MAX SPEED to 70%.

4. Program M3 (rabbit mode) MAX SPEED to 100%.

5. Operate the truck in each drive mode and check for different top speeds.

If the speeds are all different, and in the proper order, then the mode selection feature is working.

If top speed does not change between the different drive modes, the traction motor controller may be faulty. See TRACTION MOTOR CONTROLLER, TESTING. 6. Reprogram the traction motor controller to the correct values. See PROGRAMMING THE TRACTION MOTOR CONTROLLER. Troubleshooting Without A Programmer Handset If a Programmer Hand Set is not available, communication FROM the dash display TO the traction motor controller can be checked using a digital volt ohmmeter. While depressing brake, check the voltage levels on wires DM1 and DM2 by looking at the traction motor controller connector pins 3 and 4 with respect to B-terminal of the traction motor controller. See TRACTION MOTOR CONTROLLER CONNECTOR PIN-OUT, Figure 3-17.

NOTE: Do not disconnect the wire harness at the dash display or the traction motor controller. Voltage checks must be performed with all connections in place.

CAUTION: Only use a digital volt-ohm meter during this test procedure. Use of other test equipment can cause the internal components of the dash display and/ortraction motor controllerto malfunction.

The voltages should be as follows:

Table 3-20 -Dash Display Drive Mode Test Voltages

A constant "High" can indicate an open in the respective circuit. A constant "Low" can indicate a short in the respective circuit. Undefined can indicate an open in both circuits.

If the voltages at DM1 and DM2 are correct in relation to the different drive modes, but lift truck operation doesn't reflect the changes, the problem could be that the 3 different drive modes are not programmed differently or that the traction motor controller is faulty. A Programmer Hand Set is necessary for further troubleshooting.

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting See TROUBLESHOOTING WITH A PROGRAMMER HAND SET. No Warnings or Faults Displayed (DRIVE CTRL FAULT may appear on the dash display.)

Communication FROM the traction motor controller TO the dash display occurs through two wires, FM1 and FM2.

Wires FM1 and FM2 are located in the X-14 connector of the traction motor controller and in the X-6 connector at the dash display. These two wires carry a digital code for warnings and faults concerning the traction controller.

During normal operation (no faults or warnings displayed) the voltage between FM1 and battery-and FM2 and battery-should both be less than +5.0 volts. See Table 3-21.

During the three faults, the voltage between FMi and battery-and/or FM2 and battery-will change. See Table 3-21.

Table 3-21 -Dash Display Status/Warning/Fault Test/ Voltages

A constant "High" can indicate an open in the respective circuit. A constant "Low" can indicate a short in the respective circuit.

If the dash display is not showing a fault or warning and you suspect it is not reporting legitimate traction motor controller related faults and/or warnings, a test can be performed to verify properdashoperation. Disconnect the X-14 connector from the traction motor controller. Connect a jumper wire between battery-and FM1 and/or battery-and FM2 at the X-14 connector as shown in Table 3-22.

NOTE: Do not ground the pins of the traction motor controller during this test. The X-14 plug (2 wire) at the traction motor controller must be disconnected from the traction motor controller for this test.

Table 3-22 -Testing the Dash Display Status/Warning/Fault Inputs

MIB/Dash Display Communication Communication FROM the MIB TO the dash display and FROM the dash display TO the MIB occurs through a shielded four conductor cable. This cable carries signals concerning lift interrupt, hourmeter input, travel direction and MIB generated STATUS, WARNING OR FAULT information. See STATUS, WARNING AND FAULT CODE TROUBLESHOOTING, "SIGNAL SOURCE".

Lift Interrupt Wire #85 carries the lift interrupt signal from the dash to the MI B. Normally this signal is low (less than + 5.0 volts) when the BDI is not flashing. When the BDI is in the red flashing zone (lift interrupt) then the signal will be high (greaterthan + 1 O.Ovolts).

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting If you suspect a dash display lift interrupt circuit malfunction, you can bypass the lift interrupt function of the dash display. Connect a jumper wire from the battery to the #85 wire of the X-6 plug at the dash display assembly. If lift still does not operate properly, disconnect the battery and check the continuity of wire #85 from the dash displayX-6 plug to the MI B J1 plug. See 3-18 for MIB plug pin out. If wire #85 tests good, check MIB codes and troubleshoot. See STATUS, WARNING AND FAULT CODE TROUBLESHOOTING. If lift interrupt does not occur when the BDI is in the red flashing zone, then wire #85 may be shorted to battery-or another wire. If wire #85 tests good check MIB codes and troubleshoot. See STATUS, WARNING AND FAULT CODE TROUBLESHOOTING. Lost MIB Signal Displayed Wires #81, #82, and #83 carry signals which are used to transfer information (serial communications link) to the dash display concerning all STATUS, WARNING and FAULT information not previously discussed. Troubleshooting ofthese signals cannot be done with normal equipment. If "LOST MIB SIGNAL" is displayed on the dash display, you can only check the continuity of these wires. If the wires test good, verify the correct operation of the dash display and MIB. Consult Yale Service for further information.

Hourmeter Input The lift pump hourmeter input is from wire #37 which comes from the auxiliary switch on the lift contactor. The contacts of the switch are closed when the lift pump contactor is energized. If the lift pump hourmeter is not functioning properly, check for battery volts at wire #37 plug X-4 at the dash display with the lift pump operating. If the signal is atthe dash pin 1-9, butthe meter does not accrue lift pump time the dash display has failed. See WIRING SCHEMATICS AND DIAGRAMS located at the end of this section for plug and wire locations.

Forward/Reverse Inputs Drive (forward and reverse) hourmeter input is from wires #6 and #8. If the drive hourmeter is not functioning properly check for battery volts at dash display during travel. For forward travel check pin #4-6, wire #6. For reverse travel check pin #4-7, wire #8.

Removal The dash display is mounted to the mast at eye level. The dash display assembly cannot be repaired and must be replaced if testing determines it to be faulty.

1. Move the lift truck to a safe level area. Turn the key switch off and remove the key. Put a "DO NOT OPERATE" tag on the multi-function control handle. Put blocks underthe drivewheels to keep the lift truck from moving. See Section 1 -HOW TO PUT A LIFT TRUCK ON BLOCKS. WARNING: Disconnect the battery and separate the connector before opening the compartment cover or inspecting/repairing the electrical system. If a tool causes a short-circuit, the high current flow from the battery can cause an injury or parts damage.

2. Disconnect and separate the battery connector.

3. Remove screws holding dash and plastic cover to bracket.

4. Remove screws between front and rear covers.

5. Disconnect the two plugs X-4 and X-6 from the rear of the dash display assembly.

6. Remove the two thumbscrews and the retainers securing the dash display assemblytotheinstrumentpanel.

Removethe dash display assembly.

Installation 1. Adjust the pots on the rear of the dash display assembly. See DASH DISPLAY, ADJUSTMENT. 2. Connect the two plugs X-4 and X-6 to the rear of the dash display.

3. Install the retainers and the thumbscrews to the rear of the dash display to retain the dash display assembly to

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting the instrument panel.

4. Connect the battery.

5. Remove the blocks from under the drive wheels, remove the "DO NOT OPERATE" tag and install the key.

Figure 3-19 -Battery Indicator Adjustment Adjustment (Setup) The dash display assembly has two adjustment pots. The pots are located on the back of the dash assembly between the connectors. See Figure 3-18. Trucks are shipped from the factory with the pots adjusted as follows: RESET "B" DISCHARGE "L" Adjustment is performed by inserting a small screwdriver through the access hole in the rear of the dash display and into the long slot of the adjustment screw. See Figure 3-18. Rotate the screwdriver fully clockwise to align the blade with E (reset pot) or P (discharge pot). Rotate the pot counterclockwise to the desired setting. Dots on one end of the screwdriver slot indicate which end should be aligned with the appropriate setting.

Table 3-23 -Battery Indicator Reset Adjustment

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting The RESET potentiometer determines the level to which the battery must be charged before the indicator will reset to display a charged battery. The RESET potentiometer is set at the factory to B. Batteries with open circuit voltages greater than 2.09 volts per cell will cause the battery indicator to read fully charged. The RESET function operates only when a battery has been disconnected for at least 15 seconds and another battery connected. The replacement battery must be charged to at least 90% of its capacity.

The RESET potentiometer increases the voltage at which the battery is accepted when turned from B toward E (clockwise). The specific gravity of the battery must be more than 1.245.

The RESET potentiometer decreases the voltage at which the battery is accepted (indicator resets to display a charged battery) when turned from B toward A. The specific gravity of the battery is less than 1.245. See Table 3-23 for alternate settings.

If a battery that is connected does not have the correct specific gravity, the battery indicator will remain in its original position.

The DISCHARGE potentiometer determines the level at which the LIFT interrupt function occurs. The potentiometer is set at the factory to L. The L setting is equal to 1.63 volts per cell.

Turning the DISCHARGE potentiometer from L toward K lets the battery discharge MORE before LIFT interrupt occurs.

Turning the DISCHARGE potentiometer from L toward P lets the battery discharge LESS before LIFT interrupt occurs. (See Table 3-24) for alternate settings.

Table 3-24 -Battery Indicator Discharge Adjustment

TRACTION MOTOR CONTROLLER Description/Features The Curtis Model 1244-4505 SEM Traction Motor Controller uses a sophisticated microprocessor to control the logic and operation of the controller, eliminating the need for forward and reverse contactors. The SEM motor controller operates on the principle of controlling the motor field circuit and the motor ar-mature circuit independently. The controller has many pro-grammable features, including acceleration rate, maximum speed, braking current limit and throttle braking current limit. The operator can also select from three different performance modes to customize the operation of the truck to the applica-tion, as required. The SEM controller includes a full range of features as well as diagnostic and set-up capability for reliable operation.

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

Figure 3-20 -TRACTION MOTOR CONTROLLER The Curtis Model 1307 Programmer Hand Set (Yale P/N 150035908) is used to program and troubleshoot the traction motor controller. Refer to PROGRAMMER HAND SET. The traction motor controller communicates with the dash dis-play for selection of performance modes and for diagnostic in-formation. The performance mode selection feature allows the operator to choose from three different motor controller perfor-mance levels by pushing a button on the dash display. The rate of acceleration, maximum top speed, and throttle braking rate can be specifically assigned for each mode using the program-mer hand set.

Simplified diagnostic information is communicated to the dash display to alert the operator to adverse conditions such as con-troller over temperature, operator sequence error or motor con-troller malfunction.

Removal 1. Move the lift truck to a safe level area. Turn the key switch to the "OFF" position and remove the key. Put a "DO NOT OPERATE" tag on the control handle. Put blocks under the drive wheels to keep the lift truck from moving.

See section 1 -HOW TO PUT A LIFT TRUCK ON BLOCKS. WARNING: Disconnect the battery and separate the connector before opening the compartment cover or inspecting/repairing the electrical system. If a tool causes a short-circuit, the high current flow from the battery can cause an injury or parts damage.

2. Disconnect and separate the battery connector. Remove the battery. See the section PERIODIC MAINTENANCE. Refer to HOW TO CHANGE THE BATTERY 3. Remove the electrical compartment cover.

WARNING: The capacitor in the traction motor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. Discharge the capacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller's B + and B -terminals. DO NOT use a screwdriver to discharge the traction motor controller.

4. Discharge the controller by connecting a load across ter-minals B+ and B-.

5. Unplug the connector from the traction motor controller. Tag and disconnect the wires to the power terminals.

6. Remove the washers and nuts retaining the controller to the frame. Carefully remove the traction motor controller from the lift truck.

Testing Refer to PROGRAMMER HAND SET for complete testing and troubleshooting procedures for the Traction Motor Controller.

The traction motor controller cannot be repaired. The traction motor controller is sealed and contains no serviceable parts. If testing has determined the traction motor controller to befaulty, it must be replaced.

Installation 1. Make certain that the mounting surface for the traction mo-tor controller is clean. There should be no dirt

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting between the frame and the traction motor controller. Align the traction motor controller in the lift truck on the studs. Install the washers and nuts to retain the controller to the frame. The studs must be installed from the back wall through the controller. They are driven in place using a small ball peen hammer.

2. Connect the power wires to the terminals. See Figure 3-21. Plug the X-3 connector into the J1 receptacle of the traction motor controller.

3. Refer to PROGRAMMING THE TRACTION MOTOR CONTROLLER to set-up the controller.

X-19 PIN 1: KEY SWITCH INPUT X-19 PIN 2: BRAKE SWITCH X-19 PIN 3: DRIVE MODE SELECT #2 INPUT X-19 PIN 4: DRIVE MODE SELECT #1 INPUT X-19 PIN 5: FAULT 2 OUTPUT X-19 PIN 6: FAULT 1 OUTPUT X-19 PIN 7: NOT USED X-19 PIN 8: NOT USED X-19 PIN 9: KEY SWITCH INPUT (COIL RETURN) X-19 PIN 10:FORWARD SIGNAL INPUT X-19 PIN 11: REVERSE SIGNAL INPUT X-19 PIN 12:NOT USED X-19 PIN 13:NOT USED X-19 PIN 14:THROTTLE REFERENCE VOLTAGE X-19 PIN 15:0-5 VOLT THROTTLE SIGNAL INPUT X-19 PIN 16:NOT USED X-19 PIN 17:TRACTION COIL DRIVER X-19 PIN 18:NOT USED X-19 PIN 19:NOT USED X-19 PIN 20:ELECTROMAGNETIC BRAKE DRIVER(A861 X-19 PIN 21:NOT USED X-19 PIN 22:NOT USED X-19 PIN 23:NOT USED X-19 PIN 24:NOT USED Figure 3-21 -TRACTION MOTOR CONTROLLER PIN ARRANGEMENT PROGRAMMER HANDSET Description/Features The Programmer Hand Set is a hand held tool that allows the user to PROGRAM, TEST and DIAGNOSE the

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting Traction Motor Controller. It has been designed for ease of use with eight keys to control all functions. A MORE I NFO key is included to provide more detail on any display item.

The programmer is powered by the controller. When the pro-grammer is plugged into the controller, it will acquire all the con-troller function values and display the model number, date of manufacture and revision code. Afterthe initial display, the pro-grammer will prompt the user with further instructions.

Figure 3-22 -CURTIS MODEL 1307 PROGRAMMER HANDSET The display window contains a four line LCD display. This dis-play is visible in most lighting conditions. When the program-mer is in the PROGRAM, TEST or DIAGNOSTICS mode, four lines of a menu are displayed. The item at the top of the display window is the selected item (in the PROGRAM menu, the se-lected item will be highlighted with a flashing arrow).

SCROLL DISPLAY Keys To scroll up and down within a menu, use the two SCROLL DIS-PLAY arrow keys. The SCROLL DISPLAY arrow keys can be pressed repeatedly or held down. When a key is held down, the scrolling speed increases the longer the key is held.

To the left of the PROGRAM, TEST and DIAGNOSTICS menu, a small scroll bar is displayed. The scroll bar gives a rough in-dication of the position of the four displayed items within the en-tire menu. That is, when the scroll bar is atthe top of the window, the top of the menu is displayed. When scrolling through the menu, the bar will move downward. When the bar is at the bot-tom, the end of the menu has been reached.

CHANGE VALUE Keys The CHANGE VALUE arrow keys increase or decrease the val-ue of the selected menu item. There is an LED on each arrow key to indicate when the key is active and a change is permissi-ble. When the LED is off, the limit setting (maximum or mini-mum) of the function has been reached.

ELECTRICAL SYSTEM The CHANGE VALUE keys may be pressed repeatedly or held in the same manner as the SCROLL DISPLAY keys.

The longer the key is held the faster the value changes. This allows rapid changing of any function value.

MORE INFO Key The MORE INFO key is used to display additional information about the selected item and to access the SPECIAL PRO-GRAM MENU and the DIAGNOSTICS HISTORY MENU. When the programmer is in any of the operating modes, the MORE INFO key may be pressed to display additional informa-tion about the selected item. Press the MORE INFO key again to return to the original list. In the PROGRAM menu, a bar graph is displayed along with the

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting minimum and maximum values available for the selected item. If the minimum or maximum val-ue has been programmed, a message replaces the bar graph and any dependencies are listed.

OPERATION Connecting the Handset to the Traction Motor Controller NOTE: Each time the programmer hand set is connected to the controller, it acquires all of the controller function value set-tings and stores them in its temporary memory. This allows the userto revert backto the original settings at anytime. The SPE-CIAL PROGRAM menu selection RESET ALL SETTINGS is used to revert to the original settings. Any inadvertent change made to any of the function values can be "undone" in this man-ner, as long as the programmer has not been unplugged or the key switch turned off (power disconnected).

1. Turn the key switch to the "OFF" position.

2. Disconnect and separate the battery connector.

3. Remove the cover.

WARNING: The capacitor in the traction motor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. Discharge the capacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller's B + and B -terminals. DO NOT use a screwdriver to discharge the traction motor controller.

4. Discharge the capacitors in the traction motor controller by connecting a load (such as a contactor coil or a horn) across the controller's B+ and B-terminals.

NOTE: The Programmer Hand Set should only be connected and disconnected with the key switch in the "OFF" position.

5. Connect the Programmer Hand Set to the 4 pin Molex connector on the traction motor controller. See Figure 3-21.

6. Reconnect the battery.

NOTE: The brake pedal must be released (up position).

7. Turn the key switch to the "ON" position. Ensure the battery disconnect switch is closed.

Disconnecting the Hand Set from the Traction Motor Controller 1. Turn the key switch to the "OFF" position.

2. Disconnect and separate the battery connector.

WARNING: The capacitor in the traction motor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. Discharge the capacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller's B + and B -terminals. DO NOT use a screwdriver to discharge the traction motor controller.

3. Discharge the capacitors in the traction motor controller by connecting a load (such as a contactor coil or a horn) across the controller's B+ and B-terminals.

4. Disconnect the Programmer Hand Set from the 4 pin Molex connector on the traction motor controller.

NOTE: The Programmer Hand Set should only be con-nected and disconnected with the key switch in the "OFF" position.

5. Install the cover.

6. Reconnect the battery.

Programmer Self Test You can test the programmer by displaying two special test screens. Press and hold the MORE INFO key while the pro-grammer is powering up. During the SELF TEST, you can toggle between the two test screens by pressing the

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting SCROLL DISPLAY keys. The first screen turns on every LCD element, and the second screen displays all the charac-ters used in the various menus. As part of the SELF TEST, you can also test the keys by pressing each one and observ-ing whether its corner LED lights up. To exit the SELF TEST, unplug the programmer or turn the key switch to the "OFF" position.

Figure 3-23 -PROGRAMMER HAND SET SELF TEST OPERATING MODES Program Menu TABLE 3-25 -PROGRAM MENU

Press the PROGRAM key to enter the PROGRAM mode. The LED in the corner of the PROGRAM key illuminates to indicate that the programmer has been placed in the PROGRAM mode. All of the adjustable functions and features are shown in the dis-play window, four at a time, with the corresponding settings. The setting of the selected item (the item at the top of the dis-play with the flashing arrow) can be changed using the CHANGE VALUE keys. The CHANGE VALUE keys have LEDs to indicate whether the key can be used to increase or decrease the value any further. When the LED is no longer lit, the limit for the key direction has been reached.

Press the MORE INFO keyto display more detailed information for the setting selected, including a bar graph indicating the position of the current setting relative to the range for the set-ting, the unit of measure, and the specific minimum and maxi-mum values for the setting. If the range is limited by the values assigned for a different function,

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting the name of the limiting func-tion is displayed in place of the minimum and maximum values.

Test Menu Press the TEST key to enter the TEST mode. The LED in the corner of the TEST key illuminates to indicate that the program-mer has been placed in the TEST mode. The TEST menu dis-plays real time information about the status of the inputs, outputs and controller temperature. In the TEST mode, the item of interest does not need to be the top item in the window; it only needs to be one of the four items displayed in the window. The TEST mode is useful for checking out the operation of the con-troller during initial installation. The MORE INFO key, when used in the TEST mode, displays additional information about the top item in the window.

TABLE 3-26 -TEST MENU

TABLE 3-27 -DASH DISPLAY DRIVE MODE INPUTS

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

Diagnostics Menu Press the DIAGNOSTIC key to enter the DIAGNOSTIC mode. The LED in the corner of the DIAGNOSTIC key illuminates to indicate that the programmer has been placed in the DIAG-NOSTIC mode. The DIAGNOSTICS menu displays all current-ly active faults detected by the controller. It is capable of dis-playing 20 different faults, four at a time.

TABLE 3-28 -DIAGNOSTICS AND DIAGNOSTIC HISTORY DISPLAY

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

NOTE: The DIAGNOSTICS and DIAGNOSTIC HISTORY display shown in Table 3-28 is not a menu as such, but simply a list of the possible messages displayed when the program-mer is operating in the DIAGNOSTICS or DIAGNOSTIC HIS-TORY modes. The messages are listed in alphabetical order for easy reference.

Diagnostic History Press the DIAGNOSTICS key and the MORE INFO key simul-taneously to enter the DIAGNOSTIC HISTORY menu.

The DIAGNOSTIC HISTORY lists all of the faults observed and re-corded by the controller since the history was last cleared. Press the SCROLL DOWN key to display any recorded faults. Each fault will be listed only once, regardless of the number of times the fault may have occurred.

The diagnostic history can be cleared from the controller using the SPECIAL PROGRAM MENU function, "CLEAR DIAG HIS-TORY". Press the PROGRAM key while holding the MORE INFO key. Press the SCROLL DOWN key until CLEAR DIAG HISTORY appears in the top line of the display. Press the MORE INFO key again, and then press the VALUE UP key to clear the history, or VALUE DOWN to cancel the operation.

Special Program Menu Press and hold the MORE INFO key, then press the PRO-GRAM key to enter the SPECIAL PROGRAM menu. The SPE-CIAL PROGRAM menu allows the user to: revert the controller to previous settings, save controller settings to the programmer memory, load controller settings from the programmer memory, clear diagnostic history, adjust the contrast of the programmer display, select language, and display basic controller and pro-grammer information.

Press the SCROLL DISPLAY key until the desired function is on the top line. Press the MORE INFO key for

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting information on how to make the desired adjustment.

TABLE 3-29 -SPECIAL PROGRAM MENU

The SPECIAL PROGRAM menu also allows the user to "clone" controllers. After one controller is programmed with all of the desired values, the values can be saved to the programmer hand set memory. The programmer hand set can then be used to load the saved values to other similar controllers (same mod-el number).

PROGRAMMING THE TRACTION MOTOR CONTROLLER WARNING: NEVER adjust function settings outside the range recommended for the specific truck model.

WARNING: Program changes affect lift truck performance and operation. If function settings are changed, make sure all operators of the lift truck know that the truck has been changed and may operate differently.

1. Turn the key switch to the "OFF" position.

2. Disconnect and separate the battery connector.

3. Remove the cover.

WARNING: The capacitor in the traction motor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. Discharge the capacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller's B + and B -terminals. DO NOT use a screwdriver to discharge the traction motor controller.

4. Discharge the capacitors in the traction motor controller by connecting a load (such as a contactor coil or a horn) across the controller's B+ and B-terminals.

5. Connect the PROGRAMMER HAND SET to the traction motor controller. The cord of the hand set plugs into the 4 pin Molex, Mini-Fit Jr. receptacle on the front of the controller.

NOTE: Each time the programmer hand set is connected to the controller, it acquires all of the controller function value settings and stores them in its temporary memory. This allows the userto revert backto the original settings at anytime. The SPECIAL PROGRAM menu selection RESET ALL SETTINGS is used to revert to the original settings.

Any inadvertent change made to any of the function values can be "undone" in this manner, as long as the programmer has not been unplugged or the key switch turned off (power disconnected).

6. Reconnect the battery.

NOTE: The brake pedal must be released (up position).

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting 7. Turn the key switch to the "ON" position. Ensure battery disconnect switch is closed.

8. Press the PROGRAM button on the PROGRAMMER HANDSET. The green LED in the corner of the PROGRAM button lights to indicate that the HAND SET has been placed in the PROGRAM mode.

9. Press the SCROLL DISPLAY buttons, as required, until the desired function is shown on the top line of the display.

10. Press the MORE INFO button to display additional information, if desired, on the selected function. The green LED in the corner ofthe MORE INFO button lights to indicate that the MORE INFO option has been selected.

NOTE: Some functionvaluesarelimitedbyvaluessetforother functions. For example, the value for M2 ACCELERATION RATE (Mid Mode) must be equal to or less than the value for M1 ACCELERATION RATE (Turtle Mode) and equal to or greater than the value for M3 ACCELERATION RATE (Rabbit Mode). Press the MORE INFO key to display the limiting function, shown on the bottom line in place of the minimum and maximum values normally displayed.

WARNING: NEVER adjust function settings outside the range recommended for the specific truck model.

11. Press the CHANGE VALUE buttons to change the function value higher or lower, as required. A green LED on each CHANGE VALUE button lights to indicate that the function value can be changed in the corresponding direction. If the green LED on one of the CHANGE VALUE buttons is not illuminated, the value has reached the limit for the corresponding direction.

WARNING: Program changes affect lift truck performance and operation. If function settings are changed, make sure all operators of the lift truck know that the truck has been changed and may operate differently.

12. Press the MORE INFO button to return to the PROGRAM menu, if the MORE INFO screen had been selected.

13. Repeat Steps 9 thru 12, as required, until all of the functions are set to the desired values.

NOTE: Any inadvertent change made to any of the function values can be "undone" using the SPECIAL PROGRAM menu selection RESET ALL SETTINGS, as long as the programmer has not been unplugged or the key switch turned off (power disconnected).

14. Turn the key switch to the "OFF" position.

15. Disconnect and separate the battery connector.

WARNING: The capacitor in the traction motor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. Discharge the capacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller's B + and B -terminals. DO NOT use a screwdriver to discharge the traction motor controller.

16. Discharge the capacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller's B+ and B-terminals.

17. Disconnect the programmer hand set cord from the trac-tion motor controller.

18. Install the cover.

TABLE 3-30 -SEM TRACTION MOTOR CONTROLLER FACTORY VALUES AND MINIMUM / MAXIMUM RANGES

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

TROUBLESHOOTING The traction motor controller provides diagnostic information to the programmer hand set, the dash display and the status LED on the controller. The following four-step process is recom-mended for diagnosing and troubleshooting an inoperative vehicle: 1. Visually inspect the truck for obvious problems.

2. Diagnose the problem using the DIAGNOSTIC menu in the programmer hand set.

3. Test the circuitry (inputs/outputs) using the TEST menu in the programmer hand set.

4. Correct the problem.

Status LED Diagnostics A status LED is built into the traction motor controller. It is visible through a window in the label on the top of the controller. The status LED displays fault codes when there is a problem with the controller or with the inputs to the controller. During normal operation, with nofaults present, the status LEDflashes steadi-ly on and off. If the controller detects a fault, a 2-digitfault identi-fication code is flashed continuously until the fault is corrected. For example: code "3,2" - welded traction contactor -appears as three flashes, pause, two flashes, long pause, three flashes, pause, two flashes, long pause ...and so on continuously until the problem is corrected.

TABLE 3-31 -STATUS LED FAULT CODES

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

NOTE: Only one LED fault code is indicated at a time, and faults are not queued up. Operational faults -such as a fault in SRO sequencing -are cleared by cycling the key switch.

Programmer Diagnostics The programmer presents complete diagnostic information in plain language. Faults are displayed in the DIAGNOSTIC menu. The status of the controller inputs and outputs is dis-played in the TEST menu. The DIAGNOSTIC HISTORY menu provides a list of the faults that have occurred since the diag-nostic history file was last cleared. Checking (and clearing) the diagnostic history file is recommended each time the truck is serviced.

Press the DIAGNOSTIC key to enter the DIAGNOSTIC mode. The LED in the corner of the DIAGNOSTIC key illuminates to indicate that the programmer has been placed in the DIAG-NOSTIC mode. The DIAGNOSTICS menu displays all current-ly active faults detected by the controller. It is capable of dis-playing 16 different faults, four at a time.

Press the DIAGNOSTICS key and the MORE INFO key simul-taneously to enter the DIAGNOSTIC HISTORY menu.

The DIAGNOSTIC HISTORY lists all of the faults observed and re-corded by the controller since the history was last cleared. Press the SCROLL DOWN key to display any recorded faults. Each fault will be listed only once, regardless of the number of times the fault may have occurred.

Press the TEST key to enter the TEST mode. The LED in the corner of the TEST key illuminates to indicate that the program-mer has been placed in the TEST mode. The TEST menu dis-plays real time information about the status of the inputs, out-puts and controller temperature. In the TEST mode, the item of interest does not need to be the top item in the window; it only needs to be one of the four items displayed in the window. The MORE INFO key, when used in the TEST mode, displays addi-tional information about the top item in the window.

The charts on the following pages should be used in conjunc-tion with the wiring diagrams for best results. The DIAGNOS-TIC (and DIAGNOSTIC HISTORY) menu items are shown, fol-lowed by the TEST menu items. See the section for the wiring diagrams and schematics.

Diagnostics Menu

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

Test Menu

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

MOTOR MAINTENANCE-GENERAL This portion of the electrical section describes disassembly and assembly, brush replacement, inspection and checks for malfunction of DC motors. Inspect the commutator and brushes every 350 hours of operation. The commutator is the rotating electric connection between the armature and the electric power supplied bythe battery.

Brushes made of carbon compounds slide on the rotating commutator and are the path for electricity from the battery to the commutator and the armature. The maintenance of the commutator and the brushes is important to the good operation of a DC motor.

Traction motors and hydraulic pump motors are similar in design. The hydraulic pump motors are smaller than the traction motors, but the disassembly and maintenance of these motors are similar.

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

Figure 3-24 -Traction Motor Brush and Commutator Inspection WARNING: Put blocks under each side of the truck under the drive unit frame. Position blocks on both sides of the load wheels. The blocks must prevent the lift truck from falling and causing injury or damage.

1. Raise the drive wheel off the floor. Block the lift truck. See Section 1 - HOW TO PUT A LIFT TRUCK ON BLOCKS. Disconnect the battery.

WARNING: Disconnect the battery and separate the connector before opening the compartment cover or inspecting/repairing the electrical system. If a tool causes a short-circuit, the high current flow from the battery can cause an injury or parts damage.

2. Disconnect the battery and separate the connectors.

3. Open the drive unit compartment cover.

WARNING: The capacitor in the traction motor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. Discharge thecapacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller's B+ and B- terminals (center 2 terminals). DO NOT use a screwdriver to discharge the traction motor controller.

4. Remove the compartment cover. Discharge the capacitor in the traction motor controller.

5. If used, remove the brush covers to the motor. Wear eye protection. Use a vacuum cleaner or compressed air to remove dirt and "brush dust" from the commutator area.

NOTE: Vacuum cleaning, when possible, is the recommendation of manufacturers of electric motors. The use of compressed air can send dirt particles into the bearings and other areas of the motor that can cause possible damage.

6. Visually inspect the commutator surface. See Figure 3-25 through Figure 3-33. The commutator wears slowly in normal service. The mica must be cut below the surface of the commutator bars after a long service period or after a commutator has been turned in a lathe. Carefully rotate the armature. DO NOT damage the commutator

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting if you use a tool to rotate the armature.

7. Inspect the white or gray insulation (mica) between the commutator bars. The mica must not touch the brushes or the brushes will wear very rapidly.

8. Install the brush covers, when used and closethe drive unit compartment cover.

9. Connect the battery. Remove the blocks under the drive wheel. Test operate the lift truck before returning the truck to service.

Normal Commutator Surfaces A commutator that has been in service will have a smooth and polished surface with a darker brown color where it rotates under the brushes. A variation of color on the commutator surface between light brown and darker brown is normal. This surface condition is the lubrication between the commutator and the brushes. The brushes will wear rapidly if this surface condition does not develop during the first six to ten hours of operation after a commutator with a new surface is installed.

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

Figure 3-25 -Normal Commutator Surfaces Commutator Problems Commutator problems and motor problems are shown in Figure 3-26 through Figure 3-33. See COMMUTATOR REPAIRS, this section.

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

Figure 3-26 -Commutator Problems

Figure 3-27 -Commutator Problems

Figure 3-28 -Commutator Problems

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

Figure 3-29 -Commutator Problems

Figure 3-30 -Commutator Problems

Figure 3-31 -Commutator Problems

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

Figure 3-32 -Commutator Problems

Figure 3-33 -Commutator Problems Brush Replacement-Traction and Hydraulic Motors Worn motor brushes must be replaced before they damage the surface of the commutator. Move the brush spring and remove a brush from the brush holder. Measure the length of the brush as shown in Figure 3-34. Replace all of the brushes if the length of one brush is less than the minimum length. Brushes are made to different specifications for motors used in different applications. Use only replacement brushes approved byYALE MATERIALS HANDLING CORPORATION. 1. Move the lift truck to a safe level area. Turn the key switch off and remove the key. Put a "DO NOT OPERATE" tag on the multi-function control handle. Put blocks underthe drivewheels to keep the lift truck from moving. See Section 1 -HOW TO PUT A LIFT TRUCK ON BLOCKS. WARNING: Disconnect the battery and separate the connector before opening the compartment cover or inspecting/repairing the electrical system. If a tool causes a short-circuit, the high current flow from the battery can cause an injury or parts damage.

2. Disconnect the battery and separate the connectors.

3. Open the drive unit compartment cover.

WARNING: The capacitor in the traction motor controller can hold an electrical charge after the /N battery is disconnected. To prevent electrical shock and injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. Discharge the capacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controllers B+ and B-terminals (center 2 terminals). DO NOT use a screwdriver to dischargef the traction motor controller.

4. Remove the brush covers to the motor. Wear eye protection. Use a vacuum cleaner or compressed air to

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting remove dirt and "brush dust" from the commutator area.

5. Make a note of the arrangement and connections of the brush assembly. The replacement brushes must be installed in the same positions as they were removed.

6. Loosen the screw that fastens the brush wire to its terminal. Remove the brush springs and brushes.

7. Inspect the brush holders for burns and damage. Make surethe brush holder is fastened tightlytothe mounts atthe end of the motor. Make sure the new brushes will move freely and smoothly in the brush holders.

8. Connect the new brush wire to its terminal mount.

NOTE: When the brushes must be replaced, it is recommended that the brush springs also be replaced.

9. Check the brush springs for damage from heat and corrosion. Replace damaged brush springs. Replace discolored (heat) brush springs. Check that the brush springs for approximately equal pressure. Brush springs normally have a spring pressure of approximately 1.0 to 2.0 Newtons per each cm2 (1 .5 to 3.0 Ibf per each in2) when measured with a spring scale.

NOTE: Measure the surface area on the brush which contacts the commutator (thickness x width). See (6) Figure 3-34. Multiply the surface area times 1.5 to 3.0 to determine the brush spring force.

Figure 3-34 -Traction Motor Brushes A brush for a traction motor has an area of approximately 4.27 x 0.96 cm = 4.3 cm2 (1.75 x 0.378 in = 0.665 in2).

Brush springs for the traction motor normally have a spring force of approximately 8.5 t 1.1 Newtons (2 Ibf t 4 ozf) when measured with a spring scale as shown in Figure 3-36. (Look for a reading of approximately 2 t .25 pounds on the spring scale.) These brushes will have a minimum length of 14 mm (0.55 in). Replace all brushes if any one of the brushes are less than the minimum brush length.

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

1. BRUSH 2. BRUSH SPRING Figure 3-35 -Brush Removal and Inspection A brush for a hydraulic pump motor has an area of approximately 1.74 x 0.375 in. = 0.653 in.2 (4.42 x 0.95 cm = 4.21 cm2>. Brush springs forthe hydraulic pump motor normally have a spring force of approximately 1 Ibf and 8 ozft4 ozf (6.3 t 1.1 Newtons) when measured with a spring scale as shown in Figure 3-36. (Look for a reading of approximately 1.5 t .25 pounds on the spring scale.) The minimum length of the hydraulic motor brushes is 15.9 mm (0.625 in). Replace all brushes if any one of the brushes are less than the minimum brush length.

NOTE: The brush springs used in motors made by Yale have a constant force design. The force of the brush spring against the brush stays almost constant as the brush wears and becomes shorter in its brush holder.

10. New brushes must be made to fit the surface of the commutator by an abrasive procedure called "stoning the commutator". Use a Brush Seater and Commutator Stone (No. 23-007M from the Ideal Company or an equivalent brush seater stone). See STONING THE COMMUTATOR, this section.

If new brushes are not fitted to the commutator by stoning, the contact surface can be small until the brushes wear to fit the commutator. This small surface can cause burns and a rough surface on the commutator. "Stoning the Commutator" is most easily done when the motor rotates slowly. When the motor rotates at higher speeds, the centrifugal force removes the abrasive particles from the commutator more quickly. See Figure 3-37.

11. Close the drive unit compartment cover.

12. Connect the battery.

13. Remove the blocks from under the drive wheels, remove the "DO NOT OPERATE" tag and install the key.

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting

1.

2.

3.

4.

SPRING SCALE (0-5 LB FISH SCALE) BRUSH IN BRUSH HOLDER COMMUTATOR BRUSH SPRING Figure 3-36 -Check Brush Spring Pressure

TRACTION MOTOR-REMOVAL The procedure for removing the traction motor from the lift truck and for disassembly of the traction motor from the drive unit is outlined in Section 4.

TRACTION MOTOR-INSTALLATION The procedure for assembly to the drive unit and for installing the traction motor in the lift truck is outlined in Section 4.

LIFT PUMP AND MOTOR-REMOVAL The procedure for assembly of the motor to the pump and for installing the lift pump and motor is outlined in Section 7.

LIFT PUMP AND MOTOR-INSTALLATION The procedure for installing the lift pump and motor and disassembly ofthe motor from the pump is outlined in Section 7.

STEERING PUMP AND MOTOR-REMOVAL The procedure for removing the steering pump and motor and disassembly of the steering pump from the motor is outlined in Section 6.

STEERING PUMP AND MOTOR-INSTALLATION The procedure for assembly of the pump and motor and installation of the steering pump and motor is outlined in Section 6.

Commutator Repairs WARNING: Wear eye protection. Raise the drive wheel. Operate the motor at low speed. Protect your fingers, Do not use a brush seater stone less than 2.5 in. (60 mm) in. length.

1. If the commutator has grooves or other damage, the armature must be removed so that the commutator can be repaired. Motors are normally repaired by service personnel that have the special equipment required for the repair. Connect the battery so that the motor can be operated. The drive unit compartment cover must be removed for access to the motor. Raise the drive wheel. See Section 1 -HOW TO PUT A LIFT TRUCK ON BLOCKS.

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting CAUTION: Do not permit the brush seater stone to stay in contact with the commutator too long and cause more wear than necessary.

2. Operate the motor so that the commutator rotates in the same direction as the long tips of the brushes. Apply the brush seater stone to the moving commutator with light pressure. Move the brush seater stone backward and forward across the surface of the commutator until the marks on the commutator are removed. Apply the brush seater stone to the commutator before each set of brushes so that the brush seater particles have an even distribution.

1. BRUSH SEATER STONE NOTE: A brush seater stone can also be fastened to a wood stick with glue as shown in the illustration. This arrangement makes it easier to apply a brush seater stone in small places.

Figure 3-37 -Stoning the Commutator 3. Turn the key switch to the OFF position and disconnect the battery. Check all brush contact surfaces. The brushes fit correctly when 85% of the brush contact surface touches the commutator. This procedure normally requires approximately 15 to 45 minutes.

4. When the brushes have the correct contact surface with the commutator, use compressed air to remove the abrasive dust from the commutator area and the motor.

5. When the installation and checks are complete, install the brush cover. Make sure that the wires to the brushes do not touch any part of the motor case and cause a short-circuit.

Tests Damaged Field and Armature The tests described in the following paragraphs are to help a service person check a motor for damage and determine if it must be sent to a repair service for rebuilt motors. The resistance checks will not normally indicate a short-circuit in a motor winding. A resistance greater than 1 to 2 ohms can indicate a damaged winding. The motor must be removed from the lift truck and disassembled as shown in the illustrations before the tests can be done.

The armature windings in large electric motors normally have less than one ohm of resistance. The two commutator bars for a winding are found 180 degrees apart on the commutator. If a volt ohmmeter (R x 1 scale) is used to check the resistance between the two commutator bars of the winding, a resistance of more than one ohm indicates a problem in that winding. A resistance of infinity (oo) indicates an open (damaged) winding.

If the armature has an open circuit, there will normally be two burned commutator bars on opposite sides of the commutator. These burned areas will cause the brushes to wear rapidly. When the motor operates, large electric sparks and arcs occur as the damaged commutator bars rotate under each brush. See Figure 3-30.

Short-Circuit in an Armature Winding A short-circuit in a motor winding is difficult to test because of the normal low resistance (less than one ohm) of a good armature. Use a Meggar to check for a short-circuit in a motor winding. A motor with a short-circuit in an

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting armature winding will have a different sound when it begins to operate, but a service person must have experience to hear and understand the difference in sound. A winding with a short-circuit will also run hotter than a good winding and can have indications of heat damage. A winding that shows heat damage when the other windings are normal can have a short-circuit.

Another indication of a short-circuit will be a higher than normal current draw by the motor. A higher than normal current draw can also indicate other problems or needed adjustments and does not always indicate a short-circuit in a motor winding.

1. ARMATURE SHAFT 2. COMMUTATOR 3. PROBES TO OHMMETER Figure 3-38 -Test for an Armature Short-Circuit Short-Circuit in the Armature A volt ohmmeter (R x 10,000 scale) can be used to test for a short-circuit between an armature winding and the armature shaft. Put one probe on the armature shaft and the other probe on a commutator bar. See Figure 3-38. A resistance of less than one megohm indicates a problem between a winding and the armature shaft.

NOTE: Clean the dirt and "brush dust" from the commutator area before making a test for a short-circuit.

Open Circuit in a Field Coil The field windings in large electric motors normally have less than one ohm of resistance. If a volt ohmmeter (R x 1 scale) is used to check the resistance between the two terminals of the winding, a resistance greaterthan one ohm indicates a problem in that winding or corrosion in the terminal connection. See Figure 3-39.

1. FIELD COIL TERMINAL 2. OHMMETER Figure 3-39 -Test for an Open Field Circuit Short-Circuit in a Field Coil

Sheet 3: Electrical System--Programmer Handset,Operating Modes,Troubleshooting A short-circuit in a motorfield winding is difficult to test because of the normal low resistance (less than one ohm) of a good field. A Meggar can be used to check for a short-circuit in a motor winding. A motorwith a short-circuit in afield winding will have a different sound when it begins to operate, but a service person must have experience to hear and understand the difference in sound. A winding with a short-circuit will also run hotter than a good winding and can have indications of heat damage.

Another indication of a short-circuit will be a higher than normal current draw by the motor. A higher than normal current draw can also indicate other problems or needed adjustments and does not always indicate a short-circuit in a motor winding.

Short-Circuit Between Field and Motor Case A volt ohmmeter (R x 10,000 scale) can be used to test for a short-circuit between the field and the motor case. Put one probe on the motor case and the other probe on a field terminal. Check the resistance between the field terminal and the motor case. A resistance of less than one megohm indicates a problem between the field terminal and the motor case. Make sure that carbon dust has been cleaned from the motor before making this test.

Brush Holder Make sure the carbon dust has been removed from the brush holders. Use a volt ohmmeter (R x 10,000 scale) to measure the resistance between the brush holder and the motor case. The correct resistance should be infinity (oo).

Sheet 4: Electrical System--Wiring Schematics ELECTRICAL SYSTEM

FIGURE 3-40 -WIRING SCHEMATIC 36 VOLT -TYPE "E" A861

Sheet 4: Electrical System--Wiring Schematics

FIGURE 3-41 -WIRING SCHEMATIC 36 VOLT -TYPE "E" A861

Sheet 4: Electrical System--Wiring Schematics

FIGURE 3-42 -WIRING SCHEMATIC 36 VOLT -TYPE "E" A861

Sheet 4: Electrical System--Wiring Schematics

FIGURE 3-43 -WIRING SCHEMATIC 36 VOLT -TYPE "E" A861

Sheet 4: Electrical System--Wiring Schematics

FIGURE 3-44 -WIRING SCHEMATIC 36 VOLT -TYPE "E" A861

Sheet 4: Electrical System--Wiring Schematics

FIGURE 3-45 -WIRING SCHEMATIC 36 VOLT -TYPE

524135978

Sheet 4: Electrical System--Wiring Schematics

FIGURE 3-46 -WIRING SCHEMATIC 36 VOLT TYPE "E" A861

Sheet 5: Electrical System--Wiring Schematics ELECTRICAL SYSTEM

FIGURE 3-47 -WIRING SCHEMATIC 36 VOLT TYPE "E" C829

Sheet 5: Electrical System--Wiring Schematics

FIGURE 3-48 -WIRING SCHEMATIC 36 VOLT TYPE "E" C829

Sheet 5: Electrical System--Wiring Schematics

FIGURE 3-49 -WIRING SCHEMATIC 36 VOLT TYPE "E" C829

Sheet 5: Electrical System--Wiring Schematics

FIGURE 3-50 -WIRING SCHEMATIC 36 VOLT TYPE "E" C829

Sheet 5: Electrical System--Wiring Schematics

FIGURE 3-51 -WIRING SCHEMATIC 36 VOLT

524138370 TYPE "E"

Sheet 5: Electrical System--Wiring Schematics

FIGURE 3-52 -WIRING SCHEMATIC 36 VOLT TYPE "E" C829

Sheet 5: Electrical System--Wiring Schematics

FIGURE 3-53 -WIRING SCHEMATIC 36 VOLT TYPE "E" C829

Sheet 6: Drive Unit DRIVE UNIT GENERAL This section provides a description and the repair and adjustment procedures for the parts of the master drive unit (MDU). The traction motor, steering and brake repair procedures are in separate sections.

The articulating axle is fabricated from metal components and provides the proper spacing between the MDU, caster wheels and axle shaft locations. A pivot pin passes through the center of the articulating axle weldment and is supported by two support blocks. This mounting provides the articulating capability to allow for floor variations between the drive wheel and the caster wheel. The amount of variation is limited by the adjustable articulation stops.

Both articulation stops are located in the drive unit compartment and are easily accessible.

DESCRIPTION The main parts of the MDU are the case, pinion (motor) and large gear set, the pinion and spiral bevel gear set, bearings, and the axle and wheel. The large ball bearing for steering is part of the upper housing of the MDU. The traction motor fastens to an adapter ring fastened to the MDU. This adapter ring is part of the large ball bearing and allows the MDU to turn on the axis of the traction motor. The traction motor does not turn with the MDU. Six capscrews fasten the large ball bearing and MDU to the articulating axle. The bearing lets the MDU turn for steering. There is a small helical pinion on the motor armature shaft. This pinion turns a large helical gear attached to the bevel pinion shaft in the MDU. The bevel pinion shaft turns the bevel gear attached to the axle shaft to turn the drive wheel. The brake is fastened to the top end of the motor shaft to stop rotation of the shaft. The brake action works through the gears to stop the unit.

Figure 4-1 -Master Drive Unit with Wheel and Traction Motor ARTICULATION STOP ADJUSTMENT The stability and traction will be affected if the drive unit articulation stops are not adjusted properly. The articulation stop screws must be adjusted to the proper setting as listed in NO TAG. Adjustment is required every 350 hours during routine maintenance, when a drive and/or caster wheel is changed, or when any repairs are carried out on the articulation axle.

DRIVE UNIT ARTICULATION STOPS DRIVE SIDE ADJUSTMENT CASTER SIDE ADJUSTMENT

Sheet 6: Drive Unit

Figure 4-2 -Drive Unit Articulation Stops Capacity Plate Table 4-32 -Articulation Chart

STOP SETTING DRIVE SIDE CASTER SIDE

MAX. FORK HEIGHT 6909 mm BELOW (272 in) 6909 mm AND (272 in) ABOVE 4.8-6.4 mm 1.6-3.2 mm (0.19-0.25 in) (0.06-0.125 in) 4.8-6.4 mm 4.8-6.4 mm (0.19-0.25 in) (0.19-0.25 in)

NOTE: The articulation stop settings are also listed on the capacity plate.

ARTICULATION ADJUSTMENT PROCEDURE 1. Position the truck on a flat, level floor.

2. Disconnect the battery.

3. Open the drive unit compartment door.

4. Check the articulation stop clearance on both the drive and caster stop screws. If the clearance between the stops are not within the range listed in the ARTICULATION CHART, loosen the locknuts and adjust the stop screws to the correct setting.

5. Tighten the locknuts and torque to 108 Nm (80 Ibf ft).

6. Close and lock the compartment door.

AXLE ASSEMBLY The axle assembly consists of an axle weldment which is the mount for the master drive unit (MDU), the hydraulic steering motor and the caster. The traction motor fastens to the top of the MDU near the left end of the axle weldment. The MDU is attached to the bottom of the axle weldment and rotates on a large bearing. The traction motor supplies the power to turn the drive wheel. The hydraulic steering motor rotates the MDU for steering. The caster supports the right end of the axle weldment. The axle weldment assembly is fastened to the lift truck by an articulating shaft. The articulating axle assembly pivots on the shaft.

TRACTION MOTOR The traction motor is not part of the steering system. The motor is part of the MDU assembly and must be removed to remove the axle assembly from the lift truck.

Sheet 6: Drive Unit

Figure 4-3 -Traction Motor and MDU 1. TRACTION MOTOR 2. ARTICULATING AXLE 3. CAPSCREW TO FASTEN BEARING AND MDU 4. ADAPTER PLATE 5. CAPSCREW TO FASTEN MOTOR 6. LARGE BALL BEARING 7. BEARING SHIELD 8. TOP CASE 9. HELICAL PINION (MOTOR) 10. HELICAL GEAR 11. HOUSING 12. BEVEL PINION SHAFT AND GEAR SET 13. COVER 14. AXLE SHAFT Removal 1. Disconnect the battery. Open the drive unit compartment door.

2. Tag the power cables of the traction motor for correct installation during installation. The motor terminals are identified on the motor as Al, A2, Fi or F2. Remove the power cables from the terminals of the traction motor.

Fasten the cables in a location to prevent damage during motor removal.

3. Tag and disconnect the wires to the brake switch on the NR-CA or electric brake on the NR-GA. CAUTION: Brake fluid damages paint. Immediately remove any brake fluid that is on a painted surface.

4. On the NR-CA position a container under the slave cylinder to catch the brake fluid and remove the hose assembly. Cap the hose assembly. Allow the brake fluid to drain from the slave cylinder.

5. Make an identification mark on the motor housing and the axle weldment for correct motor alignment during installation. Remove the six M8 capscrews and lockwashers retaining the flange of the traction motor to the

Sheet 6: Drive Unit MDU upper housing.

WARNING: The traction motor is heavy. Be sure that all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the traction motor. The traction motor can weigh approximately 40 kg (85 Ibs).

6. Use a sling around the traction motor and an overhead crane to carefully lift the traction motor. Do not damage the drive gear on the motor shaft or the brake assembly on the top of the motor. Position the motor on its side so that the gear and the brake assembly are not damaged.

Installation 1. Install a new O-ring on the traction motor housing. Use O-ring lubricant on the O-ring.

WARNING: The traction motor is heavy. Be sure that all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the traction motor. The traction motor can weigh approximately 40 kg (85 Ibs).

2. Use an overhead crane and a sling to carefully lift the traction motor into the correct position on the MDU upper housing. Do not damage the drive gear or the brake assembly. Make sure that the motor and the MDU are aligned with the mark made during removal before the motor is completely lowered onto the upper housing.

3. Install and tighten the six capscrews and lockwashers using a crisscross pattern to 20 Nm (15 Ibf ft) torque.

4. Connect the power cables to the motor terminals.

CAUTION: See Section 5 of this manual to remove the air from the brake system. Do not operate the lift truck without removing the air from the brake system.

CAUTION: Brake fluid damages paint. Immediately remove any brake fluid that is on a painted surface.

5. On the NR-CA remove the cap from the brake line from the master cylinder and attach the line to the slave cylinder. Add brake fluid to the brake reservoir. Bleed the air from the brake system. See Section 5.

6. Install the wires to the brake switch.

7. Close the drive unit compartment door. Connect the battery.

HYDRAULIC STEERING MOTOR Description Lift truck steering is achieved when the hydraulic steering motor rotates the master drive unit (MDU) using a steering chain. See Figure 4-4. The hydraulic steering motor uses a rotor assembly to change hydraulic energy into mechanical energy. The rotor assembly has a fixed rotor with seven vanes and a stator. There is hydraulic pressure between the vanes and stator. The pressure makes the stator rotate in the rotor.

Figure 4-4 -Hydraulic Steering System

Sheet 6: Drive Unit 1. HYDRAULIC STEERING MOTOR 2. MASTER DRIVE UNIT (MDU) 3. STEERING CHAIN Removal 1. Use the steering system to move the master drive unit for access to the chain anchor of the steering chain.

Disconnect the battery and open the drive unit compartment cover.

2. Remove the steering chain from the sprocket of the hydraulic motor. To remove the chain, first make a mark on the chain anchor and the MDU upper housing at the chain anchor. Remove the cotter pin from the end of one offset pin at the chain anchor. Remove the link pin and chain. Remove the chain from the sprocket of the hydraulic motor. Use wire to fasten the chain so that it does not fall.

3. Remove the capscrews and lockwashers that retain the hydraulic motor to the articulating axle weldment.

Remove the motor.

4. Install labels on the hydraulic lines for proper installation at assembly. Disconnect the hydraulic lines and install caps on the lines and fittings or ports of the motor.

5. Put the flange of the motor in a soft jawed vise. Hold the sprocket and remove the nut and washer. Do not damage the sprocket teeth.

6. Carefully remove the sprocket and woodruff key. Do not let the woodruff key fall. The woodruff key is located between the sprocket and shaft.

NOTE: Most service personnel do not repair the hydraulic motor. The cost of repairs can be greater than the cost of a replacement motor.

Installation 1. If the hydraulic motor is a new replacement, remove the nut, washer and tape used to retain the woodruff key in the shaft. Do not use the washer, use the washer removed from the original motor.

2. Install the woodruff key in the shaft of the hydraulic steering motor. Align the slot of the sprocket with the woodruff key and carefully install the sprocket in the shaft. Install the washer removed during the removal procedure. Install and tighten the nut. Do not damage the sprocket teeth when tightening the nut.

3. Refer to the labels made during removal and connect the two hydraulic hoses to their correct ports on the hydraulic motor. If necessary, install the fittings from the old motor on the new motor. Use new O-rings. Make sure that the hoses will not be twisted when the motor is in the correct position on the articulating axle weldment.

NOTE: If the chain anchor came off the MDU upper housing, install the chain anchor at the mark made during removal.

4. Install the shims and motor on the articulating axle weldment. Use the steering chain to check that the sprocket is aligned with the chain flange on the master drive unit. If necessary, add or remove shims between the motor and axle weldment for correct alignment. Install the capscrews and lockwashers. Tighten the capscrews to 68 N m (50 Ibf ft) torque.

5. Install the steering chain on the chain anchor. Install the offset link and link pin on the chain anchor. Use a new cotter pin to complete the assembly.

6. Operate the steering system to check that the system is operating correctly. Check for hydraulic leaks.

REPAIR Removal -Articulating Axle Weldment 1. Make sure the key is in the OFF position. Disconnect the battery. Raise and block the drive/steering wheel off the floor. See Section 1 -HOW TO RAISE THE DRIVE/STEER TIRE AND CASTER WHEELS. 2. Open the drive unit compartment. Remove the traction motor, master drive unit (MDU) and hydraulic motor. See REMOVAL-TRACTION MOTOR, REMOVAL-MASTER DRIVE UNIT and REMOVAL-HYDRAULIC MOTOR. On the NR-GA, disconnect caster brake line.

Sheet 6: Drive Unit 3. Position a floor jack under the lower part of the axle weldment.

4. Remove the capscrew, washer and nut retaining the pivot pin.

5. Raise the jack so that it is the support for the axle weldment, but does not support the lift truck. Install a 1/2-13 UNC capscrew in the threaded hole in the pivot pin and pull the pivot pin out through the hole provided in the lift truck. The shims between the lift truck frame and the articulating axle weldment will fall free. Straighten and wire the shims together for reuse at installation.

WARNING: The truck frame and axle weldment are heavy. Be sure that all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the truck frame and axle weldment. The axle weldment can weigh approximately 60 kg (125 lb).

6. Use an overhead crane and sling to raise the truck frame off the axle weldment. Move the frame away from the axle weldment and lower the frame to the floor.

7. Remove the bushings in the axle weldment. Use a long brass drift to remove the bushings. The brass drift must be approximately 250 mm (10 in) long. Use a block of hard wood against the bushing and a large hammer to remove the bushings. Do NOT use a hammer on the bushings.

Installation -Articulating Axle Weldment 1. Install new bushings in the axle weldment. Use the brass drift and the block of hard wood to install the bushings in the lift truck frame. Do NOT use a hammer on the bushings.

2. Apply multi-purpose grease in the I D of the bushings and on the OD of the pivot pin.

Figure 4-5 -Articulating Axle Installed 1.

2.

3.

4.

5.

6.

SHIMS BUSHINGS PIVOT PIN CAPSCREW NUT ARTICULATING AXLE WELDMENT

WARNING: The axle weldment is heavy. Be sure that all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the axle weldment. The axle weldment can weigh approximately 60 kg (125 Ib).

3. Use the overhead crane and sling and position the axle weldment in the lift truck frame.

4. Align the bores of the axle weldment and the lift truck frame using the floor jack. Make certain to install the shims between the frame of the lift truck and the axle weldment. Install the tapered end of the articulating shaft into the bore. Use a brass hammer or a hammer with a soft face to install the articulating shaft. Do not install the shaft too far into the bore. Install the shaft so that the groove near the end of the shaft is aligned with the hole for the

Sheet 6: Drive Unit capscrew. The total end movement must not exceed 0.76 mm (0.03 in). If the end movement exceeds the recommended limit, install additional shims as required. Bend the ends of the shims protruding below the lift truck frame over so the shims do not rotate and fall out.

5. Install the capscrew, washer and nut to retain the articulating axle. Tighten the nut to 31 Nm (23 Ibf ft) torque.

Lubricate the articulating shaft and bushings using the grease fitting with the recommended grease as listed in the LUBRICATION SCHEDULE, Section 2.

6. Install the hydraulic motor, master drive unit and traction motor. Refer to INSTALLATION -HYDRAULIC MOTOR, INSTALLATION - MASTER DRIVE UNIT and INSTALLATION -TRACTION MOTOR. On the NR-GA connect caster brake line.

7. If removed, install the caster wheel assembly. Remove the blocks and lower the drive/steering wheel to the floor.

Connect the battery.

Description The master drive unit (MDU) is turned bythe steering chain and the hydraulic motor. The housing for the steering bearing is fastened to the bottom of the articulating axle weldment. The traction motor is also fastened to this bearing housing.

Removal CAUTION: The capscrews used to fasten the Master Drive Unit (MDU) and traction motor are all metric. Do not damage them using the wrong tools.

WARNING: There are close clearances between the MDU, drive chassis and base arm assembly that can cause serious injury. NEVER put hands, arms, head or legs between these parts unless the parts have blocks to prevent movement.

1. Move the steering wheel so that the drive wheel is in a position for straight travel. Make certain the key switch is in the OFF position.

2. Disconnect and remove the battery. Use the CHANGING THE BATTERY procedure in the OPERATING MANUAL or Section 2 of this manual.

3. Open the drive unit compartment door. Fasten the doors so that they are fully open. Put a pan under the MDU drain plug and remove the drain plug. After the oil has completely drained, install the drain plug. Tighten the drain plug to 22 Nm (16 Ibf ft) torque.

WARNING: The traction motor is heavy. Be sure that all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the traction motor. The traction motor can weigh approximately 40 kg (85 Ibs).

4. Remove the three capscrews and lockwashers that fasten the traction motor to the adapter ring on the MDU. Carefully lift the motor and set the motor out of the way. Do not damage the pinion gear on the motor shaft. Use rope to fasten the motor to prevent the motor from falling.

5. Loosen the locknut at the chain anchor for the steering chain. Remove the capscrew at the chain anchor. Put a mark on the MDU for the location of the pin that fastens the chain anchor to the sprocket. Remove the pin.

Carefully remove the chain anchor and chain from the sprocket.

WARNING: The lift truck is heavy. Be sure that all lifting devices (hoists, cables, chains, slings etc.) are suitable and of adequate capacity to lift the lift truck. The lift truck can weigh up to approximately 4312 kg (9500 Ibs) empty.

6. Carefully put a sling under the lift truck frame on the mast side of the MDU. 7. Remove the six capscrews and lockwashers that fasten the adapter ring and MDU to the frame or axle plate.

8. Hold the MDU and raise the lift truck frame so that the MDU is free. The axle weldment will pivot on the pivot pin.

Carefully lower the MDU to the floor and move the MDU from under the lift truck. Lower the lift truck frame on blocks.

Installation WARNING: There are close clearances between the MDU, drive chassis and base arm assembly that can cause serious injury. NEVER put hands, arms, head or legs between these parts unless the parts have blocks to prevent

Sheet 6: Drive Unit movement.

1. Use a crane and chain or sling with a capacity rating of 450 kg (1000 Ibs) to Iift the frame. Lift the frame for clearance to slide the MDU under the frame. Temporarily install blocks under the frame to prevent lowering. Lay the MDU on the floor. Slide the MDU under the drive chassis.

2. Move the MDU into approximate alignment under the frame or axle plate.

3. Hold the MDUintheverticalpositionthroughtheholeinthe plate. Do NOT put any part of your body between the MDU and the frame or axle plate. Carefully raise the frame and remove the blocks. Carefully lower the frame and align the capscrew holes in the large ball bearing, adapter plate and the axle weldment.

4. Install the six capscrews and lockwashers that fasten the adapter plate and MDU to the axle weldment. Use a cross pattern to slowly tighten the capscrews to approximately 25 Nm (34 Ibf ft) torque. Make sure the large ball bearing and adapter plate are in the correct position around the complete circumference. Use the cross pattern to tighten the capscrews to 68 Nm (50 Ibf ft) torque.

NOTE: If the chain anchor came off the MDU upper housing, install the chain anchor at the mark made during removal.

5. If the helical pinion on the motor shaftwas removed, install the key, pinion, lockwasher and nut. Tighten the nut to 54 Nm (40 Ibf ft) torque. If an impact wrench is used, make sure it does not tighten the nut to more than the correct torque.

6. Install a new O-ring on the motor using O-ring lubricant. Carefully install and align the motor on the adapter plate and MDU. Do NOT damage the helical pinion on the motor shaft or the helical gear of the MDU. Install the three capscrews and lockwashers. Tighten the capscrews to 20 Nm (15 Ibf ft) torque.

7. Make sure the MDU is in the position for straight travel with the tire to the left of the case (facing MDU). Carefully install the steering chain. Use the pin to install the chain anchor on the adapter plate. Use the capscrew to fasten the two chain anchors together. Adjust the steering chain.

8. Lubricate the large ball bearing using the recommended grease listed in Section 2. Add the grease through both fittings. Slowly rotate the MDU while filling the fittings with grease. A dry bearing will take approximately 55 g (0.12 lb) of grease to fill the bearing completely.

9. Lower the lift truck to the floor. Fill the MDU to the level/fill plug using the recommended oil listed in Section 2.

Add the oil slowly. The oil must go through the bearings to the lower part of the MDU. Fill until the oil just starts to run out. Install the plug and tighten to 22 Nm (17 Ibf ft).

10. Close the drive unit compartment door. Install and connect the battery.

Disassembly (See Figure 4-6 and Figure 4-7) NOTE: Before disassembling the drive unit make certain the work area is clean and all the necessary tools are available. The nuts retaining the drive axle and upper gear on the pinion shaft are staked in place and the staked portion must be removed before attempting any disassembly.

CAUTION: The capscrews and nuts used on the MDU are all metric. Do not damagethern using the !M wrong tool.

1. Remove the wheel nuts and the drive/steer wheel.

2. Remove the nine capscrews that fasten the lower housing to the upper housing. Remove the four capscrews inside the upper housing. See Figure 4-6. There are also two capscrews inside the case that are secured with washers and nuts on the opposite side of the upper housing. Make certain to remove the capscrews, lockwashers and nuts before attempting to separate the upper housing from the lower housing.

Sheet 6: Drive Unit

Figure 4-6 -Separating Upper and Lower Housing 1.

2.

3.

4.

5.

UPPER HOUSING CAPSCREWS INSIDE TOP CASE HOUSING CAPSCREWS DOWEL

3. The upper housing is retained to the lower housing with two dowel pins. Use a plastic hammer against the lower portion of the upper housing to separate the upper housing from the lower housing. Carefully slide the upper housing for clearance between the upper housing and helical gear. Remove the upper housing.

CAUTION: The helical gear and pinion shaft assembly can only be removed after the bevel gear M and axle shaft have been removed from the drive unit lower housing.

5. Remove the capscrews retaining the drive unit cover. Remove the drive unit cover.

6. Install two wheel nuts on to the wheel bolts. Position a piece of wood or bar between the nuts to retain the drive axle while removing the special capscrew retaining the bevel gear to the axle shaft. Remove the special capscrew (24 mm) and the special washer.

WARNING: If the MDU falls, it can cause an 0 injury. Hold the MDU vertical to prevent it from falling.

WARNING: Toxic vapors may be generated by heating the axle shaft to remove the Loctite. Wear !M a protective mask during this operation. Use gloves to remove the bevel gear if it has been heated.

NOTE: The bevel gear is secured to the axle shaft using Loctite No. 270. It may be necessary to use a welding torch to heat the bevel gear to 100 to 120°C (212 to 248°F) to free the bevel gear from the axle shaft.

CAUTION: Be careful not to damage the threads or splines on the axle shaft.

6. Use a strap wrench or place a wood wedge under the helical gear to keep the gear from rotating. Remove the nut retaining the helical spur gear. Use a gear puller to remove the helical gear from the pinion shaft. Carefully remove the pinion shaft and bearing cone from the lower housing. Use a plastic hammer, if necessary. Remove the spacer bushing from the pinion shaft.

7. Use a copper mandrel and a plastic hammer to drive the axle shaftout of the lower housing. Removethe bevel pinion out of the lower housing.

Sheet 6: Drive Unit CAUTION: Keep all shim sets together and labeled for correct location and installation during assembly.

NOTE: If the bevel pinion and gear set will NOT be replaced, the same shim sets can be used during assembly.

Adjustment will not be necessary.

Figure 4-7 -Master Drive Unit Parts 1. SCREW 2. CENTERING RING 3. SOCKET HEAD SCREW 4. WASHER 5. NUT 6. SOCKET HEAD SCREW 7. SOCKET HEAD SCREW 8. SOCKET HEAD SCREW 9. DOWEL PIN 10. UPPER HOUSING 11. BREATHER VALVE

Sheet 6: Drive Unit 12. PLUG/OIL FILL 13. SEAL RING 14. LUBE FITTING 15. PINION GEAR 16. LOCKNUT 17. GEAR 18. BEARING 19. SHIM 20. PLUG/OIL DRAIN 21. SEAL RING 22. CAPSCREW 23. COVER 24. WHEEL SHAFT 25. WHEEL STUD 26. SEALING RING 27. BEARING 28. SHIM 29. OIL RING 30. SEALING RING 31. CAPSCREW 32. DISK 33. RING AND PINION 34. BEARING 35. SHIM 36. LOWER HOUSING 8. If necessary, remove the bearing cones from the axle shaft, from the bevel gear and from the bevel pinion shaft.

To remove the bearing cone from the axle shaft it is necessary to cut the bearing cage, then open the cage and remove the rollers. Use a puller to remove the cage from the axle shaft.

9. Remove the bearing shield from the lower housing using a plastic hammer. See Figure 4-8.

Figure 4-8 -Removing Bearing Shield 10. If necessary, remove the motor nut, lockwasher, bevel pinion and key from the motor shaft. Remove the O-ring from the motor.

11. Remove the wheel bolts from the axle shaft, using a hydraulic press, if necessary.

12. If necessary, remove the bearing cups. Use a puller or copper mandrel and a plastic hammer. Do NOT damage or lose the shims between the cups and the bore in the case. Keep each set of shims together and separate from the other sets of shims. Put a label on each set so that the sets can be installed in the correct position

Sheet 6: Drive Unit during assembly. Measure the distance between the edge of the case and the inner seal ring at the axle bore.

The replacement seal ring MUST be installed in the same position as the old seal. Remove the seal ring.

Assembly NOTE: If neither the bevel pinion shaft and gear set nor the lower case are being replaced, use the upper bearing shim set and lower bearing shim set removed during disassembly.

WARNING: Cleaning solvents can be flammable and toxic, and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. Wear eye protection.

1. Clean all components thoroughly. Remove all traces of Loctite. Use Loctite Fast Cleaner No. 706 to remove Loctite from the lower housing in the area where the thread protecting shield had been located. Spray the cleaner from a distance of approximately 30 cm (0.50 in), while holding the can upright. Allow the cleaner to work, then thoroughly remove the dissolved dirtfrom the lower housing using a clean cloth. Spray the surface with the cleaner again and allow to air dry.

Figure 4-9 -Bearing and Shim Location 1. UPPER PINION BEARING CUP 2. LOWER PINION BEARING CUP 3. INNER AXLE SHAFT BEARING CUP 4. OUTER AXLE SHAFT BEARING CUP 5. SHIMS-UPPER PINION BEARING 6. SHIMS-LOWER PINION BEARING 7. SHIMS-INNER AXLE SHAFT 8. SHIMS-OUTER AXLE SHAFT 9. INNER SEAL RING 10. BEARING SHIELD 2. Check all parts for damage or cracks. Replace any damaged parts.

CAUTION: The axle and gear assemblies are installed and removed several times during this procedure. Be careful not to damage the seals.

Sheet 6: Drive Unit

Figure 4-10 -Installing Bevel Pinion Shaft NOTE: There are two numbers stamped on the bevel pinion shaft. There are also two numbers stamped on the bevel gear. One number on each part is the set number. These numbers MUST be the same. Check that the bevel pinion shaft and the bevel gear are a matched set by comparing the set numbers. The second number on the bevel pinion shaft is the assembly dimension of the shaft (dimension B, below). The second number on the bevel gear is the gear clearance number.

1.

2.

3.

4.

5.

6.

7.

8.

BEVEL PINION SHAFT SPACER SPECIAL MEASURING TOOL LOWER CASE LOWER BEARING LOWER BEARING SHIM SET UPPER BEARING SHIM SET UPPER BEARING

NOTE: The helical pinion and gear and the bevel pinion shaft and bevel gear are matched sets and MUST be replaced as sets. When replacing the gear sets, always replace the tapered roller bearings. The bearing cup and bearing cone MUST be from the same manufacturer. Lubricate the bearings with clean transmission oil prior to assembly.

NOTE: Assembly of the drive unit requires the use of a standard micrometer, torque wrench and a dial indicator. The procedure below specifies the use of a special measuring tool (Yale P/N 518096888) and a special clamping tool (Yale P/N 518096890). The measuring tool can be fabricated, if desired, as follows: Make a bushing to fit the bore of the lower pinion shaft bearing. The bushing must have an outside diameter of 51.5 mm (2.03 in) and a length of 67.5 mm (2.66 in) long. The special clamping tool fascilitates easy assembly but can be substituted for as well.

3. Insert the special measuring tool in the pinion shaft lower bearing bore. Determine the correct thickness for the lower bearing shim set (dimension X) as follows (see Figure 4-10): a. Measure dimension F (the difference between the bearing bore for the axle and the end of the bushing). b. Subtract the value Ffrom the length (L) of the bushing. c.

Add the value of d/2. The result is dimension E. E=L-F+d/2 L = bushing length F = the difference between the bearing bore for the axle and the end of the bushing d/2 = HFK300 = 44.45 mm (1.7500 in)

Sheet 6: Drive Unit HFK400 = 45.00 mm (1.7716 in) d. Measure dimension T (the width of the lower bearing). e. Subtract assembly dimension B (stamped on the bevel pinion shaft) from dimension E (found in Step c., above).

Then subtract dimension T. The result is dimension X (the correct thickness of the lower bearing shim set).

X=E-B-T E = the value found in Step c.

B = the number stamped on the bevel pinion shaft T = the total thickness of the bearing 4. Assemble the proper combination of shims to equal the correct thickness for the lower bearing shim set, as determined above ( t 0.05 mm [0.002 in]). Install the lower bearing shim set into the lower bearing bore. Press the lower bearing cup into the bore.

Figure 4-11 -Wheel Shaft Shim Sets CAUTION: Do not use damaged or distorted shims in the following steps.

5. Install the shim set removed during disassembly from the inner bearing bore of the wheel shaft into the inner bearing bore. This shim set will be used for the preliminary adjustment of the wheel shaft. Drive the inner bearing cup into the inner bearing bore (see Figure 4-11).

6. Install the shim set removed during disassembly from the outer bearing bore of the wheel shaft into the outer bearing bore. This shim set will be used for the preliminary adjustment of the wheel shaft. Press the outer bearing cup into the outer bearing bore (see Figure 4-11).

NOTE: Do not install the wheel shaft seal until after the adjustment procedure has been completed.

7. Press the taper roller bearing cone up to the stop on the pinion shaft.

8. Lubricate the bearing cup with transmission oil. Install the pinion shaft into the housing and preload it against the bearing cup with the special clamping tool or a piece of wood.

9. Measure the distance "A" between the shoulder of the pinion shaft and the bottom of the bore for the upper bearing (see Figure 4-12).

10. Add 0.02 mm (0.00078 in) to the value of dimension A and install a shim set equal to that sum into the bearing bore. Shim set (mm) = A + 0.02 mm.

Sheet 6: Drive Unit

Figure 4-12 -Shim Measurement 11. Press the upper bearing cup into the bearing bore. Press the upper bearing cone onto the pinion shaft up to the stop.

12. Place the helical gear onto the pinion shaft and install the nut. Hold the helical gear with a strap wrench and tighten the nut to a torque value of 54 NM (40 Ibf ft). Do not stake the nut. The bearing clearance must be checked and adjusted before staking the nut.

13. Remove the special clamping tool or piece of wood holding the pinion shaft in place.

14. Press the pinion shaft downward by hand while turning the shaft several times toalign the taper rollers within the bearing.

15. Place the dial indicator on the housing as shown in Figure 4-13. Adjust the dial to indicate zero. Mark the point of measurement on the helical spur gear with a colored pencil. Lift the pinion shaft upward by carefully prying up beneath the helical spur gear with two levers. Read any deflection on the dial indicator. This value is the bearing clearance. Repeat the procedure to be sure to obtain the correct value.

Figure 4-13 -Checking Pinion Shaft Bearing Clearance 16. Remove the pinion shaft and bearing. Remove the upper bearing cup. Additional shims must be added to the upper bearing bore to preload the bearing. To determine the correct amount of additional shims, add 0.07 mm (0.0028 in) to the clearance value measured in Step 15. Install shims equal to that sum into the bearing bore with the shims installed earlier.

Additional shim set (mm) = value measured on dial indicator + 0.07 mm.

If no clearance was measured, add a total of 0.02 mm (0.00078 in) to the shims installed earlier.

17. Install the pinion shaft. Press the upper bearing cup into the bearing bore. Press the upper bearing cone onto the pinion shaft up to the stop.

Sheet 6: Drive Unit 18. Cover the splines of the helical gear with a thin coat of Loctite 270. Wipe off any excess Loctite with a clean rag.

19. Place the helical gear onto the pinion shaft and install the nut. Hold the helical gear with a strap wrench and tighten the nut to a torque value of 54 Nm (40 Ibf ft). Stake the nut to the pinion shaft.

20. Press the wheel bolts into the wheel shaft until the bolt contacts the stop. Be sure the flattened side of the bolt faces the wheel shaft center.

21. Push the sealing ring onto the wheel shaft. Press the outer wheel bearing cone onto the wheel shaft until the bearing contacts the stop. Wait to grease the bearing until after the preload adjustments are performed.

NOTE: After the proper backlash has been obtained, grease the seal ring and fill the outer bearing cone using Shell Alvania R3 grease prior to assembly.

22. Press the inner wheel bearing cone onto the bevel gear until the bearing cone contacts the stop.

23. Insert the bevel gear into the MDU housing.

NOTE: Do not install the inner seal ring until the bearing preload has been adjusted.

24. Insert the wheel shaft into the housing and engage the splines of the shaft into the bevel gear. Secure the bevel gear on the wheel shaft using the M16 capscrew and special washer.

25. Prevent the axle from turning. Tighten the M16 capscrew to 245 Nm (332 Ibf ft) torque.

26. Use a dial indicator to check the backlash between the bevel gear and the pinion. The backlash is the clearance between the teeth of the bevel gear and the teeth of the pinion gear. See Figure 4-14. Position the dial indicator on the housing so that the dial indicator foot is as close as possible to being perpendicular to the tooth flank of the bevel gear. Install a wood wedge under the large gear at the top of the MDU to keep the gear and pinion from moving.

Figure 4-14 -Checking Backlash 1. SPIRAL BEVEL GEAR 2. DIAL INDICATOR 3. WOOD WEDGE 27. Adjust the dial indicator to zero. Turn the wheel shaft in both directions to measure any deflection. The admissable range for backlash is between 0.03 and 0.11 mm (0.0012 to 0.0043 in). Backlash is adjusted by adding or removing shims beneath the inner wheel bearing cup. The ideal backlash is 0.07 mm (0.028 in).

28. Check the tooth contact pattern by coating 3-4 tooth flanks of the bevel gear with ink. Mesh the coated teeth with the pinion gear several times and then inspect the wear pattern of the ink on the coated teeth. Slight deviations from the ideal tooth contact pattern are admissable. Significant tooth contact pattern misalignment is an indication that a mistake was made at an earlier step in the procedure and will necessitate repeating the assembly procedure. See Figure 4-16.

29. Check the wheel bearing clearance. Press down on the wheel shaft by hand and rotate it several times. Arrange the dial indicator on the housing as shown in Figure 4-15. Adjust the dial to indicate zero. Lift the wheel shaft upward by carefully prying up beneath the bevel gear with two levers. Read any deflection on the dial indicator.

This value is the bearing clearance. Repeat the procedure to be sure to obtain the correct value.

Sheet 6: Drive Unit

Figure 4-15 -Checking Wheel Shaft Bearing Clearance STEP 1. Apply a colored dye or grease to approximately 12 of the teeth of the spiral bevel gear.

STEP 2. Apply a small friction load to the edge of the gear so that the gear does not turn easily. Rotate the gear one revolution by turning the large gear on the spiral bevel pinion.

STEP 3. Check the tooth contact pattern on the spiral bevel gear. Make sure that the pattern is checked on the side of the tooth where the pinion teeth apply the force.

CORRECT CONTACT PATTERN

WRONG TOOTH CONTACT PATTERN The spiral bevel pinion is too far from the center of the spiral bevel gear.

Some movement in the direction of the arrows can be necessary. Adjust the thickness of the shim sets as described in the assembly procedure.

The spiral bevel pinion is too close to the center of the spiral bevel gear. Some movement in the direction of the arrows can be necessary. Adjust the thickness of the shim sets as described in the assembly procedure.

The spiral bevel pinion is too far from the center of the spiral bevel pinion.

Some movement of the spiral gear away from the spiral bevel pinion can be necessary. Adjust the shim sets at the spiral bevel gear as described in the assembly procedure.

The spiral bevel pinion is too far from the center of the spiral bevel pinion. Some movement of the spiral gear toward the spiral bevel pinion can be necessary. Adjust the shim sets at the spiral bevel gear as described in the assembly procedure.

Figure 4-16 - Tooth Contact Pattern

Sheet 6: Drive Unit

Figure 4-17 -Checking Backlash 1. SPIRAL BEVEL GEAR 2. DIAL INDICATOR 3. WOOD WEDGE 30. Remove the wheel shaft and outer bearing. Remove the outer bearing cup. Add or remove shims as required to obtain a bearing clearance of 0.02 mm (0.00078 in). Install the outer bearing cup, bearing, and wheel shaft.

Repeat Step 29. After the bearing clearance is confirmed to be 0.02 mm (0.00078 in), remove the wheel shaft, outer bearing and outer bearing cup again. Add 0.10 mm (0.004 in) additional shims to the outer bearing bore to preload the bearing.

31. Install the outer bearing cup, outer bearing, and wheel shaft. Verify that the wheel shaft can be turned by hand. If not, reduce the preload set in the previous step in 0.01 mm (0.00039 in) increments until the wheel shaft can be turned by hand.

32. After the bearing preload has been properly set, check the backlash again. Use a dial indicator to check the backlash between the bevel gear and the pinion. The backlash is the clearance between the teeth of the bevel gear and the teeth of the pinion gear. See Figure 4-17. Position the dial indicator on the housing so thatthe dial indicator foot is as close as possible to being perpendicular to the tooth flank of the bevel gear. Install a wood wedge under the large gear at the top of the MDU to keep the gear and pinion from moving.

33. Adjust the dial indicator to zero. Turn the wheel shaft in both directions to measure any deflection. The admissable range for backlash is between 0.03 and 0.11 mm (0.0012 to 0.0043 in). If the backlash needs to be adjusted at this point, the total thickness of the outer plus the inner shims must remain constant (i.e.: If you remove a shim from beneath the inner bearing cup, you must add it to the shims beneath outer bearing cup).

The ideal backlash is 0.07 mm (0.0028 in).

34. After the proper backlash and preload has been obtained, remove the bevel gear and wheel shaft in order to mount the thread protective shield and the radial shaft seal.

Figure 4-18 -Inner Seal Installation 35. Thoroughly clean the seat of the thread protective shield on the housing with Loctite Fast Cleaner 706 or equivalent.

Sheet 6: Drive Unit 36. Coat the seat of the thread protective shield with Loctite No. 270. Press the thread protective shield on the lower housing as far as possible. See Figure 4-18.

37. Remove the outer bearing cup and shims. Thinly coat the radial shaft seal with Loctite No. 574. Install the inner seal into the lower housing. The inner seal should be flush with the bottom edge of the outer bearing bore, when properly installed. See Figure 4-18. Install the shims and outer bearing cup.

38. Coat the entire surface of the inner splines of the bevel gear with Loctite No. 270. Insert the bevel gear in the housing. See Figure 4-19.

39. Fill the inner seal ring and the cone on the wheel shaft with Shell Alvania R3 grease. See Figure 4-19.

Figure 4-19 -Wheel Shaft Assembly 40. Insert the wheel shaft into the housing and engage the splines of the shaft into the bevel gear. Remove excess Loctite with a clean cloth.

41. Secure the bevel gear on the wheel shaft using the M16 capscrew and special washer. Prevent the axle from turning. Tighten the M16 capscrew to 245 Nm (332 Ibf ft) torque.

42. Coat the flat housing surface with Loctite No. 574 before mounting the housing cover. Apply one drop of Loctite No. 243 to the threads of each of the housing cover mounting bolts and install the bolts.

NOTE: If the tapped holes in the bottom of the lower housing extend through the housing, completely seal the capscrews with Loctite to prevent oil from leaking from around the threads.

43. Tighten the housing cover capscrews to 9.5 Nm (7 Ibf ft) torque.

44. Inspect the upper part of the MDU. The upper part of the MDU must be replaced if: a. The caulked cover plate on the trunnion bearing has separated. Check visually. b. The trunnion bearing is difficult to turn or binds. Check manually. c.

The maximum trunnion bearing clearance is exceeded. Check as described below.

45. Clamp the upper part of the MDU to an assembly table. Install three eyebolts into the outer race of the trunnion bearing and rotate the bearing several times. See Figure 4-20.

46. Install a cable in each eye bolt. Position three dial indicators on the trunnion bearing and set the indicators to zero. Mark the position of one dial indicator on the trunnion bearing with a marking pen.

Sheet 6: Drive Unit

Figure 4-20 -Check Trunnion Bearing

Figure 4-21 -Install Drive Venting Filter and Grease Fitting 47. Raise the upper housing using a lifting device and a spring balance to obtain approximately 50 kg (110 Ib) of force. Rotate the trunnion bearing several times and position at the mark again. The maximum bearing clearance is 0.03 mm (0.0012 in). If the bearing clearance is more than the recommended clearance, the trunnion bearing and upper housing must be replaced.

NOTE: The large ball bearing is part of the upper housing. The upper housing and the ball bearing are replaced as a unit.

48. Install the drive venting filter as far as possible into the upper part of the MDU. See Figure 4-21.

49. Install grease fitting. See Figure 4-21.

50. Use Loctite 574 to install the upper housing on the lower housing. Make sure the upper housing is aligned correctly and use a punch to install the two dowels, if removed. Install the capscrews. Tighten the 8 mm capscrews to 23 Nm (17 Ibf ft) torque. Tighten the 10 mm capscrews to 46 Nm (34 Ibf ft) torque. Install the Allen head capscrews and the washers and nuts. Tighten the nuts to 23 Nm (17 Ibf ft) torque.

51. Install the wheel and the lug nuts. Tighten the nuts in a cross pattern to one-half thetorquevalue specified in Section 2. Tighten the lug nuts again using the cross pattern to obtain the proper torque.

52. Lubricate trunnion bearing using the recommended grease listed in Section 2. Add the grease through both fittings. Slowly rotate the MDU while filling the fittings with grease. A dry bearing will take approximately 55 g (0.12 lb) of grease to fill the bearing completely.

53. Fill the MDU to the level/fill plug using the recommended oil listed in Section 2. Add the oil slowly. The oil must go through the bearings to the lower part of the MDU. Fill until the oil just starts to run out. Install the plug and tighten to 22 Nm (171bfft).

TROUBLESHOOTING PROBLEM Lift truck will not move.

Master drive unit makes noise.

POSSIBLE CAUSE Traction motor not operating.

Damaged gears or bearings.

There is not enough lubricant or the wrong lubricant has been used.

Dry or damaged bearings.

Sheet 6: Drive Unit Oil leaks at the housing cover.

Oil leaks at the wheel shaft.

Oil leaks at the filler plug or drain plug.

Oil leakage between lower and upper housings.

Oil leaks in motor compartment.

Banging noise at helical gears.

Ringing noise.

Grinding noise.

Trunnion bearing difficult to turn, binds or exceeds maximum clearance.

Wrong bearing or gear adjustment.

Worn or damaged gears.

Housing cover is not sealed or properly seated.

Capscrews not sealed off or not tightened to specified torque.

Shaft seal incorrectly mounted or damaged.

Surface of axle shaft damaged.

Dirt between sealing ring and housing.

Plugs not tightened to specified torque.

Sealing surface not sealed off.

Capscrews not tightened to specified torque.

Too much oil in MDU. Breather defective.

Traction motor seal defective.

Teeth on the helical gear or helical pinion damaged.

Helical gear and pinion running without lubrication.

Bearing preload or backlash not properly adjusted.

The centering ring has separated and dirt has penetrated into the bearing.

Cage segments are damaged.

Deformation of the balls or ball races.

Bearing not properly lubricated.

Sheet 7: Brake System BRAKE SYSTEM GENERAL (C829) This section provides the description and repair procedures for the brake assembly for models NR045/NDR030GA (C829).

NOTE: Many of the procedures need the compartment door open. To open the door, remove two capscrews that fasten the door and open the door.

The brake assembly is a mechanical brake mechanism that is installed on the top of the traction motor. The brake assembly has a brake drum, two brake shoes, a cam and cam lever and the return spring for the brake shoes. The cam moves the brake shoes against the brake drum. A spring and linkage operates the cam lever to apply the brake. A hydraulic slave cylinder moves this same linkage to release the brake. The brake drum rotates with the armature of the traction motor. The brake shoe assembly and the linkage are fastened to the traction motor housing.

A master cylinder and brake pedal assembly is fastened to the frame under the operator compartment. The brake pedal extends through the floor plate and is foot operated. There is a hydraulic line between the master cylinder and the slave cylinder. The master cylinder assembly operates the slave cylinder using hydraulic pressure from the master cylinder and pedal operation. A reservoir for the brake fluid is mounted on the traction motor compartment door.

The brake is a normally ON type of mechanism. The brake is fully applied when the brake pedal is in the UP position. Releasing the brake pedal permits a spring to move the cam lever and apply the brake shoes against the brake drum. A brake switch prevents the operation of the traction system when the brake pedal is released to apply the brake.

To RELEASE the brake, the operator must step on the brake pedal. The brake pedal moves the push rod of the master cylinder to apply hydraulic pressure to the slave cylinder. The push rod pushes the control bar against the brake spring to release the brake shoes. The shoe springs move the brake shoes away from the brake drum. The brake shoes will be gradually released as the brake pedal is depressed. The brake pedal must be depressed as far as possible to completely release the brake. Movement of the control bar operates the brake switch when the brake pedal is depressed to release the brake. The brake switch must be ON before the traction system can operate.

BRAKE ASSEMBLY (C829) NOTE: Remove the two capscrews that fasten the door and open the door.

Removal and Disassembly See Figure 5-1 and Figure 5-3) NOTE: The complete brake assembly normally does not need to be removed to make repairs. Remove only the parts necessary to make the repair.

1. Disconnect the battery. Put blocks on each side of the drive wheel to prevent movement of the lift truck. Open the motor compartment door for access to the brake assembly.

Sheet 7: Brake System

Figure 5-1 -Brake Arrangement (C829) 1.

2.

3.

4.

BRAKE RESERVOIR BRAKE ASSEMBLY BRAKE PEDAL AND MASTER CYLINDER TRACTION MOTOR

WARNING: Put a "DO NOT OPERATE" tag in the operator's compartment and remove the key as a warning to prevent operation. To help prevent injury or damage, do not operate the lift truck without a brake.

2. Remove the nut that attaches the brake drum to the armature shaft of the traction motor. Remove the hardened washer. Depress and hold the brake pedal to release the brake shoes. Remove the brake drum from the armature shaft.

3. Check for damaged or broken parts. Replace any damaged or broken parts. Replace both brake shoes if the minimum thickness of either brake lining is 2.4 mm (0.09 in) or less. Disconnect the shoe return springs to remove the brake shoes. See Figure 5-2. The maximum allowable inside diameter of the brake drum is 153.2 mm (6.032 in). Replace the brake drum if the maximum inside diameter exceeds the maximum allowable inside diameter.

Sheet 7: Brake System

Figure 5-2 -Brake Assembly (C829) 1.

2.

3.

4.

5.

6.

CAM LEVER CAM BRAKE SHOE SHOE RETURN SPRING SUPPORT PLATE BRAKE LINING

WARNING: Do not allow brake fluid, grease or oil to get on the brake linings or shoes.

4. Loosen the locknut on the actuation rod. Remove the jam nut and lockwasher retaining the actuation rod to the cam lever on the brake assembly. Remove the two socket head capscrews and lockwashers retaining the brake assembly to the brake mounting bracket. Be certain to note the position that the capscrews are assembled in.

Remove the brake assembly.

CAUTION: Brake fluid damages paint. Immediately remove any brake fluid that is on a painted surface.

5. Loosen the jam nut retaining the set screw and push rod to the slave cylinder. Remove the capscrew, lockwasher and hose clamp retaining the hose assembly. Back off on the set screw far enough to remove the push rod. Position a container under the slave cylinder to catch any excess brake fluid. Remove the hose assembly. Cap the hose assembly. Remove the capscrew and lockwashers retaining the slave cylinder to the brake mounting bracket. Refer to SLAVE CYLINDER -DISASSEMBLY AND ASSEMBLY if the slave cylinder requires repairs.

6. Tag and remove the wires to the brake switch. Remove the two screws, lockwashers, nut plate and insulator retaining the brake switch to the brake mounting bracket.

WARNING: The spring has tension and can release with enough force to cause an injury.

7. Use a drift pin to drive the groove pin retaining the spring guide to the control bar. Remove the control bar, bushings and brake spring.

8. Remove the locknut, tube, bearing and actuation rod from the control bar.

9. Remove the shoulder screw, bushings, flat washer and nut to remove the control bar from the brake mounting bracket.

10. Remove the four socket head capscrews and lockwashers retaining the brake mounting bracket to the traction motor. Remove the brake mounting bracket, brake drum spacer and the brake assembly spacer.

11. Check for damaged or broken parts. Replace any damaged or broken parts.

Assembly and Installation (See Figure 5-3 and Figure 5-4) 1. Align the brake assembly spacer and brake mounting bracket on the traction motor. Position the brake assembly on the spacer and install the four socket head capscrews and lockwashers. Tighten the capscrews to 23 Nm (17 Ibf ft) dry.

Sheet 7: Brake System 2. Install the bushings for the spring guide in the control bar. Position the brake spring on the spring guide, align the spring guide and spring with the control bar and install the groove pin.

3. Install the bushings for the shoulder screw in the control bar. Align the control bar with the brake mounting bracket. The spring guide must be located so the guide will fit through the opening in the brake mounting bracket. Position the flatwasher between the control bar and the brake mounting bracket and install the shoulder screw and jam nut. The control bar must be free to move.

Figure 5-3 -Brake Assembly (C829) 1.

2.

3.

4.

5.

6.

LOCKNUT WASHER BRAKE DRUM SOCKET HEAD CAPSCREW LOCKWASHER SOCKET HEAD CAPSCREW

Sheet 7: Brake System 7. LOCKWASHER 8. BRAKE ASSEMBLY 9. JAM NUT 10. LOCKWASHER 11. CAPSCREW 12. LOCKWASHER 13. SLAVE CYLINDER 14. HOSE ASSEMBLY 15. BRAKE MOUNTING 16. BRACKET CLAMP 17. LOCKWASHER 18. CAPSCREW 19. PUSH ROD 20. ACTUATION ROD 21. BRAKE SPRING 22. SPRING GUIDE 23. BUSHING 24. CAPSCREW 25. FLAT WASHER 26. CONTROL BAR 27. GROOVE PIN 28. BEARING 29. TUBE 30. LOCKNUT 31. SCREW 32. LOCKWASHER 33. MICRO SWITCH 34. INSULATOR 35. SPACER-BRAKE-ASSEMBLY 36. SPACER-BRAKE-DRUM 37. NUT PLATE 38. JAM NUT 39. JAM NUT 40. SETSCREW 41. BUSHING 42. RESERVOIR 43. CLAMP 44. FEED HOSE 45. TY WRAP 4. Install the bushing for the actuation rod in the control rod. Install the actuation rod in the control rod. Install the tube and locknut on the actuation rod. Install the two socket head capscrews and lockwashers to retain the brake assembly to the brake mounting bracket. Align the cam lever of the brake assembly and the actuation rod and install the jam nut and lockwasher.

5. Align the slave cylinder with the brake mounting bracket and install the capscrews and lockwashers. Install the hose clamp, capscrew and lockwasher. Connect the hose to the slave cylinder. Loosen thejam nut and loosen the set screw and install the push rod between the set screw and the slave cylinder. Adjust the set screw so the push rod remains in place between the slave cylinder and the set screw, then tighten the jam nut.

6. Depress the brake pedal. Install the brake drum spacer, brake drum, hardened washer and locknut. Tighten the locknut to 136 Nm (100 Ibf ft).

7. Install the brake switch on the brake mounting bracket using the insulator, lock plate, capscrew and lockwasher.

Connect the wires to the brake switch. Adjust the switch so that the switch will open when the pedal is depressed.

8. Adjust the brakes as described in CHECKS AND ADJUSTMENTS. 9. Remove the air from the brake system as described in CHECKS AND ADJUSTMENTS. 10. Remove the blocks from under the drive wheel. Close the compartment door. Connect the battery.

Sheet 7: Brake System

Figure 5-4 -Brake Assembly Installation (C829) MASTER CYLINDER AND PEDAL ASSEMBLY (C829) Removal and Disassembly (See Figure 5-5) 1. Remove the floor plate assembly from the operator's compartment.

CAUTION: Brake fluid damages paint. Immediately remove any brake fluid that is on a painted !M surface.

2. Position a drain pan under the master cylinder. Remove both the hose assembly and brake fluid feed hose from the master cylinder. Install caps on the brake hoses and master cylinder port or fitting.

3. Hold the master cylinder assembly. Remove the two capscrews, washers and nuts that fasten the master cylinder to the lift truck frame.

NOTE: It is not necessary to remove the pedal from the master cylinder to replace the pedal pad.

4. Straighten and remove the cotter pin and flat washer. Use a punch to remove both the groove pin and rod end pin that fastens the brake pedal weldment to the master cylinder. Remove the brake pedal weldment from the master cylinder. Remove the bushings from the master cylinder.

5. Check for damaged or broken parts. Replace any damaged or broken parts. If the master cylinder requires repairs, see MASTER CYLINDER-DISASSEMBLY AND ASSEMBLY Assembly and Installation 1. Install the bushings in the master cylinder. Align the pedal and the master cylinder. Install the groove pin.

2. Install the rod end pin through the brake pedal weldment and the master cylinder. Install the flat washer and a new cotter pin.

3. Install the brake pedal pad on the brake pedal weldment.

4. Align the master cylinder to the lift truck frame and install the two capscrews, lockwashers and nuts.

CAUTION: Brake fluid damages paint. Immediately remove any brake fluid that is on a painted surface.

5. Remove the caps and install the hose assembly and brake fluid feed hose. Fill the reservoir using clean brake fluid as listed in the Maintenance Schedule.

6. Install the floor plate assembly in the operators compartment.

7. Adjust the brakes as described in CHECKS AND ADJUSTMENTS. 8. Remove the air from the brake system as described in CHECKS AND ADJUSTMENTS. FLOOR PLATE ASSEMBLY (C829 & A861) Removal and Disassembly

Sheet 7: Brake System 1. Lift the floor plate assembly from the operator's compartment.

2. Disconnect plug X13. Remove the floor plate assembly from the truck.

NOTE: To replace the operator sensing switch, the floor pad must be removed. The floor pad has an adhesive backing. It must be replaced with a new pad after removal.

Assembly and Installation 1. Position the operator sensing switch on the floor plate. Pass the wire leads through the hole in the plate.

2. Remove the liner to expose the adhesive backing on the new floor pad. Install the floor pad on the floor plate.

3. Connect plug X13. Install the floor plate in the operator's compartment.

Figure 5-5 -Master Cylinder and Pedal Assembly (C829 & A861) 1. FLOOR PAD 2. OPERATOR SENSOR 3. FLOOR PLATE 4. BRAKE PRESSURE HOSE 5. BRAKE FLUID FEED HOSE 6. MASTER CYLINDER 7. CAPSCREW 8. GROOVE PIN 9. BUSHING 10. ROD END PIN

Sheet 7: Brake System 11. BRAKE PEDAL WELDMENT 12. NUT 13. LOCK WASHER 14. FLAT WASHER 15. COTTER PIN 16. BRAKE PEDAL PAD 17. VIBRATION ISOLATION MOUNT 18. LOCK WASHER 19. NUT MASTER CYLINDER (C829 & A861) Disassembly (See Figure 5-6) CAUTION: Brake fluid damages paint. Immediately remove any brake fluid that is on a painted surface.

1. Remove the cup and the boot from the end of the piston of the master cylinder.

2. Use a pair of internal snap ring pliers and remove the retaining ring.

WARNING: Do NOT use mineral oil solvent to clean the master cylinder or brake system parts. Mineral oil will damage rubber seals. Damage to the seal can cause brake failure. Clean the master cylinder using isopropyl alcohol, or a solvent approved for cleaning brake parts.

3. Remove the parts shown in Figure 5-6. Remove the valve seal from the valve stem. Clean the cylinder body and all metal parts. Check the bore for wear and damage (scratches or holes). If the bore is worn or has damage, replace the master cylinder.

Figure 5-6 -Master Cylinder (C829 & A861) 1.

2.

3.

4.

5.

6.

SPRING SPRING RETAINER PISTON * CUP RETAINING RING * RUBBER BOOT *

Sheet 7: Brake System 7. CUP 8. VALVE RETAINER 9. VALVE SPRING 10. VALVE STEM 11. VALVE SEAL 12. CONNECTION BOLT 13. GASKET 14. FITTING 15. GASKET 16. CYLINDER BODY 17. HOSE CONNECTION Assembly 1. Keep all parts clean. If the bore and parts are in good condition, lubricate the bore and all parts with clean brake fluid.

2. Install the valve seal on the valve stem. Align the parts as shown in Figure 5-6 and install the parts in the cylinder body.

3. Install the retaining ring in the cylinder body. Install the boot and cup.

4. Install caps in both ports if the master cylinder is not being installed on the lift truck immediately.

5. Assemble the master cylinder to the brake pedal weldment and install the pedal and master cylinder to the lift truck frame. See MASTER CYLINDER AND PEDAL ASSEMBLY-ASSEMBLY AND INSTALLATION. SLAVE CYLINDER (C829) & (A861) Disassembly (See Figure 5-7) CAUTION: Brake fluid damages paint. Immediately remove any brake fluid that is on a painted surface.

1. Remove the rubber boot from the slave cylinder.

2. Remove the cup and piston from the slave cylinder body.

WARNING: Do NOT use mineral oil solvent to clean the slave cylinder or brake system parts. Mineral oil will damage rubber seals. Damage to the seal can cause brake failure. Clean the slave cylinder using isopropyl alcohol, or a solvent approved for cleaning brake parts.

WARNING: Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear eye and face protection during removal and installation.

Assembly 1. Keep all parts clean. If the bore and parts are in good condition, lubricate the bore and all parts with clean brake fluid.

2. Install the piston into the cylinder body. Install the cup and rubber boot. Make sure to install a cap at the brake line port until the slave cylinder is installed in the lift truck.

3. Install the slave cylinder in the lift truck. See BRAKE ASSEMBLY-ASSEMBLY AND INSTALLATION.

Figure 5-7 -Slave Cylinder (C829)

Sheet 7: Brake System 1.

2.

3.

4.

5.

RUBBER BOOT CUP PISTON CYLINDER BODY BLEED SCREW

Figure 5-8 -Slave Cylinder (A-861) 1. BLEEDER 2. RETAINING RING 3. SPRING 4. BODY 5. CUP 6. CYLINDER 7. SNAP RING 8. BOOT 9. PLUG 10. ROD END ASSEMBLY BRAKE SWITCH-REPLACE (C829) (SEE FIGURE 5-3 AND FIGURE 5-9) 1. Disconnect the battery. Put blocks on each side of the drive wheel to prevent movement of the lift truck. Open the door for access to the brake assembly.

2. Tag and disconnect the brake switch wires from the brake switch.

3. Remove the brake switch. See BRAKE ASSEMBLY-REMOVAL AND DISASSEMBLY 4. Install the replacement brake switch. See BRAKE ASSEMBLY-ASSEMBLY AND INSTALLATION. 5. Close the compartment door and turn the screw one quarter turn to lock the door. Remove the blocks from under the drive wheels. Connect the battery.

CHECKS AND ADJUSTMENTS (C829) Brake Adjustment (See Figure 5-9)

Sheet 7: Brake System NOTE: If the brake shoes need replacing, replace them before adjusting the brake. Check and replace the brake shoes.

1. Disconnect the battery. Put blocks on each side of the drive wheel to prevent movement of the lift truck. Open the door for access to the brake assembly.

2. Tighten the actuation locknut until the brake spring length is 63.5 t 0.8 mm (2.50 t 0.03 in).

3. Loosen the jam nut and set screw retaining the push rod between the setscrew and slave cylinder sothatthe push rod is loose, but cannot be removed.

4. Tighten the setscrew until the push rod causes the slave cylinder to bottom. Back off on the setscrew one full turn and lock in place by tightening the jam nut.

5. The brakes must hold a lift truck with a rated load on a 15% grade with the pedal in the up position.

6. Fill the brake reservoir with the recommended brake fluid and remove air from the brake system. See REMOVE AIR FROM THE BRAKE SYSTEM. Remove Air from the Brake System 1. Before the air is removed from the brake system, make sure the brake is correctly adjusted. Make sure the master cylinder reservoir is filled with the recommended brake fluid. See Section 2 for the recommended brake fluid and the quantity of brake fluid for the brake system.

2. Put one end of a rubber hose on the bleed screw at the top of the slave cylinder. Put the other end of the hose into a clear container of brake fluid.

3. Loosen the bleed screw one turn. Slowly push the brake pedal and hold it at the end of its stroke. Close the bleed screw and release the brake pedal. Repeat the procedure until there are no air bubbles from the rubber hose. Visually check the level of the brake fluid in the reservoir for the master cylinder during this procedure to make sure not to drain the reservoir and put air into the brake system.

Sheet 7: Brake System

Figure 5-9 -Brake Assembly Adjustments (C829) TROUBLESHOOTING PROBLEM The brake will not release.

The brake will not stop the lift truck.

POSSIBLE CAUSE The brake system is not adjusted correctly.

There is air in the brake system.

The master or slave cylinder needs repair.

The brake system is not adjusted correctly.

The brake shoes are worn or damaged.

There is oil or grease on the lining material.

GENERAL (A861) This section provides the description and repair procedures for the brake assembly for models NR045/NDR030GA (A861).

NOTE: Many of the procedures need the compartment door open. To open the door, remove two capscrews and lockwashers that fasten the door and open the door.

The brake system consists of a spring applied, electrically released brake mounted on the traction motor and a spring applied, hydraulically released brake on the caster assembly.

The electric brake is actuated in two ways. The first is via the traction controller box. When the controller senses that

Sheet 7: Brake System the truck is stopped, the brake is applied. The second is via the brake pedal by a switch mounted to the brake pedal linkage. When the operator removes his foot from the brake pedal, the brake is applied.

Mechanical drum brakes are mounted on the same shaft with each caster wheel. The caster wheels are mounted to brake drums via wheel studs within the drums. Each brake drum houses a tapered bearing set. An integral linkage applies spring force to both brake drums simultaneously. A master cylinder, actuated by the operator through the pedal weldment, provides oil to the slave cylinder which counters the spring force and releases the brakes.

WARNING: Put a "DO NOT OPERATE" tag in the operator's compartment and remove the key as a warning to prevent operation. To help prevent injury or damage, do not operate the lift truck without a brake.

ELECTRIC BRAKE ASSEMBLY NOTE: Remove two capscrews and lockwashers that fasten the door and open the door.

Removal and Disassembly (See Figure 5-10 and Figure 5-11) NOTE: The complete brake assembly normally does not need to be removed to make repairs. Remove only the parts necessary to make the repair.

1. Disconnect the battery. Put blocks on each side of the drive wheel to prevent movement of the lift truck. Open the motor compartment door for access to the brake assembly.

Figure 5-10 -Brake Arrangement (A861) 1.

2.

3.

4.

BRAKE RESERVOIR BRAKE ASSEMBLY BRAKE PEDAL AND MASTER CYLINDER TRACTION MOTOR

WARNING: Put a "DO NOT OPERATE" tag in the operator's compartment and remove the key as a warning to

Sheet 7: Brake System prevent operation. To help prevent injury or damage, do not operate the lift truck without a brake.

NOTE: The complete brake assembly normally does not need to be removed to make repairs. Remove only the parts necessary to make the repair.

2. Open the motor compartment for access to the brake assembly. Disconnect the wires to the brake.

Removethethree socket head capscrews that attach the upper half of the brake to the adapter. Remove the upper half of the brake.

3. Remove the six friction pads from the friction carrier. Check the friction carrier, the adapter, and the armature for damaged or broken parts. Replace all friction pads if any show sufficient or unusual wear.

Figure 5-11 -Electric Brake Assembly 1. LOCKNUT 2. SPACER 3. CAPSCREW 4. KEY 5. SPACER 6. SHIM 7. MAGNET 8. COIL 9. ARMATURE 10. FRICTION CARRIER 11. FRICTION PAD 12. ADAPTER 13. SPACER 14. SOCKET HEAD SCREW 3 15. COMPRESSION SPRING Assembly and Installation (See Figure 5-11) 1. Align the upper half of the brake assembly on the adapter and install the three capscrews.

2. Adjust the three spacers to set the air gap of the friction pads at 0.01 inch.

Sheet 7: Brake System 3. Connect the electric brake connector to the wire harness.

CASTER BRAKE ASSEMBLY (A861) Removal and Disassembly (See Figure 5-12 and Figure 5-13) CAUTION: Brake fluid damages paint. Immediately remove any brake fluid that is on a painted surface.

1. Remove the floorpad and floor plate. Raise the corner of the truck high enough off the ground to allow removal of the caster wheel assembly. Place a drip pan under the area to catch any brake fluid.

2. Remove the live swivel from the caster assembly by backing the alien head screw out until the live swivel releases from the king pin. Remove the two bolts holding the brake swivel retainer and remove the retainer.

Remove the caster locking nut and locking washer, and lower the caster assembly to the ground and place on a workbench, with a vise, for further tear-down.

WARNING: The caster brake assembly weighs 34 kg (75 Ibs).

Figure 5-12 -Caster Brake Installation 1. CAPSCREW 2. LOCKWASHER 3. RETAINER 4. LIVE SWIVEL 5. LOCKWASHER, BEARING 6. BRAKE DRUM 7. LOCKNUT, BEARING 8. SNAP RING 9. AXLE-ARTICULATING 10. LOCKWASHER 11. CASTER ASSEMBLY 12. NUT 13. STUD 14. WHEEL 15. BEARING 16. LUG NUT 3. Check for damaged or broken parts. Replace any parts that are damaged or broken. Remove the four lug nuts from each wheel and remove the wheels.

4. Secure the caster assembly by turning it upside down and clamping the flats of the king pin in a vice. Be careful not to damage, or clamp the round part of the king pin or to damage the brake fluid hose.

5. Remove four capscrews holding the hose guard. Remove the hose guard. Remove two pins holding the guard

Sheet 7: Brake System weldment and remove the guard weldament.

6. Release all tension on the actuator brake assembly by backing the two jam nuts all the way out. To do this you will need two 3/4" wrenches (for the jam nuts) and a 3/8" wrench to hold the threaded rod.

7. Remove the two brake drum hubs by first removing the bearing locknut and lockwasher.

8. Replace both brake shoes if the minimum thickness of either brake lining is 2.4 mm (0.09 in) or less. Disconnect the shoe return springs to remove the brake shoes. The maximum allowable inside diameter of the brake drum is 153.2 mm (6.032 in). Replace the brake drum if the maximum inside diameter exceeds the maximum allowable inside diameter.

Assembly and Installation (See Figure 5-12 and Figure 5-13) WARNING: Do not allow brake fluid, grease, or oil to get on the brake linings or shoes.

1. Replace the two brake drum hubs and install the bearing lockwashers and locknuts.

2. Adjust the spring tension on the actuator brake assembly to 69.85 mm (2.75 inches) by tightening the jam nuts.

3. Align the guard weldment on the side plate weldment and insert the two pins that hold the guard weldment.

4. Align the hose guard on the guard weldment and secure with four capscrews.

5. Remove caster assembly from vise. Be careful not to damage the round part of the king pin or to damage the brake fluid hose.

6. Install the two wheels and secure each with four lug nuts. Tighten the lug nuts to 136 Nm (100 If ft).

7. Align caster assembly in axle and install locking washer and locknut. Tighten locknut to 102-169 Nm (75-125 lb ft).

8. Install the live swivel and secure by tightening the alien head screw to 2 Nm (15 Ib in). Install retainer and secure with two lockwashers and capscrews. Tighten to 11 Nm (8 Ib ft).

9. Remove the drip pan and lower the truck back to the ground. Replace the floor plate and floor pad.

CAUTION: Brake fluid damages paint. Immediately remove any brake fluid that is on a painted surface.

Sheet 7: Brake System

Figure 5-13 -Caster Brake Assembly 1. NUT 2. LOCKWASHER 3. CAPSCREW 4. PIN 5. BEARING LOCKWASHER 6. BEARING LOCKNUT 7. BRAKE ACTUATOR 8. BRAKE DRUM HUB 9. WHEEL ASSEMBLY 10. WELDMENT 11. UPPER GUARD 12. BRAKE ASSEMBLY W/O LEVER 13. GUARD WELDMENT 14. LUG NUT

Sheet 7: Brake System 15. INTERNAL SNAP RING 16. BEARING 17. WHEEL STUD

Sheet 8: Steering System STEERING SYSTEM STEERING SYSTEM-INTRODUCTION A hydrostatic steering system is used in the narrow aisle lift truck series. This system utilizes a Steering Control Unit (SCU) and a Hydraulic Steering Motor. The components are mounted inside the drive unit compartment. The SCU is connected to the steering tiller through a steering column assembly. The steering tiller is positioned for easy operation and requires only five turns to obtain full steering of 180°.

When the SCU is activated by turning the tiller, hydraulic oil is directed to the steering motor assembly. The steering motor assembly, mounted on the articulating axle weldment, is connected to the drive unit with a chain. The hydraulic oil from the SCU drives the steering motor assembly to turn the drive unit in the desired direction.

WARNING: THE NARROW AISLE SERIES LIFT TRUCK MAY BE FURNISHED WITH EITHER AUTOMOTIVE OR REVERSE STEERING. BEFORE WORKING ON ANY OF THESE LIFT TRUCKS, BE SURE OF THE TYPE OF STEERING BEING USED. The steering system draws hydraulic oil from the same hydraulic tank used by the mast and reach assembly. The hydraulic oil is directed to the SCU by a power steering and auxiliary gear pump. The pump has a priority flow valve, which will provide hydraulic oil for power steering first if both the power steering and auxiliary functions are being used at the same time. The gear pump is driven by a permanent magnet motor. The motor can either be 24 or 36 volts.

Refer to Section 7 for information on the HYDRAULIC SYSTEM. HYDRAULIC STEERING MOTOR Description Lift truck steering is achieved when the hydraulic steering motor rotates the master drive unit (MDU) using a steering chain. The hydraulic motor rotates the MDU for steering the lift truck.

The hydraulic steering motor uses a rotor assembly to change hydraulic energy into mechanical energy. The rotor assembly has a fixed stator and a rotor with seven vanes. There is hydraulic pressure between the vanes and stator.

The pressure makes the rotor rotate in the stator.

A drive link, in the motor housing, has two purposes: a. to rotate the output shaft, and b. to rotate the commutator The commutator is a valve that controls the flow of oil to and from the motor assembly. This control of oil flow permits the valve to control the amount of hydraulic energy. The need for hydraulic energy changes as the need for mechanical energy changes. The mechanical energy needed at the output shaft changes with the steering conditions.

Sheet 8: Steering System

Figure 6-1 -Steering System 1. STEERING TILLER 2. STEERING CONTROL UNIT (SCU) 3. HYDRAULIC STEERING MOTOR

Sheet 8: Steering System

Figure 6-2 -Steering System 1. LOCKNUT 2. HARDENED WASHER 3. SPROCKET 4. LOCKWASHER 5. CAPSCREW 6. STEERING MOTOR 7. FITTING w/O-RING 8. HOSE ASSEMBLY 9. HOSE ASSEMBLY 10. 90°FITTING w/O-RING 11. 90°FITTING w/O-RING 12. FITTING w/O-RING 13. STEER CONTROL UNIT

Sheet 8: Steering System 14. LOCKWASHER 15. CAPSCREW 16. STEER COLUMN ASSEMBLY 17. CAPSCREW 18. LOCKWASHER 19. NUT 20. NUT 21. HARDENED WASHER 22. CAPSCREW 23. CAPSCREW 24. BRACKET 25. TILLER AND KNOB ASSEMBLY Removal WARNING: Make sure the brake pedal is released and the brake is applied. Put blocks on both sides (front and back) of the drive/steer tire and the caster wheels to prevent movement of the lift truck. Put a block on each side (front and back) of the load wheels to prevent movement of the lift truck.

1. Use the steering system to move the master drive unit for access to the chain anchor of the steering chain.

Disconnect the battery. Open the drive unit compartment cover. Block the drive/steer tires, caster wheels and load wheels on both sides to prevent movement of the lift truck.

2. Remove the steering chain from the sprocket of the hydraulic motor. To remove the chain, first make a mark on the chain anchor and the MDU housing at the chain anchor. Remove the cotter pin from the end of one offset pin at the chain anchor. Remove the link pin and chain. Remove the chain from the sprocket of the hydraulic motor.

Use wire to fasten the chain so that it does not fall.

3. Remove the capscrews and lockwashers that retain the hydraulic motor to the articulating axle weldment.

Remove the shims and motor. Wire the shims together for use at assembly.

4. Install labels on the hydraulic lines for proper installation at assembly. Disconnect the hydraulic lines and install caps on the lines and fittings. Plug the ports of the motor.

5. Put the flange of the motor in a soft jawed vise. Hold the sprocket and remove the nut and washer. Do not damage the sprocket teeth.

6. Carefully remove the sprocket and woodruff key. Do not let the woodruff key fall. The woodruff key is located between the sprocket and shaft.

NOTE: Most service personnel do not repair the hydraulic motor. The cost of repairs can be greater than the cost of a replacement motor.

Installation 1. If the hydraulic motor is a new replacement, remove the nut, washer and tape used to retain the woodruff key in the shaft. Do not use the washer, use the washer removed from the original motor.

2. Install the woodruff key in the shaft for the hydraulic steering motor. Align the slot of the sprocket with the woodruff key and carefully install the sprocket in the shaft. Install the washer removed during the removal procedure. Install and tighten the nut. Do not damage the sprocket teeth when tightening the nut.

3. Refer to the labels made during removal and connect the two hydraulic hoses to their correct ports on the hydraulic motor. If necessary, install the fittings from the old motor on the new motor. Use new O-rings. Make sure that the hoses will not be twisted when the motor is in the correct position on the articulating axle weldment.

Sheet 8: Steering System

Figure 6-3 -Hydraulic Steering Motor 1.

2.

3.

4.

5.

6.

HOSE STEERING MOTOR CAPSCREW LOCKWASHER SPROCKET NUT

NOTE: If the chain anchor came off the MDU housing, install the chain anchor at the mark made during removal.

4. Install the shims and motor on the articulating axle weldment. Use the steering chain to check that the sprocket is aligned with the chain flange on the master drive unit. If necessary, add or remove shims between the motor and axle weldment for correct alignment. Install the capscrews and lockwashers. Tighten the capscrews to 68 N m (50 Ibf ft) torque.

5. Install the steering chain on the chain anchor. Install the offset link and link pin on the chain anchor. Use a new cotter pin to complete the assembly. The chain should be adjusted to obtain a chain deflection of 3.05 mm (0.12 in) at the center of the span using a force of 9 to 11 kg (20 to 25 Ibs).

NOTE: An alternative method to adjust the steering chain is to use a torque wrench to tighten the chain adjusting capscrew to obtain a 1.24 Nm (11 Ibf in) torque. The steering chain must not be tight.

6. Remove the block from under the wheels. Close the drive unit compartment door. Connect the battery.

7. Operate the steering system to check that the system is operating correctly. Check for hydraulic leaks.

STEERING CONTROL UNIT Removal WARNING: Make sure the brake pedal is released and the brake is applied. Put blocks on both sides (front and back) of the drive/steer tire and the caster wheels to prevent movement of the lift truck. Put a block on each side (front and back) of the load wheels to prevent movement of the lift truck.

1. Disconnect the battery. Block the drive/steer tires, caster wheels and load wheels on both sides to prevent movement of the lift truck. Open the drive unit compartment cover. Remove the battery compartment cover and the drive unit cover.

2. Install labels on the hydraulic lines for proper installation at assembly. Disconnect the hydraulic lines and install caps on the lines and fittings.

3. Remove the socket head capscrew, lockwasher and nut retaining thetiller and knob assemblytothe shaft of the steering column assembly.

4. Remove the two capscrews and lockwashers retaining the steering column and steering control unit to the mounting bracket.

5. Remove the two capscrews and lockwashers retaining the steering column to the steering control unit.

Installation

Sheet 8: Steering System 1. Align the steering column and the steering control unit and install the two capscrews and lockwashers.

2. Align the steering column and steering control unit with the mounting bracket and install the two capscrews and lockwashers.

3. Align the tiller and knob assembly and the steering column unit and install the socket head capscrew and lockwasher.

4. Remove the caps from the hydraulic lines and the plugs from the steering control unit. Install the hydraulic lines on the steering control unit.

WARNING: If the hoses are incorrectly connected the tiller will move with high force when the truck is started. Do not place the hands near the tiller when testing.

5. Install the drive unit cover and the battery compartment cover. Remove the blocks from the tires and wheels.

Connect the battery and test the steering control unit. Check for leaks. Close the drive unit compartment cover.

Figure 6-4 -Steering Tiller, Steering Column, and Steering Control Unit 1.

2.

3.

4.

SOCKET HEAD CAPSCREW STEERING CONTROL UNIT STEERING COLUMN MOUNTING BRACKET

Disassembly 1. Put the control unit in a vise with soft jaws. Make an identification mark on the length of the control unit.

Sheet 8: Steering System

Figure 6-5 -Steering Control Unit in Vise 1. STEERING CONTROL UNIT 2. VISE 2. Remove the cover on the bottom of the steering control unit.

Figure 6-6 -Cover Removal 1. CAPSCREW 2. COVER 3. O-RING 3. Remove the spacer (if used), the stator, rotor and port plate. Put a mark on the stator so that the same side is toward the body of the control unit. Remove the O-rings. Remove the center shaft.

Sheet 8: Steering System Figure 6-7 -Stator and Rotor Removal 1.

2.

3.

4.

5.

STATOR ROTOR PORT PLATE O-RING CENTER SHAFT

4. Remove the screw for the check valve assembly. Remove the parts for the check valve. For some units the check ball is in the opposite end of the control unit.

Figure 6-8 -Check Valve Removal 1. SCREW 2. CHECK VALVE ASSEMBLY 3. CHECK BALL 5. Remove the spool and sleeve assembly. Remove the thrust bearing assembly from the spool. Push the center pin from the sleeve. Carefully remove the spool from the sleeve.

(Rotate the spool slowly during removal.) Remove the ring from the sleeve. Remove the neutral position springs from the spool.

Figure 6-9 -Spool and Sleeve Assembly Removal

Sheet 8: Steering System 1.

2.

3.

4.

5.

6.

7.

8.

SPOOL AND SLEEVE ASSEMBLY THRUST WASHER THRUST BEARING CENTER PIN SLEEVE SPOOL RING NEUTRAL POSITION SPRINGS

WARNING: Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear eye and face protection during removal and installation.

6. When installed, remove the snap ring, bushing, O-ring and seal ring. Remove the oil seal from the bushing or housing.

Figure 6-10 -Oil Seal and Bushing Removal 1.

2.

3.

4.

5.

SNAP RING SEAL BUSHING O-RING OIL SEAL

Cleaning WARNING: Cleaning solvents can be flammable and toxic, and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer's recommended safety precautions.

Clean all the parts in solvent. Dry the parts with compressed air. Do not dry the parts with a cloth. Make sure all surfaces are free of scratches and sharp edges.

Assembly Use new seals, O-rings and neutral position springs during assembly. Lubricate all parts with clean hydraulic oil.

1. Install the dust seal.

Sheet 8: Steering System

Figure 6-11 -Seal Installation 1. HOUSING 2. DUST SEAL 2. Put the spool (3) on the work bench then put the housing (6) onto the spool as shown. Install the guide ring (2) with the O-ring (1) on the end of the spool. Put a large thrust washer (4, see STEP 4) on top of the guide ring and O-ring assembly. Use a socket or tube (5) to push on the washer and install the O-ring and guide ring in the housing. Carefully remove the washer, tube and spool from the housing. Install the housing as described in the FRAME Section.

Figure 6-12 -O-ring Installation 1.

2.

3.

4.

5.

6.

O-RING GUIDE RING SPOOL WASHER TUBE HOUSING

3. Carefully assemble the spool and sleeve. Make sure the spool rotates freely in the sleeve.

Sheet 8: Steering System

Figure 6-13 -Spool and Sleeve Assembly 1. SPOOL 2. SLEEVE 4. Assemble the neutral position springs then push them into position in the spool (4). Make sure the flat springs (1) are installed to the outside of the curved springs (2). Install the center pin (3). I nstall the ring (5) on the sleeve (over the neutral position springs). The ring must turn freely on the sleeve.

Figure 6-14 -Spring Installation 1.

2.

3.

4.

5.

NEUTRAL POSITION SPRINGS (FLAT) NEUTRAL POSITION SPRINGS (CURVED) CENTER PIN SPOOL RING

5. Install the thrust washers and thrust bearing on the spool. Carefully install the spool and sleeve assembly in the housing. Install the dust seal (9) in the bushing (6). Install the bushing (6), seal (8) and the O-ring (3) in the housing. Use the snap ring (7) to hold the bushing in position. Make sure the sleeve rotates freely in the housing.

Sheet 8: Steering System

Figure 6-15 -Spool and Housing Assembly 1.

2.

3.

4.

5.

6.

7.

8.

9.

HOUSING SPOOL AND SLEEVE ASSEMBLY O-RING THRUST WASHER THRUST BEARING BUSHING SNAP RING SEAL DUST SEAL

6. Install the check ball and sleeve. Make sure the sleeve is O-ring (3) and install the O-ring and port plate (4).

Align the even with or below the surface of the housing (2). Lubricate the holes in the port plate with the holes in the housing.

Figure 6-16 -Check Ball and Port Plate Installation 1.

2.

3.

4.

CHECK BALL SLEEVE HOUSING O-RING PORT PLATE

7. Install the center shaft (1) so that it engages with the center pin (2) in spool and sleeve assembly. Make sure the center pin is still parallel to the surface with the ports. Install the rotor (3) on the center shaft. Make sure that a valley in the rotor aligns with the slot (center pin) in the center shaft. Install the O-ring (5) and stator (4). Make sure to align the marks made during disassembly.

Sheet 8: Steering System

Figure 6-17 -Stator and Rotor Assembly 1.

2.

3.

4.

5.

CENTER SHAFT CENTER PIN ROTOR STATOR O-RING

8. Install the spacer plate (1). Install the O-ring (2) and the Nm (265 Ibf in). Make sure the capscrew (4) with the pin fits in end cap (3). Tighten the capscrews for the end cap in the the hole for the check ball (5). sequence shown to 17 Nm (150 Ibf in), then tighten them to 30

Figure 6-18 -End Cap Installation 1.

2.

3.

4.

5.

SPACER PLATE O-RING END CAP CAPSCREW CHECK BALL

9. Install the steering column on the steering control unit. Make sure the spines are aligned.

Sheet 8: Steering System STEERING TILLER MOUNTING BRACKET ASSEMBLY Removal and Disassembly WARNING: Make sure the brake pedal is released and the brake is applied. Put blocks on both sides (front and back) of the drive/steer tire and the caster wheels to prevent movement of the lift truck. Put a block on each side (front and back) of the load wheels to prevent movement of the lift truck.

1. Disconnect the battery. Block the drive/steer tires, caster wheels and load wheels, on both sides to prevent movement of the lift truck. Open the drive unit compartment cover. Remove the battery compartment cover and the drive unit cover.

2. Remove the socket head capscrew, lockwasher, and nut retaining the steering tiller to the shaft. Remove the tiller.

3. Remove the capscrews, hardened washers, and nut plate retaining the steering tiller mounting bracket assembly to the lift truck frame.

Assembly and Installation 1. Install the mounting bracket on the lift truck frame using the two capscrews, hardened washers, and nut plate.

2. Install the drive unit cover and the battery compartment cover. Remove the blocks from the tires and wheels.

Connect the battery and test the steering control unit. Closethe drive unit compartment cover.

STEERING PUMP AND MOTOR Steering Pump Specifications Pump Relief Valve Setting: 8.4 t 0.35 MPa (1200 t 50 psi) Hydraulic Steering Pump Flow Rate: 11.7 I/min (3.1 gpm) at 2000 rpm Removal-Pump and Motor WARNING: Make sure the brake pedal is released (in the UP position) and the brake is applied. Put blocks on both sides (front and back) of the drive/steer tire and the caster wheels. Put a block on each side (front and back) of the load wheels to prevent movement of the lift truck.

NOTE: The recommended maintenance and repairs for the steering pump motor is covered in MOTOR MAINTENANCE, Section 3, this manual.

1. Disconnect and remove the battery. Refer to CHANGING THE BATTERY, Section 2, this manual.

2. Remove the battery compartment cover. Cover is held in place by spring clips and snaps off.

3. Identify and tag the power cables on the terminals of the motor for correct connection during installation.

Disconnect the cables from the motor.

Figure 6-19 -Battery Compartment Cover Removal 1. BATTERY COMPARTMENT COVER

Sheet 8: Steering System 4. Install labels on the hydraulic lines for proper installation at assembly. Disconnect the hydraulic lines and install caps on the lines and fittings.

WARNING: The motor and pump assembly have a weight of approximately 27 kg (60 lb). The !M steering pump motor has ceramic magnets. Do not let the motor fall. The magnets can be damaged.

5. Remove the four capscrews, lockwashers, brackets, and rubber channel mounts. Remove the pump and motor assembly from the lift truck frame.

6. Remove and inspect the motor brushes. Refer to MOTOR MAINTENANCE, Section 3, this manual.

NOTE: If the motor must be disassembled for cleaning or repairs, remove the pump so a new oil seal can be installed in the motor.

7. Remove the mounting plate from the motor.

8. Mark the pump mounting flange and the motor housing for alignment during assembly. Mark the parts of the motor housing for proper orientation during assembly.

9. Remove the two capscrews and lockwashers retaining the pump to the motor.

Assembly and Installation-Pump and Motor 1. Install a new seal in the motor end housing.

2. Coat the splines of the pump shaft with the recommended multi-purpose grease listed in the LUBRICATION SCHEDULE, Section 2, this manual.

3. Align the pump shaft with the opening in the motor. Align the marks made during disassembly.

4. Install the pump on the motor using the two capscrews and lockwashers.

WARNING: The motor and pump assembly has a weight of approximately 27 kg (60 lb). The steering pump motor has ceramic magnets. Do not let the motor fall. The magnets can be damaged.

5. Install the mounting plate on the motor.

6. Install the pump and motor assembly in the truck using the four capscrews, lockwashers, brackets and rubber channel mounts.

7. Remove the caps from the hydraulic lines and fittings. Connect the hydraulic lines to the fittings identified during removal.

8. Connect the power cables to the proper motor terminals.

9. Install the battery compartment cover using the five capscrews that retain the cover to the frame.

10. Install and connect the battery. Refer to CHANGING THE BATTERY, Section 2, this manual.

11. Check the oil level in the hydraulic tank. Remove blocks from wheels. Test operate the steering system and check for leaks.

Sheet 8: Steering System

Figure 6-20 -Steering Pump and Motor Mounting 1.

2.

3.

4.

5.

6.

7.

8.

PUMP AND MOTOR ASSEMBLY CAPSCREW LOCKWASHER BRACKET NUT RUBBER CHANNEL MOUNT MOUNTING PLATE FLAT WASHER

Figure 6-21 -Steering Pump and Motor 1.

2.

3.

4.

5.

6.

7.

8.

90°FITTING w/O-RING NIPPLE FITTING w/O-RING 90°FITTING w/O-RING 90°FITTING w/O-RING STEER PUMP ASSEMBLY CAPSCREW LOCKWASHER STEER MOTOR ASSEMBLY -36 VOLT

Sheet 8: Steering System Disassembly-Steering Pump 1. Disassemble the fittings, elbows, and O-rings from the pump body. Disassemble the pressure relief valve from the pump body.

WARNING: Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear eye and face protection during removal and installation.

2. Use a pair of snap ring pliers and remove the snap ring retaining the shaft seal to the drive gear shaft. Remove the shaft seal.

3. Mark the flange, pump body, and load sensing valve assembly for orientation during assembly.

4. Remove the four capscrews from the pump body. Separate the mounting flange and the end cover from the pump body. Remove the back-up rings, seals,bushings, and O-rings.

5. Remove the idler gear and drive gear.

6. Inspect the drive gear, idler gear, and the pump body for damage. If any of these parts are damaged, the pump must be replaced with a new pump. All seals, O-rings, back-up rings, and snap ring must be replaced if the present pump is to be used.

NOTE: The manufacturer does not recommend servicing the individual components within the load sensing valve assembly.

Figure 6-22 -Steering Pump 1. CAPSCREW 2. SNAP RING 3. SHAFT SEAL 4. FLANGE 5. BACK-UP RING 6. SEAL 7. BUSHING 8. O-RING 9. DOWEL 10. PUMP BODY 11. IDLER GEAR 12. DRIVE GEAR SHAFT 13. LOAD SENSING VALVE ASSEMBLY 14. PRESSURE RELIEF VALVE Assembly-Steering Pump

Sheet 8: Steering System 1. Apply clean hydraulic oil to all the pump components before assembly.

2. Align and install the idler gear and drive gear in the pump body. Install new O-rings in the pump body.

3. Install both bushings on the shafts. Install the seals and back-up rings in the body of each of the bushings.

4. Align the load sensing valve assembly, pump body, and mounting flange. Install the four capscrews. Tighten the capscrews to 68-74 Nm (50-55 Ibf ft) torque.

5. Install a new shaft seal on the drive gear shaft.

WARNING: Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear eye and face protection during removal and installation.

6. Install a new snap ring.

7. Install new O-rings on the fittings and elbows. Install the fittings and elbows in the pump. Install the pressure relief valve in the pump body. Make sure the valve is properly adjusted.

8. Align the pump shaft with the opening in the motor. Align the marks made during disassembly.

9. Install the pump on the motor using the two capscrews and lockwashers.

CHECKS AND ADJUSTMENTS Remove Air from Steering System Air can enter the system when a hydraulic line is disconnected. If the operation is rough, turn the key on and rotate the steering tiller from stop to stop several times in each direction. The air will be removed without disconnecting any lines. If the operation is still rough, check if air is entering the system at a loose fitting.

Steering Pressure Adjustment The steering pump does not normally require any adjustment. After servicing the pump for any reason, the pump should be checked to make certain that the pump operating pressure is correct.

1. Disconnect the battery.

2. Remove the battery compartment cover by removing the five capscrews that retain the cover to the frame.

3. Place a cloth under the pump to keep hydraulic oil off the other components. Remove the plug on the rear of the pump.

4. Install a hydraulic line and a 20 MPa (3000 psi) pressure gauge to check and adjust the steering pressure.

CAUTION: Do not hold the steering tiller so that the steering pump and motor is operating for more than three seconds. The steering pump motor may overheat and be damaged.

5. Connect the battery and operate the steering system to remove air. Refer to REMOVE AIR FROM STEERING SYSTEM. Operate the steering system for a full turn. Do not hold the steering tiller in a full turn for more than three seconds without letting the motor cool. Check that the maximum pressure is 8.4 t 0.35 MPa (1200 t 50 psi).

6. To adjust the pressure relief valve, remove the plug covering the adjusting screw on top of the pump. Use a screwdriver to make the adjustment as required. When the proper pressure has been obtained, install the plug covering the adjusting screw.

7. After the pressure check is completed, remove the gauge and hydraulic line. Install the plug in the rear of the pump.

8. Operate the steering system again to remove any air that may have entered the system. Refer to REMOVE AIR FROM STEERING SYSTEM. 9. Install the battery compartment cover using the five capscrews that retain the cover to the frame.

TROUBLESHOOTING

Sheet 8: Steering System PROBLEM No steering action when the steering wheel is turned.

The lift truck steers slowly. The steering tiller is difficult to turn.

The steering tiller turns the steering tires in the wrong direction.

The steering continues to turn after the steering wheel stops.

POSSIBLE CAUSE Low oil level or no oil in hydraulic tank.

Hydraulic hoses or connections are open.

The sleeve and spool in the control unit will not move.

Low oil level or no oil in hydraulic tank.

The hydraulic lines to the control unit are damaged or have a restriction.

The sleeve and spool in the control unit are worn.

The parts of the metering section are worn.

The check valve in the control unit does not open.

The relief valve in the manifold block is damaged or not adjusted correctly.

The hydraulic hoses at the control unit are not connected correctly.

The metering rotor is not aligned correctly The neutral position springs are broken.

The spool or sleeve is damaged.

Sheet 9: Hydraulic System HYDRAULIC SYSTEM HYDRAULIC SYSTEM-INTRODUCTION The hydraulic system for these lift trucks is comprised of three separate sub-systems. These sub-systems are: •

Main Hydraulic -Lift and Lower

•

Auxiliary Hydraulic -Reach, Tilt and Optional Sideshift

•

Power Steering

The hydraulic system includes two pumps. The hoist pump will only operate when the control handle is moved to start the hoist function. The hoist pump and motor is located in the drive unit compartment. The steering pump operates when the key switch is turned on and the operator is in the proper position in the operator's compartment.

The steering pump provides hydraulic oil for the auxiliary functions and the power steering function. The steering pump has a built in priority valve to insure priority flow to the power steering. When both the power steering and auxiliary functions are used at the same time, the priority valve will insure that full flow is provided to the power steering. The steering pump is located in the compartment above the battery. See Section 6 for information on the steering pump.

The main and auxiliary hydraulic functions are controlled by an electro hydraulic control valve. This valve is custom designed to provide full proportional control of the Hoist, Reach, Tilt and Sideshift functions. To provide maximum control, each function is operated electronically using an electro proportional EPV Series Valvistor D valve. The valve also provides proportional control for the auxiliary functions. Separate hoist and auxiliary relief valves are provided to allow operation at different pressures and minimize energy consumption.

The electro-hydraulic control valve is actuated by the control handle. The multi-function control handle is a two axis control, used for both hydraulic and traction operation. Each auxiliary function, Reach, Tilt and Sideshift (optional) has a separate switch located on the control handle. There is also a switch for the horn. Not all functions are used on each lift truck See Figure 7-1 and Table 7-1.

The control handle is moved horizontally for forward and reverse travel. Up and down movement while pressing an auxiliary function switch, controls the auxiliary hydraulic functions. Up and down movement without pressing an auxiliary function switch operates the lift function, up for lift, down for lower. Once the handle is moved from the neutral position the switch can be released. The function will be locked until the handle is returned to the neutral position.

NOTE: Diagonal movement of the handle will control both travel and a hydraulic function simultaneously.

Figure 7-1 -Control Handle Table 7-1 -Hydraulic Oil Tank Capacities Switch A B C D

Truck Model NR/NDR Horn Extend Tilt Sideshift (If so equipped)

If the operator wants to perform an auxiliary function in one direction, immediately followed by the reverse direction (example: extend then retract), the reach auxiliary function switch should be pressed and held until the handle is moved from the extend (up) position, through the neutral position into the retract (down) position. If the switch is not held while moving through the neutral position the control will select the lowering function and mast lowering will

Sheet 9: Hydraulic System occur.

WARNING: Unintentional mast lowering can cause damage or injury.

The power steering system is controlled by the movement of the steering tiller. Turning the steering tiller will direct the flow of hydraulic oil to the steering control unit and the steering motor. The steering tiller will turn from lock to lock in five revolutions and provide 180°of steering angle at the drive/steer wheel.

The hoist system features a single pump and motor. The motors that drive the hoist or steering pumps can be 24 or 36 volts. The 24 volt hoist pump motor is rated at 7.9 hp while the 36 volt motor is rated at 14.5 hp. The 24 volt power steering/auxiliaryfunction pump motor is rated at 2.5 hp and the 36 volt motor is rated at 2.4 hp. See Section 3 for additional information concerning the motors.

The hydraulic system also includes a molded plastic tank. The tank is common for all hydraulic functions. The size of the tank is determined by the size of the battery compartment. See Table 7-2.

Table 7-2 -Hydraulic Oil Tank Capacities BATTERY OIL TANK CAPACITY COMPARTMENT SIZE TO FULL MARK 477.5 mm (18.8 in) 25.3 litres (6.68 gal) 535.9 mm (21.1 in) 25.3 litres (6.68 gal) Hydraulic System = Tank Capacity +4.01 litres (1.06 gallons) in lines The hydraulic level dipstick is externally mounted and may be accessed without opening any covers. The compartment cover must be removed to service the hydraulic tank. There is a breather/filler screwed onto the top of the tank to cover the fill spout and strainer. The strainer and breather/filler assembly are mounted in the fill spout. A second breather is also screwed into the top of the hydraulic tank. There is a 10-micron spin on filter located in the return line to the hydraulic tank. The breather/filler assembly, strainer, breather and filter should be serviced in accordance with the recommended lubrication charts found is Section 2.

Sheet 9: Hydraulic System

Figure 7-2 -Hydraulic Schematic

Sheet 9: Hydraulic System

Figure 7-3 -Hydraulic System 1. HOSE CLAMP 2. HOSE, MOLDED ELBOW 3. TUBE-SUCTION 4. HOSE 5. HOSE 6. HOSE 7. HOSE 8. HOSE 9. HOSE 10. HOSE 11. HOSE CLAMP 12. FILTER ELEMENT 13. CAPSCREW 14. LOCKWASHER 15. HOSE 16. HOSE FITTING 17. HYDRAULIC TANK

Sheet 9: Hydraulic System 18. HOSE ASSEMBLY 19. HOSE 20. BREATHER TUBE 21. BREATHER-FILTER 22. TY WRAP 23. NUT PLATE 24. ISOLATOR 25. BRACKET 26. CAPSCREW 27. LOCKWASHER 28. CAPSCREW 29. BRACKET 30. BUMPER 31. NUT 32. WASHER 33. WASHER 34. NUT 35. CAPSCREW 36. CAPSCREW 37. HOIST PUMP AND MOTOR 38. CAPSCREW 39. FLAT WASHER 40. LOCKWASHER 41. NUT 42. MOUNTING PLATE 43. RUBBER MOUNT 44. BRACKET 45. STEERING PIMP AND MOTOR 46. CONTROL VALVE 47. CAPSCREW 48. FLAT WASHER SPECIFICATIONS Electro-hydraulic Control Valve NOTE: The port identification for all the ports is stamped on the body of the Electro-Hydraulic Control Valve.

Hoist Relief Valve Setting

2800±100 psi

Auxiliary Relief Valve Setting

2100±50 psi

Figure 7-4 -Electro-Hydraulic Control Valve 1.

2.

3.

4.

PROPORTIONAL VALVE LOWERING LIFT VALVISTOR LOWER VALVISTOR MAIN RELIEF VALVE

Sheet 9: Hydraulic System 5. AUXILIARY RELIEF VALVE 6. CHECK VALVE Electro-hydraulic Control Valve-Manual Lowering SCREW WARNING: Allow no one under or near the lift mechanism or load during the manual lowering procedure.

A provision is provided on the lowering valve to allow manual lowering of the forks if necessary. Manual lowering is accomplished by inserting an 1/8 inch alien wrench into the manual lowering screw (located in the center of the lowering Valvistor) and slowly turning it clockwise until the forks begin to lower. See Figure 7-4. Be sure to return the screw tothe original position once the manual lowering process is complete by slowly turning the screw counterclockwise until it stops.

WARNING: Failure to return the manual lowering screw to the full counterclockwise position will cause the forks to lower unexpectedly.

Hoist Pump The rated flow for the hoist pump for the 24 volt lift trucks is 26.8 I/min (7.1 gpm) at 2000 rpm.

The rated flow for the hoist pump for the 36 volt lift trucks is 42.4 I/min (11.2 gpm) at 2000 rpm.

Steering Pump Pump Relief Valve Setting: 8.4 t 0.35 MPa (1200 t 50 psi) HOIST PUMP AND MOTOR Removal WARNING: Make sure the brake pedal is released (in the UP position) and the brake is applied. Put blocks on both sides (front and back) of the drive/steer tire and the caster wheels to prevent movement of the lift truck. Put a block on each side (front and back) of the load wheels to prevent movement of the lift truck.

1. Turn the key switch to OFF. Disconnect the battery.

2. Open the drive unit compartment door. Position a drain pan under the hoist pump. Loosen and disconnect the feed and return lines to the hoist pump. Install plugs in the hydraulic lines to prevent dirt from entering the system and to prevent hydraulic oil from draining out.

Sheet 9: Hydraulic System

Figure 7-5 -Hoist Pump and Motor 1.

2.

3.

4.

5.

6.

7.

MOTOR PUMP O-RING 90°ELBOW CAPSCREW LOCKWASHER 45°ELBOW

WARNING: The hoist pump and motor is heavy. Be sure that all lifting devices (lifts, cables, chains, or slings) are suitable and of adequate capacity to lift the hoist pump and motor. The hoist pump and motor assembly can weigh approximately 253.6 kg (115 lb).

Sheet 9: Hydraulic System

Figure 7-6 -Hoist Pump Disassembled 1. SNAP RING 2. SHAFT SEAL 3. MOUNTING FLANGE 4. BACK-UP RING 5. SEAL 6. BUSHING 7. O-RING 8. PUMP BODY 9. IDLER GEAR 10. DRIVE GEAR 11. END COVER 12. CAPSCREW 3. Position a lifting device around the hoist pump motor. Remove the four capscrews, lockwashers, flat washers and isolator mounts retaining the hoist pump and motor to the lift truck frame.

4. Move the hoist pump and motor to a clean work area to disassemble the hoist pump and motor.

NOTE: The recommended maintenance and repairs of the hoist pump motor is covered in Section 3.

Installation WARNING: The hoist pump and motor is heavy. Be sure that all lifting devices (lifts, cables, chains, or slings) are suitable and of adequate capacity to lift the hoist pump and motor. The hoist pump and motor assembly can weigh approximately 253.6 kg (115 lb).

1. Align the hoist pump and motor with the mounting holes in the frame using a lifting device.

2. Install the four isolator mounts, flat washers. lockwashers and capscrews.

3. Remove the plugs from the hydraulic lines. Install the hydraulic lines on the hoist pump.

4. Remove the blocks from under the drive/steer wheel, caster wheels and load wheels. Check the hydraulic level.

Connect the battery.

HOIST PUMP Disassembly

Sheet 9: Hydraulic System 1. Remove the two capscrews and lockwashers that retain the hoist pump to the motor. Separate the pump from the hoist motor. See Section 3 for repairs on the hoist pump motor.

2. Disassemble the elbows and O-rings from the pump body.

WARNING: Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear eye and face protection during removal and installation.

3. Use snap ring pliers and remove the snap ring from the pump drive gear shaft. Remove the shaft seal.

4. Remove the four capscrews from the pump body. Separate the mounting flange and the end cover from the pump body. Remove the back-up rings, seals, bushings and O-rings.

5. Remove the idler gear and drive gear.

6. Inspect the drive gear, idler gear and the pump body for damage. If any of these parts are damaged the pump must be replaced with a new pump. All seals, O-rings, back-up rings, and snap ring must be replaced if the present pump is to be used.

Assembly 1. Apply clean hydraulic oil to all the pump components before assembly.

2. Align and install the idler gear and drive gear in the pump body. Install the O-rings in the pump body.

3. Align the end cover, pump body and mounting flange. Install the four capscrews.

4. Install a new shaft seal on the drive gear shaft.

5. Install both bushings on the shafts. Install the seals and back-up rings in the body of each of the bushings.

WARNING: Be careful when removing or installing snap rings. These snap rings can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear eye and face protection during removal and installation.

6. Install a new snap ring.

7. Install new O-rings on the elbows and install the elbows in the pump.

8. Align the splined shaft of the pump with the motor and insert the shaft in the motor. Install the two lockwashers and two capscrews.

HYDRAULIC CONTROL VALVE Removal WARNING: Make sure the brake pedal is released (in the up position) and the brake is applied. Put blocks on both sides (front and back) of the drive/steer tire and the caster wheels to prevent movement of the lift truck. Put a block on each side (front and back) of the load wheels to prevent movement of the lift truck.

1. Turn the key switch to OFF. Disconnect the battery.

2. Remove the battery. Refer to Section 2 for instructions on How to Remove the Battery.

3. Remove the battery compartment cover.

4. Identify and tag all electrical and hydraulic connections to the hydraulic control valve. Remove the electrical connections. Disassemble and cap the hydraulic hoses and plug the openings in the hydraulic control valve to prevent dirt from entering the system and from the hydraulic oil leaking.

WARNING: The hydraulic control valve is heavy. Be sure that all lifting devices (lifts, cables, chains, or slings) are suitable and of adequate capacity to lift the hydraulic control valve. The hydraulic control valve can weigh approximately 110.3 kg (50 lb).

5. Remove the two capscrews and flat washers retaining the hydraulic control valve to the top of the battery compartment. Remove the hydraulic control valve from the lift truck.

Sheet 9: Hydraulic System Installation WARNING: The hydraulic control valve is heavy. Be sure that all lifting devices (lifts, cables, chains, !M or slings) are suitable and of adequate capacity to lift the hydraulic control valve. The hydraulic control valve can weigh approximately 110.3 kg (50 lb).

1. Align the hydraulic control valve with the mounting holes in the battery compartment. Install the capscrews and flat washers.

2. Remove the plugs from the hydraulic control valve and the plugs from the hydraulic lines. Install the hydraulic lines on the hydraulic control valve. Install the electrical connections to the hydraulic control valve.

3. Install the battery. Refer to Section 2 for battery installation procedures.

4. Check the level of the hydraulic oil in the tank using the dipstick. Install the battery compartment cover.

5. Remove the blocks from under the drive/steer wheel, caster wheels and load wheels. Connect the battery.

Disassembly The disassembly of the hydraulic control valve is limited to replacing the Coils, Valvistor (Lift or Lower), Proportional Valve Relief Valves (Main and Auxiliary) and Check Valve. The O-rings and back-up rings must be replaced when removing any of the items listed above. See Figure 7-7.

Figure 7-7 -Electro-Hydraulic Control Valve 1.

2.

3.

4.

5.

6.

PROPORTIONAL VALVE LIFT VALVISTOR LOWER VALVISTOR MAIN RELIEF VALVE AUXILIARY RELIEF VALVE CHECK VALVE

NOTE: Make certain that the work area is clean. The hydraulic control valve and its components are manufactured to close tolerances. Any dirt in the system could cause the components to stick and the valve will not operate properly.

1. Remove all the fittings from the hydraulic control valve.

2. Remove the Proportional Valve by removing the four socket head capscrews retaining the valve to the main body of the hydraulic control valve.

3. Remove the Lower Valvistor. Use a 1-1/2 inch open end wrench to remove the Valvistor.

4. Remove the Lift Valvistor. Use a 1-1/2 inch open end wrench to remove the Valvistor.

WARNING: The springs used for the main relief valve, the auxiliary relief valve and the check valves have tension and can release with enough force to cause injury.

5. Remove the Main Relief Valve. Use a 1-1 /2 inch open end wrench to remove the valve plug. Remove the valve plug slowly so the valve plug will not be released with excessive force. Remove the spring and the Main Relief

Sheet 9: Hydraulic System Valve subassembly. The subassembly cannot be disassembled any further.

6. Remove the Auxiliary Relief Valve. Use a 1 inch open end wrench to remove the Auxiliary Relief Valve. Remove the valve slowly so the valve will not be released with excessive force.

7. Remove the Check Valve. Use a 1-1 /2 inch open end wrench to remove the Check Valve. Remove the valve slowly so the valve will not be released with excessive force.

8. Inspect the valves or Valvistorfor damage, erosion orworn parts. Replace any of the items that may be suspect..

Replace all O-rings and back-up rings.

Assembly 1. Lubricate the O-rings and back-up rings using clean hydraulic oil before installing them. Lubricate all the internal parts of the valves and Valvistor before installing them in the body of the hydraulic control valve.

2. Install the O-rings and back-up ring on the Check Valve. Install the Check Valve. Tighten the Check Valve to 109 to 122 Nm (80 to 90 Ibf ft) torque.

3. Install the O-rings and back-up ring on the Auxiliary Relief Valve. Install the Auxiliary Relief Valve in the body of the hydraulic control valve. Tighten the Auxiliary Relief Valve to 47 to 54 Nm (35 to 40 Ibf ft) torque.

4. Install the O-rings and back-up ring on the Main Relief Valve. Install the Main Relief Valve subassembly in the body of the hydraulic control valve. Install the spring and valve plug. Tighten the Main Relief Valve plug to 129 to 142 Nm (95 to 105 Ibf ft) torque.

5. Install the O-rings and back-up rings on the Lower Valvistor. Install the Lower Valvistor. Tighten the Lower Valvistor to 108 to 122 Nm (80 to 90 Ibf ft) torque.

6. Install the O-rings and back-up rings on the Lift Valvistor. Install the Lift Valvistor. Tighten the Lift Valvistor to 108 to 122 Nm (80 to 90 Ibf ft) torque.

7. Install the O-rings in the Proportional Valve A light coat of grease will hold the O-rings in place. Locate the Proportional Valve on the hydraulic control valve body using the locating pin. Install the four socket head capscrews and tighten the capscrews to 4.5 to 6.0 Nm (40 to 50 Ibf in) torque.

8. Install the fittings in the main body of the hydraulic control valve.

HYDRAULIC TANK Removal WARNING: Make sure the brake pedal is released and the brake is applied. Put blocks on both sides (front and back) of the drive/steer tire and the caster wheels to prevent movement of the lift truck. Put a block on each side (front and back) of the load wheels to prevent movement of the lift truck.

1. Turn the key switch to OFF. Disconnect the battery. Position block on both sides (front and back) of the drive/steer tire and the caster wheels. Put a block on each side (front and back) of the load wheels.

2. Open the drive unit compartment and remove the battery compartment cover. Remove the dipstick.

3. Position a drain pan in the drive unit compartment. Tag all the hydraulic lines to the hydraulic tank. Disconnect the suction tube to the hoist pump and allow the hydraulic oil to drain out of the tank. Clean up any spilled oil.

Disconnect the rest of the hydraulic lines to the tank. Plug the hydraulic lines to prevent dirt from entering the system.

4. The hydraulic tank is not physically attached to the lift truck. It can be removed by lifting the tank straight up.

Remove cap, two capscrews, lockwashers and strainer form tank.

5. Remove four capscrews, washers, thread seals, locknuts, washers, and locknuts retaining the tank cover to the hydraulic tank. Remove the tank cover and gasket.

6. Remove the hydraulic tank from the lift truck.

Sheet 9: Hydraulic System

Figure 7-8 -Hydraulic Tank 1. CAP 2. STRAINER 3. TANK COVER 4. CAPSCREW 5. LOCKWASHER 6. FLAT WASHER 7. LOCKNUT 8. GASKET 9. CAPSCREW 10. THREAD SEAL 11. HYDRAULIC TANK 12. AUX RETURN TUBE 13. HOIST RETURN TUBE 7. Inspect all components for damage and replace any defective item.

Installation 1. Position the hydraulic tank in the lift truck.

2. Apply sealant (Yale P/N 5200498-31 or equivalent) to the mating surface of the hydraulic tank. Install a new gasket on the hydraulic tank. Align the top cover with the hydraulic tank and the gasket. Install the four capscrews, washers, thread seals, locknuts, washers, and locknuts to retain the gasket and cover.

Sheet 9: Hydraulic System 3. I nstall the strainer in the tank cover using two lockwashers and capscrews.

4. Remove the plugs from the hydraulic lines. Connect all the hydraulic lines to the hydraulic tank.

5. Fill the hydraulic tank to the recommended level with the recommended hydraulic oil. See Section 2 for the recommended hydraulic oil.

6. . Fill the hydraulic tank with the recommended hydraulic oil. Refer to Section 2. Install cap.

7. Remove the drain pan, close the drive unit compartment cover. Connect the battery.

8. Operate the lift truck through all functions. Check for oil leaks. Check the hydraulic tank for the correct oil level.

9. Install the battery compartment cover on the lift truck. Remove the blocks from both sides of the wheels.

TROUBLESHOOTING PROBLEM POSSIBLE CAUSE Low hydraulic pressure Hydraulic system relief valve opens frequently The pump noise is not normal

The pump has low output The pump has leaks

Pump is worn or damaged.

Relief valve needs adjustment.

Relief valve needs adjustment or relief valve is defective.

Restriction in the system.

Oil in the hydraulic tank is low.

Restriction in the inlet hose.

Inlet fitting or inlet hose clamp is loose.

The bearings or gears are damaged.

The housing is damaged.

Loose capscrews holding the pump housing together.

Loose capscrews in the pump mounting.

Pump motor is damaged or worn.

The pump is worn.

Seals or gaskets are damaged and cause leaks.

The fitting at the pump leaks.

Fittings are loose or defective.

Loose capscrews holding the pump housing together.

Seals are defective.

Sheet 10: Mast and Reach Assembly MAST AND REACH ASSEMBLY MASTS This section provides the removal, installation and adjustment procedures for the triplex masts and for the reach and carriage assemblies. A troubleshooting chart is provided at the end of this section.

These mast assemblies, carriages and reach assemblies have wear plugs and wear strips to allow for adjustment due to wear. The wear plugs are in the stub shafts of the load rollers and slide against the center part of the channel.

A setscrew and jamnut keep each wear plug in the correct position. The load rollers take the forward and back loads during operation of the mast. The load rollers have ball bearings with grease seals. The wear strips are made of a friction material and slide against the outside edge of the channel flange.

The mast weldments must be parallel with equal clearance on each side. Correct operation depends on periodic cleaning, lubrication and adjustment of the clearance between weldments. See CHECKS AND ADJUSTMENTS at the rear of this section.

NOTE: See the GENERAL TRUCK AND LUBRICATION SECTION for the correct maintenance and inspection procedures for the masts, hydraulic cylinders, forks, chains and carriages.

WARNING: The mast, reach assemblies, carriage assemblies and their components, are heavy. To help prevent damage or an injury, a lifting device must be used during all service procedures.

NOTE: The reach assembly or carriage assembly can be removed from the mast assembly with the load backrest extension and forks attached. The triplex mast assembly can also be removed with the carriage or reach assembly installed. Do only those procedures necessary for repair.

CARRIAGE ASSEMBLY The carriage is a part of the mast assembly and moves within the vertical channels of the inner weldment. Load rollers, attached to the carriage, travel in the channels of the inner weldment. Forks or other types of load handling equipment are attached to the carriage. A load backrest extension is attached to the carriage and adds support for a load that has multiple pieces. (See Figure 8-1).

The lift truck may be furnished with an optional sideshift carriage which allows the operator to move the forks and load from side-toside. This function makes it easier for the operator to align the forks with a load or align the load with a stack. The sideshift carriage is installed on the fork bars of the standard carriage. Special bushings fit between the sideshift carriage and the fork bars. A sideshift cylinder is installed on a plate that fits on the standard carriage.

The sideshift cylinder moves the sideshift carriage on the standard carriage.

Figure 8-1 -Carriage Assembly 1. FORK 2. CARRIAGE 3. LOAD BACKREST EXTENSION

Sheet 10: Mast and Reach Assembly REACH ASSEMBLIES The reach assembly is used to extend the reach of the forks. There are two types of reach assemblies. There is a single reach assembly with one set of scissor arms. The other reach assembly has two sets of scissor arms for double reach. Both reach assemblies have a tilt cylinder to tilt the forks. Each reach assembly can also have an optional sideshift function. The parts of the reach assemblies are shown in Figure 8-2. The inner and outer frame assemblies are connected by a scissor linkage. The top of the scissor arm weldment at the inner frame is fastened to the top of the inner frame by pins. The top of each scissor arm at the outer frame or apron is fastened to the top of the frame or apron by pins. On double reach units, the ends of each set of scissor arms and scissor arm weldments are fastened together by studs with bearings. The bearings on each pin or stud permit the arms to pivot. Large bearings at the center pivot of each scissor arm and scissor arm weldment also permit the linkage to pivot.

Two hydraulic cylinders control the reach movement of the scissor arms. The tilt cylinder controls the tilt action of the pivot assemblies at the heel of the forks. The forks pivot on a large pin that connects the forks to the frame. The sideshift cylinder controls the movement of the outer frame assembly and forks.

The bottom arms at the outer frame or apron and the inner frame have load bearings that fit into channels in the frame assemblies. The load bearings permit the ends of the arms to move vertically in the frame channels. The sideshift reach assemblies have another frame that can move sideways on the apron. Two bearing blocks at the top of the apron and two at the bottom reduce the friction for side-to-side movement of the outer frame.

The flow of oil to and from the cylinders is controlled by the elecro-hydraulic control valve and Valvistors. The Valvistors on the elecro-hydraulic control valve control the rate and direction of oil flow. The switches located in the control handle, when actuated, directs the Valvistors to open and close to control the rate and direction of oil flow. A selector valve (Item 1, Figure 8-4 or Figure 8-3) directs the oil flow from the reach cylinders to the tilt cylinder.

Another selector valve with solenoids (Item 5, Figure 8-4 or Item 3, Figure 8-3) directs the flow of oil from the tilt cylinder to the sideshift cylinder for sideshift operation.

Figure 8-2 -Reach Assemblies 1.

2.

3.

4.

5.

6.

7.

INNER FRAME SCISSOR ARM OUTER FRAME FORKS TILT CYLINDER SCISSOR ARM WELDMENT LOAD BEARING

Sheet 10: Mast and Reach Assembly 8. REACH CYLINDER 9. LOAD BACKREST EXTENSION 10. OUTER FRAME 11. APRON 12. LOAD ROLLER

Figure 8-3 -Hydraulic Schematic, Reach Assembly Functions 1.

2.

3.

4.

5.

6.

7.

8.

SELECTOR (SOLENOID) VALVE, REACH/TILT RELIEF VALVE SELECTOR (SOLENOID) VALVE, TILT/SIDESHIFT REACH CYLINDERS TILT CYLINDER SIDESHIFT CYLINDER PORT PLUGS WITHOUT SIDESHIFT TO MAIN CONTROL VALVE (TRUCK)

Figure 8-4 -Hydraulic Parts for Reach Assembly

Sheet 10: Mast and Reach Assembly 1. REACH/TILT SELECTOR VALVE 2. OUTER FRAME 3. TILT CYLINDER 4. OUTER FRAME 5. TILT/SIDESHIFT SELECTOR VALVE 6. FOR APRON MOUNT 7. SIDESHIFT CYLINDER 8. TO TRUCK THROUGH MAST 9. CABLE BRACKET 10. MANIFOLD BLOCK 11. FOR SCISSOR ARM MOUNT 12. REACH CYLINDER (ONE OF TWO) 13. HOSE AND CABLE SHEAVE ASSEMBLY 14. INNER FRAME 15. MOUNT FOR REACH CYLINDER SAFETY PRECAUTIONS The following procedures must be used when inspecting or working near the mast. Additional precautions and procedures can be required when repairing or removing the mast.

WARNING: Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage.

• • • • • •

Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed. Also make sure that the power is off and the key is removed.

Put a "DO NOT OPERATE" tag in the operator's compartment. Disconnect the battery and put a tag or lock on the battery connector.

Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury.

Do NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast.

Do NOT use blocks to support the mast weldments nor to restrain their movement.

Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage.

Follow the repair procedures in this section.

WHEN WORKING NEAR THE MAST ALWAYS: Lower the mast and carriage or reach assembly completely. Push the lift/lower control lever forward and make sure there is no movement in the mast. Make sure that all parts of the mast that move are fully lowered.

OR If parts of the mast must be in a raised position, install a safety chain to restrain the moving parts of the mast.

Connect moving parts to a part that does not move. Follow these procedures: NOTE: WIRE GUARD MUST BE REMOVED TO INSTALL SAFETY CHAIN. REMOVE SAFETY CHAIN AND INSTALL THE GUARD AFTER REPAIRS ARE COMPLETE. a. Raise the mast to align the bottom crossmember of the weldment that moves within the outer weldment, with a crossmember on the outer weldment (1). On the triplex mast it is the intermediate weldment (3). b. Use a 3/8 inch minimum safety chain with a hook (4) to fasten the crossmembers together so that the movable member cannot lower. Put the hook on the back side of the mast. Make sure the hook is completely engaged with a link in the chain. Make sure the safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings or other parts on the mast. c.

Lower the mast until there is tension in the safety chain and the free lift cylinder (5) is completely retracted. Move the key to the OFF position and remove the key from the key switch. Put a "DO NOT OPERATE" tag in the operator's compartment. Disconnect the battery and put a tag or lock on the battery connector. Install a "DO NOT REMOVE" tag on the safety chain(s).

d. Install another safety chain (3/8 inch minimum) between the top or bottom crossmember of the carriage or reach assembly (6) and a crossmember on the outer weldment (1).

Sheet 10: Mast and Reach Assembly

LOAD BACKREST EXTENSION REMOVAL AND INSTALLATION 1. Loosen the two upper capscrews that fasten the load backrest extension to the carriage assembly.

2. Remove these two capscrews and lay the load backrest extension on the forks.

3. Remove the two lower capscrews that fasten the load backrest extension to the carriage assembly.

4. Lift the load backrest extension off the forks.

5. Reverse the procedure to install the load backrest extension. Tighten the capscrews to 203 Nm (150 Ibf ft) torque.

FORK REPLACEMENT A. WARNING: Forks are heavy and can cause an injury. Do not try to remove forks without using a lifting device.

Hook Forks (Optional) These forks are connected to the carriage by hooks. Latch pins fit through the top fork hooks and into slots on the top crossmember of the carriage to keep the forks in position.

To remove the forks, lift the latch lever and slide the fork to the fork removal notch on the carriage. The removal notch is in the bottom crossmember of the carriage as shown in Figure 8-6. Lower the carriage with blocks under the fork or raise the fork tip. The bottom hook of the fork will move through the fork removal notch. Lower the carriage further or raise the fork so that the top hook of the fork is disengaged from the top crossmember. Move the carriage away from the fork, or use the lifting device to move the fork away from the carriage. Follow the same procedure to remove the other fork.

To install the forks, move the fork or carriage so that the top hook on the fork engages the top crossmember of the carriage. Raise the carriage or lower the fork to move the lower hook through the removal notch. Slide the fork on the carriage so that both upper and lower hooks are engaged and the latch pin engages a notch.

Shaft Forks 1. Operate the tilt function so that the forks are fully tilted back. Operate the reach function to fully extend the forks.

Raise the forks off the floor and position a block of wood under each fork. Lower the forks to rest on the block of wood. Remove the load backrest extension as described in LOAD BACKREST EXTENSION-REMOVAL AND INSTALLATION. 2. Remove the capscrew and nut at the center of the fork shaft. If the lift truck has sideshift option, remove the hair pin and pin from both fork brackets. See NO TAG. Use a brass drift to move the fork shaft toward the center of the lift truck until the fork bracket and fork comes off the fork shaft. Use a crane and sling to move the fork.

Repeat the procedure for the other fork.

Sheet 10: Mast and Reach Assembly 3. On models with the sideshift option, remove the capscrew and flat washer retaining the bearing block and spacer to the outer frame.

4. To assemble the forks back in the outer frame, install the spacer and bearing block to the outer frame using the capscrews and flat washers on models with sideshift option.

5. Use a crane and sling to lift a fork for installation. Move the fork and fork bracket into a position of alignment with the fork shaft.

Figure 8-5 -Forks 1.

2.

3.

4.

5.

6.

7.

LATCH ASSEMBLY LEVER ROLL PIN WASHER SPRING KEEPER PIN RETAINING PIN

6. Install the fork shaft in the outer hole in the frame. Use a hammer with a brass or copper head to drive the shaft in the frame.

7. Slide the fork and fork bracket on the shaft. Drive the shaft into position to install the other fork and fork bracket.

Use the crane and sling to align the other fork and install this fork in the same way. Install the shaft so that the end of the shaft is at the outer edge of the frame.

8. Use the crane to move the load backrest into position on the frame. Install the capscrews that fasten the load backrest on the frame.

9. Align the fork and fork bracket on the shaft and install the pin through each fork bracket and fork shaft. Install the hair pins to retain the pins.

HOOK FORK CARRIAGE ASSEMBLY-REMOVAL AND INSTALLATION (SEE FIGURE 8-6 AND FIGURE 8-7)

Sheet 10: Mast and Reach Assembly

Figure 8-6-Fork Removal-Reach Assembly 1. CAPSCREW 2. NUT 3. HAIR PIN 4. PIN 5. FORK BRACKET 6. FLAT WASHER 7. BEARING BLOCK 8. SPACER 9. SPREADER BAR 10. FORK SHAFT WARNING: The carriage assembly is heavy and can cause an injury if it tips or falls. Do not try to remove carriage assembly without using a lifting device.

NOTE: The carriage assembly can be removed with the forks and load backrest extension attached, or with the forks and load backrest removed. Do only those procedures necessary for your repair. See FORK REPLACEMENT to remove the forks. See LOAD BACKREST EXTENSION-REMOVAL AND INSTALLATION to remove the load backrest extension.

NOTE: Most repairs of the carriage assembly can be completed without removing the carriage assembly from the mast.

1. Operate the tilt function so that the carriage assembly is fully tilted back. Operate the reach function to fully extend the carriage assembly. Raise the carriage assembly off the floor and position a block of wood under it.

Lower the carriage assembly to rest on the block of wood.

2. Remove the capscrew and nut at the center of the fork shaft. If the truck has sideshift option, remove the hair pin and pin from both brackets. See Figure 8-6. Use a brass drift to move one end of the fork shaft toward the center of the life truck until both fork brackets and carriage assembly attaching points come off the fork shaft.

Use a crane and sling to move the carriage assembly.

3. On models with the sideshift option, remove the capscrew and flat washer retaining the bearing block and spacer on the outer frame.

4. To assemble the carriage assembly back in the outer frame, install the spacer and bearing block to the outer frame using the capscrews and flat washers on models with side shift.

5. Use a crane and sling to lift carriage assembly for installation. Move the carriage assembly and fork bracket into position of alignment with the fork shaft.

Sheet 10: Mast and Reach Assembly 6. Install the fork shaft in the outer hole in the frame. Use a hammer with a brass or copper head to driv the shaft in the frame.

7. Slide one carriage assembly attaching point and fork bracket on the shaft. Drive the shaft into position to install the other attaching point and fork bracket. Use the crane and sling to align the other side of carriage assembly and install in same way. Install the shaft so that the end of the shaft is at the outer edge of the frame.

8. Align and install the capscrew and nut at the center of the fork shaft. If the truck has sideshift option, install the pin and hair pin in both fork brackets. See Figure 8-6.

9. See LOAD BACKREST EXTENSION-REMOVAL AND INSTALLATION and FORK REPLACEMENT to install the load backrest and fork.

Figure 8-7 -Hook Type Fork Carriage 1. CARRIAGE WELDMENT REACH ASSEMBLY-REMOVAL AND INSTALLATION 1. Operate the LIFT/LOWER control handle to raise the reach assembly until the thrust rollers of the innerframe (reach) are above the top of the outer weldment.

2. Operate the REACH/RETRACT control handle to fully retract the forks. Install safety chains so that the forks cannot extend. Install the safety chains around the center plates of the scissor arm weldment and the reach frame. Make sure a safety chain does not touch the mount for the hose sheave, lift chains, chain or hose sheaves, hoses, tubes or fittings.

3. Move the key to the OFF position and disconnect the battery. Remove the mast guard from the mast assembly.

4. Use safety chains to fasten the movable member of the mast to the outer weldment so that it cannot move.

WARNING: Be careful when removing or installing snap rings. These snap rings are large and can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear

Sheet 10: Mast and Reach Assembly eye and face protection during removal or installation.

5. Remove the snap rings, washers, thrust rollers and spacers.

6. Disconnect the hydraulic lines (sideshift or reach only) at the outer frame. Put tags on the fittings for correct connection during installation.

Make sure to put caps on the open fittings to keep dirt out of the system. Disconnect the electrical connections (reach only) at the selector valve.

NOTE: Removing the pins, at the chain anchors, will disconnect the lift chains without changing the chain adjustment. Always adjust the chains if new lift chains or other components are installed.

7. Hold the lift chains to keep them from falling. Remove the pins in the chain anchors at the back of the free lift cylinder of triplex masts. Disconnect the lift chains. Carefully move the lift chains through the sheaves and lay the lift chains over the reach assembly.

WARNING: The reach assembly is heavy and can cause an injury if it tips or falls. Make sure the reach assembly is stable during and after removal. If the forks are removed, put the reach assembly on the floor so that the load rollers are up.

CAUTION: Do not damage lift chains, hoses or electrical cables as the reach assembly is lifted out of the mast weldment.

8. Carefully lift the reach assembly out of the channels of the inner weldment. Carefully lower the reach assembly to the floor.

NOTE: The reach assembly side rollers must be adjusted while the reach assembly is out of the mast. Adjust the side rollers as described in CHECKS AND ADJUSTMENTS before installing the reach assembly.

9. To install the reach assembly, reverse the removal procedures. Always use new cotter pins when installing the lift chains. Apply Loctite to the studs of the thrust rollers during installation.

10. Adjust the reach assembly. See ADJUSTMENTS in CHECKS AND ADJUSTMENTS. Test the reach assembly for correct operation.

CARRIAGE LOAD ROLLERS-REMOVAL AND INSTALLATION (SEE FIGURE 8-8 AND FIGURE 8-9) 1. Remove the carriage or reach assembly from the mast assembly to remove and install the carriage load rollers.

See CARRIAGE ASSEMBLY or REACH ASSEMBLY-REMOVAL AND INSTALLATION. 2. Remove the jam nuts and set screws for the load rollers.

3. If necessary, replace the wear plugs by pushing at the back of the wear plug.

Sheet 10: Mast and Reach Assembly

Figure 8-7 -Reach Assembly 1. LOAD ROLLER (4 OR 6) 2. CHAIN ANCHORS 3. INNER FRAME 4. SHIMS 5. SNAP RING 6. SIDE ROLLER 7. THRUST ROLLER 8. SPACER 9. WASHER 10. GREASE FITTING 11. WEAR PLUG

Figure 8-8 -Load Roller and Wear Plug Assembly 1.

2.

3.

4.

LOAD ROLLER WITH SNAP RING REMOVED PRYBAR MAST, REACH OR CARRIAGE COMPONENT SIDE ROLLER

Sheet 10: Mast and Reach Assembly

Figure 8-9 -Removing Load Roller 1.

2.

3.

4.

5.

6.

7.

LOAD ROLLER WEAR PLUG SNAP RING SET SCREW JAM NUT STUB SHAFT MAST, REACH OR CARRIAGE COMPONENT

WARNING: Lift chains, hoses and cables can roll I/N over the sheaves to fall and cause an injury if the ends are not fastened. Keep control of the ends of the lift chains, hoses and cables as they are removed. Use wire to temporarily connect the ends of the lift chains, hoses or cable to the masts.

4. Remove the safety chains installed in Step 4, Reach Assembly, Removal, and Installation. Lower the reach assembly for access to the chain anchors at the back of the free lift cylinder. Use safety chains to fasten the movable member of the mast to the outer weldment so that it cannot move. Move the key to the OFF position and disconnect the battery.

5. Install lifting eyes in the reach assembly for chains or slings. Fasten chains or slings to the reach assembly so that the reach assembly cannot tip as it is removed from the mast weldment. Fasten the chains to the lifting eyes. Use the crane to raise the reach assembly so that the lift chains become loose.

WARNING: Be careful when removing or installing snap rings. These snap rings are large and can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear eye and face protection during removal or installation.

6. Remove the snap rings from the stub shaft for the load roller.

7. Use a prybar to remove the load roller from the stub shaft for the load roller. See Figure 8-9.

8. Use a cloth to clean each load roller. Inspect the load rollers for cracks, flat spots or bearings that do not turn freely. Replace any roller that shows wear or is damaged.

9. Install the carriage or reach assembly. See CARRIAGE ASSEMBLY or REACH ASSEMBLY-REMOVAL AND INSTALLATION. 10. Adjust the carriage or reach assembly. See ADJUSTMENTS in CHECKS AND ADJUSTMENTS. SIDE ROLLERS-DISASSEMBLY AND ASSEMBLY (SEE FIGURE 8-9) 1. Remove the carriage assembly from the mast to replace the side rollers. See CARRIAGE ASSEMBLY REMOVAL AND INSTALLATION to remove the carriage.

2. Remove the capscrews that fasten the side roller bracket.

NOTE: Observe the position of the shims.

Sheet 10: Mast and Reach Assembly 3. Inspect and replace all damaged or worn parts.

4. Reverse the procedure to install the side rollers. Adjust the carriage side rollers during assembly. See CARRIAGE ADJUSTMENTS in CHECKS AND ADJUSTMENTS. NOTE: To remove and replace load rollers, wear plugs, weldments or lift cylinders, it is necessary to remove the simplex mast assembly from the truck.

REPAIR-REACH ASSEMBLY NOTE: Most repairs of the reach assembly can be done without removing the reach assembly from the mast. These repair procedures require that the reach assembly is installed in the mast and the scissor arms are fully extended.

WARNING: The reach assembly can fall or tip easily and cause an injury when not installed in the mast. If the reach assembly cannot be installed in a mast during repair, make sure the inner frame is fastened to a support that cannot move. The inner frame must be in the same position as it is in the mast. The inner frame must also be fastened so that it cannot move on the support. The support must be strong enough to allow full extension of the reach assembly without tipping.

NOTE: It is usually not necessary to completely disassemble the reach assembly. Do only the steps of the procedures necessary to make the required repairs.

WARNING: Hydraulic oil is hot after system operation and can cause burns. Do not disconnect any hydraulic lines of the system until the oil for the system is cool.

CAUTION: Make sure the lift truck is in a location that is level and has access to a crane or other lifting device before doing any repairs on the reach assembly.

REACH ASSEMBLY OUTER FRAME Removal with Sideshifter (See Figure 8-11) NOTE: Use safety chains on the inner frame and mast weldments to keep the reach assembly and mast weldments from moving. Install the safety chains as described in SAFETY PROCEDURES. NOTE: Make sure that the reach assembly is in the fully extended position. The outer frame can be removed with the forks installed or removed.

WARNING: There are pinch points on the reach assembly that can cause an injury. Use clamps and blocks to prevent the scissor arms from moving. Install the clamps and blocks at the channels of the inner frame to make sure that the load bearings cannot move in the channel. See Figure 8-10.

NOTE: If the outer frame will NOT be disassembled, it can be removed as one unit. If disassembly is a requirement, the outer frame must be removed from the scissor arms.

1. If necessary, remove the forks as described in FORK REPLACEMENT. 2. Remove the sideshift cylinder as described in SIDESHIFT CYLI NDER-REMOVAL. 3. Install labels for correct connections during installation and disconnect the hydraulic lines at the top of the TI LT/SIDESHI FT selector valve. Install caps on the hydraulic lines and valve ports to prevent dirt from entering the system. Make a note of the location of all cable ties for correct installation of new cable ties during installation.

4. Install labels for correct connections during installation and disconnect the wires to the solenoids of the TILT/SIDESHIFT selector valve. Remove the hose and wire guide.

Sheet 10: Mast and Reach Assembly

Figure 8-10 -Install Blocks and Clamps 1.

2.

3.

4.

INNER FRAME OF REACH ASSEMBLY LOAD BEARING WOOD BLOCK CLAMP

5. Remove the roll pins that retain the pivot pins in the outer frame to the inner scissor arms. Remove the pivot pins.

6. Use a crane to lift the outer frame high enough to allow the inner extend arm rollers to come out of the bottom of the outer frame channels. Move the outer frame away from the lift truck and put it flat on the floor Disassembly (See Figure 8-11) 1. Remove the tilt cylinder and tilt pivot assemblies as described in TILT CYLI NDER AND TI LT PIVOT ASSEMBLIES. 2. If necessary, install labels for correct connection during assembly and remove any other hydraulic hoses on the selector valve. Install caps on the hydraulic lines and valve ports to prevent dirt from entering the system.

3. If necessary, remove the hose and wire guide and the selector valve.

4. If necessary, disassemble the selector valve as described in DISASSEMBLY OF TILT/SIDESHIFT SELECTOR VALVE. Cleaning and Inspection WARNING: Cleaning solvents can be flammable and toxic, and can cause skin irritation. Wear !M protection for eyes and skin. When using cleaning solvents, always follow the recommendations of the manufacturer.

CAUTION: Do NOT use steam to clean the load bearings. Do not use compressed air on the !M bearings. The bearings are sealed and permanently lubricated. The air can force the lubricant out of the bearings.

Clean all of the parts of the outer frame with solvent. Dry the parts with compressed air. Inspect the parts of the outer frame for damage and wear. Replace all bushings.

Assembly (See Figure 8-11) 1. If necessary, assemble the selector valve as described in ASSEMBLY OF TILT/SIDESHIFT SELECTOR

Sheet 10: Mast and Reach Assembly VALVE. 2. If removed, install the selector valve, and the hose and cable guide.

3. If removed, install the hydraulic hoses for the reach cylinder. Always use new O-rings on the O-ring fittings.

4. Install the tilt cylinder and tilt pivot assemblies as described in INSTALLATION OF TILT CYLINDER. Installation (See Figure 8-11) WARNING: The point between the scissor arms and the outer frame is a pinch point and can cause an injury. Do NOT put any part of your body between these assemblies. Use a screwdriver or other tool to move the bearing blocks or assemblies into the correct positions.

1. Use multi-purpose grease to lubricate the bushings on the inner and outer scissor arms. Use multi-purpose grease to hold the bottom bearings in the correct positions at the bottom of the outer frame.

2. Use a crane to lift the outer frame. Align the outer frame with the outer scissor arms. Install the pivot pins that retain the inner scissor arms to the outer frame.

3. Install the roll pins to retain the pivot pins.

4. If necessary, install the sideshift cylinder as described in INSTALLATION OF SIDESHIFT CYLINDER. Always use new O-rings on the O-ring fittings. If necessary to connect the hydraulic lines. Make sure any other hydraulic lines are correctly connected. Install the electrical cable and wires on the tilt/sideshift selector valve. Install new cable ties at the original locations for clearance of hoses and electrical cables during operation.

NOTE: The reach assembly must be installed on the mast before doing Step 5.

5. After all hydraulic lines are connected, operate the functions to check for leaks and correct operation. Remove the air from the system and adjust the stroke of the tilt cylinder as described in CHECKS AND ADJUSTMENTS. 6. If necessary, install the forks and load backrest extension as described in FORK REPLACEMENT and LOAD BACKREST EXTENSION REMOVAL AND INSTALLATION. Removal without Sideshifter (See Figure 8-12) WARNING: There are pinch points on the reach assembly that can cause an injury. Use clamps and blocks to prevent the scissor arms from moving. Install the clamps and blocks at the channels of the inner frame to make sure that the load bearings cannot move in the channel. See Figure 8-10.

CAUTION: Do NOT operate the tilt or sideshift functions if the outer frame has been removed. Hydraulic oil can come out of the hoses.

NOTE: Use safety chains on the inner frame and mast weldments to keep the reach assembly and mast weldments from moving. Install the safety chains as described in SAFETY PROCEDURES. NOTE: Make sure that the reach assembly is fully extended. The outer frame can be removed with the forks installed or removed.

1. Operate the tilt function for full back tilt. Operate the reach function to fully extend the reach assembly. If necessary, remove the load backrest extension as described in LOAD BACKREST EXTENSION-REMOVAL AND INSTALLATION. 2. If necessary, remove the forks as described in FORK REPLACEMENT. NOTE: If necessary, remove the outer frame as described in OUTER FRAME-REMOVAL . If necessary, remove the sideshift cylinder from the outer frame as described in SIDESHIFT CYLINDER-REMOVAL. 3. Install labels for correct connection during installation and remove the hoses at the top of the outer frame. For units without sideshift, see Figure 8-12. For units with sideshift, see Figure 8-11. Make a note of the location of all cable ties for correct installation of new cable ties during installation. Install caps on the hydraulic lines of the selector valve to prevent dirt from entering the system.

WARNING: The points between the scissor arms and the outer frame are pinch points and can cause an injury. Do

Sheet 10: Mast and Reach Assembly NOT put your finger in the hole when you remove the pins. Use the brass drift to remove the pins.

4. Use a punch to remove the roll pin (Item 9, Figure 8-11) (Item 7, Figure 8-12) WARNING: The outer frame is heavy and can tip forward and cause an injury when removed from the scissor arms.

Tipping is even more possible if the forks or outer frame are installed. Make sure to install the chains or slings between the crane and outer frame to prevent tipping.

5. Use a crane as a support for the outer frame. Use a brass drift to remove the pivot pin that fastens the outer frame to the top ends of the scissor arms.

CAUTION: Do not let the load bearings or shims fall off the scissor arms.

6. Carefully move the top of the outer frame away from the scissor arms. Slowly lower the outer frame until the load bearings at the bottom of the scissor arms are out of the frame channels. Move the outer frame away from the scissor arms. Put the outer frame on the ground so that the scissor side is down.

NOTE: Install labels for each set of shims and the load bearing for correct installation during installation of the outer frame or apron. When new load bearings are installed, the shim arrangement will normally be the same or similar.

Disassembly without Sideshifter (See Figure 8-13) NOTE: The bearings for the outer frame are normally removed and installed with the outer frame. The selector valve for the tilt/sideshift functions is also installed on the outer frame. Plugs are installed at the ports for the sideshift cylinder and the solenoids. The tilt pivot assembly is also installed on the outer frame.

1. Remove the tilt cylinder and tilt pivot assemblies as described in TILT CYLI NDER AND TI LT PIVOT ASSEMBLIES. 2. Remove the solenoid valve body and hose guide. Disassemble the selector valve as described in TILT/SIDESHIFT SELECTOR VALVE DISASSEMBLY

Sheet 10: Mast and Reach Assembly

Figure 8-11 -Front Frame with Sideshifter 1. HOSE ASSEMBLY 2. HOSE ASSEMBLY 3. ELBOW 4. CONNECTOR 5. HOSE ASSEMBLY 6. HOSE ASSEMBLY 7. HOSE ASSEMBLY 8. HOSE ASSEMBLY 9. ROLL PIN 10. PIVOT PIN 11. CAPSCREW 12. LOCKWASHER 13. HOSE AND WIRE GUIDE 14. CAPSCREW

Sheet 10: Mast and Reach Assembly 15. LOCKWASHER 16. SELECTOR VALVE 17. SOLENOID VALVE 18. CAPSCREW 19. LOCKNUT 20. FORK SHAFT 21. ROLL PIN 22. CYLINDER END PIN 23. LOCKNUT 24. COTTER PIN 25. WASHER (AS REOD) 26. FLAT WASHER 27. ROD END PIN 28. ROD END 29. SIDESHIFT CYLINDER 30. CAPSCREW 31. FLAT WASHER 32. BEARING BLOCK 33. SPACER 34. HAIR PIN 35. PIN 36. FORK BRACKET 37. SPREADER BAR 38. TILT CYLINDER PIN I 39. ROD END 40. CAPSCREW 41. LOCKWASHER 42. TILT ROLLER SHAFT 43. TILT ROLLER SHAFT 44. TILT PIVOT-RIGHT HAND 45. BUSHING 46. TILT SLIDER ASSEMBLY 47. BUSHING 48. CAPSCREW 49. END CAP 50. BEARING BLOCK-POLY 51. COTTER PIN 52. LOCKNUT 53. PIN-SPACER 54. ROD END 55. BUSHING 56. LOCKNUT 57. LOCKWASHER 58. TILT CYLINDER ASSEMBLY 59. TILT PIVOT-LEFT HAND 60. BUSHING 61. OUTER FRAME 62. O-RING

Sheet 10: Mast and Reach Assembly

Figure 8-12 -Front Frame without Sideshifter 1. HOSE ASSEMBLY 2. HOSE ASSEMBLY 3. ELBOW 4. CONNECTOR 5. HOSE ASSEMBLY 6. HOSE ASSEMBLY 7. ROLL PIN 8. PIVOT PIN 9. CAPSCREW 10. LOCKWASHER 11. HOSE AND WIRE GUIDE 12. CAPSCREW

Sheet 10: Mast and Reach Assembly 13. LOCKWASHER 14. SELECTOR VALVE 15. FORK RETAINING PIN 16. CAPSCREW 17. LOCKWASHER 18. CAPSCREW 19. LOCKWASHER\\.

20. FORK SHAFT 21. PIN 22. ROD END 23. CAPSCREW 24. LOCKWASHER 25. TILT ROLLER SHAFT 26. TILT ROLLER SHAFT 27. TILT PIVOT-RIGHT HAND 28. BUSHING 29. TILT ROLLER ASSEMBLY 30. BUSHING 31. COTTER PIN 32. LOCKNUT 33. PIN 34. ROD END 35. BUSHING 36. LOCKNUT 37. LOCKWASHER 38. TILT CYLINDER ASSEMBLY 39. TILT PIVOT-LEFT HAND 40. BUSHING 41. OUTER FRAME 42. O-RING Cleaning and Inspection CAUTION: Do NOT use steam to clean the load bearings. Do not use compressed air on the bearings. The bearings are sealed and permanently lubricated. The air can force the lubricant out of the bearings.

NOTE: Inspect the load bearings of the scissor arms for wear or damage. If necessary, replace the load bearings before installing the outer frame.

WARNING: Cleaning solvents can be flammable and toxic, and can cause skin irritation. Wear !M protection for eyes and skin. When using cleaning solvents, always follow the recommendations of the manufacturer.

Clean all of the parts of the outer frame or apron with solvent. Dry the parts with compressed air. Inspect the parts of the outer frame for damage and wear.

Assembly without Sideshifter (See Figure 8-12) NOTE: The bearings for the outer frame are normally removed and installed with the outer frame. The selector valve and tilt assembly are installed on the outer frame.

1. If removed, install the solenoid valve and hose guide on the outer frame.

2. Install the tilt cylinder and tilt pivot assemblies as described in TILT CYLINDER AND TILT PIVOT ASSEMBLIES. Installation without Sideshifter (See Figure 8-12) WARNING: The outer frame is heavy and can cause an injury during installation. NEVER put any part of your body between the outer frame and the scissor arm assembly. Tipping is even more possible if the forks are installed.

Make sure to install the chains or slings between the crane and outer frame to prevent tipping.

NOTE: Make all repairs for the scissor arm assembly before installing the outer frame. See SCISSOR ARMS to repair the scissor arm assembly. If necessary, install new load bearings using the same shims as marked during removal of the outer frame. When new load bearings are installed, the shim arrangement will normally be the same or similar.

Sheet 10: Mast and Reach Assembly NOTE: The outer frame can be installed with the forks installed.

1. Use a crane as a support for the outer frame. Move the outer frame into the approximate position for installation on the scissor arm assembly.

CAUTION: Do not let the load bearings or shims fall off the scissor arms.

2. Make sure the shims and load bearings are installed in the correct positions on the scissor arms. If necessary, use tape to keep the load bearings on the scissor arms. Do not let the load bearings fall during installation of the outer frame.

CAUTION: Do NOT operate the tilt or sideshift functions if the outer frame has been removed. Hydraulic oil can come out of the hoses.

NOTE: Use safety chains on the inner frame and mast weldments to keep the inner frame and mast weldments from moving. Install the safety chains as described in SAFETY PROCEDURES. WARNING: There are pinch points on the reach assembly that can cause an injury. Use clamps and blocks to prevent the scissor arms from moving. Install the clamps and blocks at the channels of the inner frame to make sure that the load bearings cannot move in the channel. See Figure 8-10.

3. Use the crane to move the outer frame for alignment with the scissor arms. Tip the outer frame forward and align the channels with the load bearings of the scissor arms. Slowly lift the outer frame to install the load bearings in the channels.

NOTE: Another removal method for the outer frame is to raise the scissor arms and inner frame as a unit. Remove the safety chains and operate the lift system of the lift truck to raise the scissor arms and inner frame off the outer frame.

4. The load bearings must move in the channels and have minimum clearance with free movement. Keep the outer frame in vertical alignment and move it up and down on the load bearings. If necessary, add or remove shims for free movement and minimum clearance. Each shim set must have the same thickness.

5. Install new bushings in the top end of each scissor arm. Lubricate the bushings with multi-purpose grease. Tip the outer frame back and align the holes for the pivot pins with the bushings in the top scissor arms.

6. Keep the pivot pins (Item 9, Figure 8-11) (Item 7, Figure 8-12) in alignment to install the roll pins. Install the pins and roll pins.

7. Install the hoses at the top of the outer or outer frame as marked during removal. For units without sideshift, see Figure 8-12. For units with sideshift, see Figure 8-11.

8. After all hydraulic lines are connected, operate the functions to check for leaks and correct operation. Remove the air from the system as described in CHECKS AND ADJUSTMENTS. Install new cable ties at the original locations for clearance of hoses and electrical cables during operation.

SINGLE REACH SCISSOR ARMS Removal and Disassembly (See Figure 8-13) WARNING: There are pinch points on the reach assembly that can cause an injury. Use clamps !M and blocks to prevent the scissor arms from moving. Install the clamps and blocks at the channels of the inner frame to make sure that the load bearings cannot move in the channel. See Figure 8-10.

NOTE: Make sure that the reach assembly is in the fully extended position.

NOTE: Use safety chains on the inner frame and mast weldments to keep the inner frame and mast weldments from moving. Install the safety chains as described in SAFETY PROCEDURES. WARNING: Be careful when removing or installing snap rings. These snap rings are large and can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear eye and face protection during removal or installation.

1. Remove the outer frame or the apron as described in OUTER FRAME OR SIDESHIFT APRON-REMOVAL. Remove the snap rings and hose sheaves at the scissor arm weldment. Fasten the cable (sideshift only) and

Sheet 10: Mast and Reach Assembly hoses at the inner frame so that they are not damaged.

2. Use a crane and chains or slings as a support for the scissor arm weldment. Do not damage the hose sheave mount.

WARNING: The points between the scissor arms and the inner frame are pinch points and can cause an injury. Do NOT put your finger in the hole when you remove the pins at the reach cylinders or scissor arm weldment. Use a brass drift to remove the pins.

3. Use a punch to remove the roll pins in the rod ends of the reach cylinders (Item 2, Figure 8-24). Use a drift to remove the pins that fasten the rod ends of the reach cylinders to the scissor arm weldment. Use wire to hold each reach cylinder and their hoses in a position for clearance as the load bearings move. Remove the bushings from the mounts.

WARNING: The load bearings and scissor arms can move and cause an injury when the clamps and blocks at the load bearings are removed. Make sure the crane is in a position to prevent movement of the scissor arms as the clamps and blocks are removed.

4. Carefully remove the clamps and blocks at the load bearings on the channels of the inner frame. Slowly move the scissor arms to align the load bearings with the removal notch in the inner frame. Raise the scissor arm weldment and the scissor arms to move the load bearings out of the inner frame.

WARNING: The scissor arms are heavy and can cause an injury if allowed to fall. Have another !M person help you support the scissor arm during removal and installation.

NOTE: Install labels for each set of shims and the load bearing on the scissor arms for correct assembly during installation of the scissor arms. When new load bearings are installed, the shim arrangement will normally be the same or similar. Remove the load bearings and shims.

5. Install labels for correct installation of the right hand or left hand scissor arms. Carefully remove the three capscrews, the lockwashers, the end cap and the two thrust washers at the center pivot for the scissor arm and scissor arm weldment. Hold the scissor arm and carefully slide it off the bushing and stub shaft of the scissor arm weldment. Remove the bushing and the other two thrust washers. Remove the other scissor arm following this same procedure.

6. Remove the roll pins and anchor pins that fasten the scissor arm weldment to the inner frame. Move the scissor arm weldment and put it on the floor without damaging the hose sheave mount. Remove the bushings.

7. If necessary, install the forks and load backrest extension as described in FORK REPLACEMENT and LOAD BACKREST EXTENSION-REMOVAL AND INSTALLATION. Cleaning and Inspection WARNING: Cleaning solvents can be flammable and toxic, and can cause skin irritation. Wear protection for eyes and skin. When using cleaning solvents, always follow the recommendations of the manufacturer.

CAUTION: Do NOT use steam to clean the load bearings. Do not use compressed air on the bearings. The bearings are sealed and permanently lubricated. The air can force the lubricant out of the bearings.

Clean all of the parts of the scissor arm assembly with solvent. Dry the parts with compressed air. Inspect the parts of the scissor arm assembly for damage and wear. Replace all bushings and load bearings.

Sheet 10: Mast and Reach Assembly

Figure 8-13 -Single Reach Arm 1. ARM 2. REACH CYLINDER 3. SCISSOR ARM WELDMENT 4. LOAD BEARING 5. PIN 6. ROLL PIN 7. BUSHING 8. SHIM 9. HOSE SHEAVE 10. MOUNT 11. SNAP RING 12. TWO THRUST WASHERS

Sheet 10: Mast and Reach Assembly 13. END CAP 14. LOCKWASHER 15. CAPSCREW 16. ROD END 17. INNER FRAME 18. REMOVAL NOTCH 19. INSTALL CLAMPS AND BLOCKS HERE Assembly and Installation WARNING: The points between the scissor arms and the innerframe are pinch points and can cause an injury. Do NOT put your finger in the hole when you install the pins at the reach cylinders or scissor arm weldment.

NOTE: Use safety chains on the inner frame and mast weldments to keep the inner frame and mast weldments from moving. Install the safety chains as described in SAFETY PROCEDURES. NOTE: Always use new bushings and load bearings. Install a thin coat of multi-purpose grease on all new bushings, all thrust washers, all shims, all stub shafts and all pins of the scissor arm assembly.

1. Use a crane and chains or slings as a support for the scissor arm weldment. Do not damage the hose sheave mount. Move the weldment into a position of alignment to install the pins that fasten the weldmentto the inner frame. Align the holes for the roll pin. Install the bushings, pins and roll pins. See Items 5, 6 and 7 of Figure 8-24.

WARNING: The scissor arms are heavy and can cause an injury if allowed to fall. Have another person help you support the scissor arm during removal and installation.

2. Install two thrust washers and the bushing on each stub shaft of the scissor arm weldment. Install the right hand and left hand scissor arms as shown in Figure 8-13. Use the other two thrust washers, the end cap, lockwashers and capscrews on each stub shaft and bushing. Tighten the three capscrews at each end cap to 41 Nm (30 Ibf ft) torque.

WARNING: The scissor assembly is heavy and can cause an injury during installation. NEVER put any part of your body between the inner frame and the scissor arm assembly. NEVER put any part of your body between the parts of the scissor arm assembly.

CAUTION: Do not let the load bearings or shims fall off the scissor arms.

3. Slowly raise the weldment so you can install the shim sets and load bearings on each scissor arm as marked during removal and disassembly. If necessary, use tape to keep the load bearings on the scissor arms.

4. Use the crane to slowly raise the scissor arm weldment and the scissor arms to align the load bearings with the removal notches in the inner frame. Use the crane to move the scissor arm assembly so that the load bearings move into the channels.

5. Slowly raise the scissor arm assembly to align the mounts with the rod ends of the reach cylinders. Install the bushings, pins and roll pins to fasten the reach cylinders to the scissor arm weldment.

WARNING: Be careful when removing or installing snap rings. These snap rings are large and can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear eye and face protection during removal or installation.

CAUTION: Do not let the load bearings or shims fall off the scissor arms.

6. Install the shims and load bearings on the scissor arm weldment as marked during removal and disassembly. If necessary, use tape to keep the load bearings on the scissor arms. Install the hoses on the hose sheaves and install the hose sheaves and snap rings at the mount of the scissor arm weldment.

DOUBLE REACH ARM Removal and Disassembly (See Figure 8-14) WARNING: There are pinch points on the reach assembly that can cause an injury. Use clamps and blocks to prevent the scissor arms from moving. Install the clamps and blocks at the channels of the inner frame to make sure that the load bearings cannot move in the channel. See Figure 8-10.

NOTE: Make sure that the reach assembly is in the fully extended position.

Sheet 10: Mast and Reach Assembly NOTE: Another installation method for the outer frame or apron, is to raise the scissor arms and inner frame as a unit. Operate the lift system of the lift truck to raise the scissor arms and inner frame above the outer frame or apron.

Use the crane and a bar to align the channels of the outer frame or apron under the load bearings of the scissor arms. Tilt the outer frame or apron forward for clearance. Have another person slowly lower the scissor assembly so that the load bearings are in the channels. Tilt the outer frame or apron back to align the scissor arms to install the pins.

NOTE: Use safety chains on the inner frame and mast weldments to keep the inner frame and mast weldments from moving. Install the safety chains as described in SAFETY PROCEDURES.

Figure 8-14 -Double Reach Arm

Sheet 10: Mast and Reach Assembly 1. SCISSOR ARM 2. REACH CYLINDER 3. SCISSOR ARM WELDMENT 4. LOAD BEARING 5. PIN 6. ROLL PIN 7. BUSHING 8. SHIM 9. HOSE SHEAVE 10. MOUNT 11. SNAP RING 12. TWO THRUST WASHERS 13. END CAP 14. SPECIAL LOCKWASHER 15. CAPSCREW 16. LOCKWASHER 17. ROD END 18. INNER FRAME 19. REMOVAL NOTCH 20. INSTALL CLAMPS AND BLOCKS HERE WARNING: Be careful when removing or installing snap rings. These snap rings are large and can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear eye and face protection during removal or installation.

1. Remove the outer frame or the apron as described in OUTER FRAME OR SIDESHIFT APRON-REMOVAL. Remove the snap rings and hose sheaves at the scissor arm weldments. Fasten the cable (sideshift only) and hoses at the inner frame so that they are not damaged.

2. Use a crane and chains or slings as a support for the scissor arm weldment "A". Make sure to install the chains or slings so that the weldment cannot slip inside the chains or slings. Do not damage the hose sheave mount.

3. Bend the corners of the special lockwashers flat. Remove the two capscrews, special lockwasher, end cap and two thrust washers (Items 12 through 15, Figure 8-14) from the bottom pivot points of scissor arms " 1 A" and "2A".

WARNING: The scissor arms are heavy and can cause an injury if allowed to fall. Have another person help you support the scissor arm during removal and installation.

4. Install labels for correct installation of the right hand or left hand scissor arms. Carefully remove the three capscrews, the lockwashers, the end cap and the two thrust washers at the center pivot for scissor arm "1 A" and scissor arm weldment "A". Hold the scissor arm "1 A" and slide it off the bushing and stub shaft of the scissor arm weldment. Remove the bushing and the other two thrust washers at the center pivot. Remove the bushing and the other two thrust washers from the stub shaft at the end of the scissor arm. Remove scissor arm "2A" following this same procedure.

5. Slowly lower scissor arm weldment "A" so that it hangs from the ends of scissor arms "1 B" and "2B". Move the crane and chains or slings so that they are a support for the scissor arm weldment "B".

WARNING: The points between the scissor arms and the innerframe are pinch points and can cause an injury. Do NOT put your finger in the hole when you remove the pins at the reach cylinders. Use a brass drift to remove the pins.

6. Use a punch to remove the roll pins in the rod ends of the reach cylinders (Item 2, Figure 8-24 ). Use a drift to remove the pins that fasten the rod ends of the reach cylinders to the scissor arm weldment "B". Use wire to hold each reach cylinder and hoses in a position for clearance as the load bearings move.

WARNING: The load bearings and scissor arms 1 B" and "213" can move and cause an injury when the clamps and blocks at the load bearings are removed. Make sure the crane (Step 5) is in a position to prevent movement of the scissor arms as the clamps and blocks are removed.

7. Carefully remove the clamps and blocks at the load bearings on the channels of the inner frame. Slowly move scissor arm weldment "A" to align the load bearings of scissor arms "1 B" and "2B" with the removal notch in the inner frame. See Figure 8-14. Use the crane to move the scissor arm assembly so that the load bearings are out of the inner frame.

NOTE: Install labels for each set of shims and the load bearing on the scissor arms " 1 B" and "2B". Install the labels

Sheet 10: Mast and Reach Assembly for correct assembly during installation of the scissor arms. When new load bearings are installed, the shim arrangement will normally be the same or similar. Remove the load bearings and shims.

8. Carefully lower the crane so the scissor arm assembly "retracts" as the ends of the scissor arms move down the outside of the channel. Do not damage the stub shafts for the load bearings.

9. Install a safety chain between the inner frame and scissor arm weldment "B" so that the weldment cannot move.

Move the crane and chains or slings so that they are a support for the scissor arm weldment "A".

10. Remove the two capscrews, special lockwasher, end cap and two thrust washers from the top pivot point of scissor arms "1 B" and "2B".

WARNING: The scissor arms are heavy and can cause an injury if allowed to fall. Have another !M person help you support the scissor arm during removal and installation.

11. Install labels for correct installation of the right hand or left hand scissor arms. Carefully remove the three capscrews, the lockwashers, the end cap and the two thrust washers at the center pivot for scissor arm "1 B" and scissor arm weldment"B". Make sure the crane is the support for scissor arm weldment "A" so that it cannot fall. Hold the scissor arm "1 B" and slide it off the bushing and stub shaft of the scissor arm weldment "B".

Remove the bushing and the other two thrust washers at the center pivot. Remove the bushing and the other two thrust washers from the stub shaft at the end of the scissor arm. Remove scissorarm"2B"followingthissameprocedure. Move scissor arm weldment "A" and put it on the floor without damaging the hose sheave mount.

12. Use the crane and chains or slings as a support for the scissor arm weldment "B" so that it cannot fall. Do not damage the hose sheave mount. Carefully remove the safety chain.

WARNING: The points between the scissor arms and the innerframe are pinch points and can cause an injury. Do NOT put your finger in the hole when you remove the pins at the scissor arm weldment. Use a brass drift to remove the pins.

13. Remove the roll pins, and anchor pins that fasten the scissor arm weldment "B" to the inner frame. Move scissor arm weldment "B" and put it on the floor without damaging the hose sheave mount. Remove the bushings.

Cleaning and Inspection WARNING: Cleaning solvents can be flammable and toxic, and can cause skin irritation. Wear !M protection for eyes and skin. When using cleaning solvents, always follow the recommendations of the manufacturer.

CAUTION: Do NOT use steam to clean the load bearings. Do not use compressed air on the !M bearings. The bearings are sealed and permanently lubricated. The air can force the lubricant out of the bearings.

Clean all of the parts of the scissor arm assembly with solvent. Dry the parts with compressed air. Inspect the parts of the scissor arm assembly for damage and wear. Replace all bushings and load bearings.

Assembly and Installation (See Figure 8-14) WARNING: The points between the scissor arms and the innerframe are pinch points and can cause !M an injury.

Do NOT put your finger in the hole when you remove the pins at the scissor arm weldment. Use a brass drift to remove the pins.

NOTE: Use safety chains on the inner frame and mast weldments to keep the inner frame and mast weldments from moving. Install the safety chains as described in SAFETY PROCEDURES. NOTE: Always use new bushings and load bearings. Install a thin coat of multi-purpose grease on all new bushings, all thrust washers, all shims, all stub shafts and all pins of the scissor arm assembly.

1. Use a crane and chains or slings as a support for scissor arm weldment "B". Do not damage the hose sheave mount. Move the weldment into a position of alignment to install the pins that fasten the weldment to the inner frame. Install the bushings, pins and roll pins. See Items 5, 6 and 7 of Figure 8-14. Slowly lower the weldment so that it hangs from the pins. Remove the crane and chains or slings.

WARNING: The scissor arms are heavy and can cause an injury if allowed to fall. Have another person help you support the scissor arm during removal and installation.

2. Install two thrust washers and the bushing on each stub shaft of scissor arm weldment "B". Install scissor arm

Sheet 10: Mast and Reach Assembly "2B" on scissor arm weldment "B" as shown in Figure 8-14. Make sure there are two thrust washers on each side of the scissor arm. Tighten the three capscrews at the end cap to 41 Nm (30 Ibf ft) torque.

3. Install two of the thrust washers and the bushing on the stub shaft at the end pivot of scissor arm "2B".

4. Install the crane and chains or slings as a support for scissor arm weldment "A". Move the weldment into a position of alignment to install the weldment on scissor arm "2B". Install the weldment, the other two thrust washers, the end cap, a new special lockwasher and the two capscrews. Tighten the two capscrews to 39 Nm (29 Ibf ft) torque. Bend the corners of the special lockwasher against the flat of each capscrew.

WARNING: The scissor arms are heavy and can cause an injury if allowed to fall. Have another !M person help you support the scissor arm during removal and installation.

5. Install scissor arm "1 B" on scissor arm weldments "B" and "A" as shown in Figure 8-14. Make sure there are two thrust washers on each side of the scissor arm at the center pivot. Also make sure there are two thrust washers on each side of the arm of scissor arm weldment "A". Use new special lockwashers at the end pivots.

Tighten the three capscrews at the center pivot to 41 Nm (30 Ibf ft) torque. Tighten the two capscrews at the end pivots to 39 Nm (29 Ibf ft) torque. Bend the corners of the special lockwashers against the flat of each capscrew.

WARNING: The scissor arm assembly is heavy and can cause an injury during installation. NEVER put any part of your body between the inner frame and the scissor arm assembly. NEVER put any part of your body between the parts of the scissor arm assembly.

CAUTION: Do not let the load bearings or shims fall off the scissor arms.

6. Slowly raise the weldment so you can install the shim sets and load bearings on scissor arms "1 B" and "2B" as marked during removal. If necessary, use tape to keep the load bearings on the scissor arms.

7. Use the crane to slowly raise scissor arm weldment "B" by lifting weldment "A" to align the load bearings with the removal notches in the inner frame. Use the crane to move the scissor arm assembly so that the load bearings move into the channels.

8. Slowly raise scissor arm assembly to align the mounts with the rod ends of the reach cylinders. Install the bushings, pins and roll pins to fasten the reach cylinders to the scissor arm weldment.

WARNING: The scissor arms are heavy and can cause an injury if allowed to fall. Have another person help you support the scissor arm during removal and installation.

9. Move scissor arm weldment "A" for alignment and install scissor arm "2A" on scissor arm weldments "A" and "B" as shown in Figure 8-14. Make sure there are two thrust washers on each side of the scissor arm at the center pivot. Tighten the three capscrews at the center pivot to 41 Nm (30 Ibf ft) torque. Also make sure there are two thrust washers on each side of the arm of scissor arm weldment "B". Tighten the two capscrews at the end pivots to 39 Nm (29 Ibf ft) torque. Bend the corners of the special lockwashers against the flat of each capscrew.

Install scissor arm "1 A" using the same procedure.

WARNING: Be careful when removing or installing snap rings. These snap rings are large and can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear eye and face protection during removal or installation.

CAUTION: Do not let the load bearings or shims fall off the scissor arms.

10. Install the shims and load bearings on scissor arm weldment "A" as marked during removal and disassembly. If necessary, use tape to keep the load bearings on the scissor arms. Install the hoses on the hose sheaves and install the hose sheaves and snap rings at the mounts of the scissor arm weldments.

INNER FRAME ASSEMBLY NOTE: If the scissor arm assembly will be removed, it is easier to remove while the inner frame is still installed in the mast. See SINGLE REACH SCISSOR ARMS-REMOVAL AND DISASSEMBLY-or DOUBLE REACH SCISSOR ARMS-REMOVAL AND DISASSEMBLY- to remove the scissor arm assembly.

Removal (See Figure 8-15) CAUTION: Do NOT operate the tilt or sideshift functions if the outer frame has been removed. !M Hydraulic oil can come out of the hoses.

Sheet 10: Mast and Reach Assembly NOTE: Remove the inner frame to replace the reach assembly load rollers or side rollers. Other repairs to the inner frame can be done without removing the inner frame. The inner frame can be removed by removing the complete reach assembly from the mast as one assembly. The inner frame assembly can also be removed after the scissor assembly has been removed.

1. If the scissor arm assembly is installed, operate the REACH/RETRACT control handle to fully retract the forks.

Use safety chains to fasten the parts of the reach assembly so that the forks cannot extend.

2. Operate the LIFT/LOWER control handle to raise the reach assembly or inner frame assembly until the thrust rollers of the inner frame are above the top of the outer weldment.

3. Move the key to the OFF position and disconnect the battery.

NOTE: Use safety chains on the inner frame and mast weldments to keep the inner frame and mast weldments from moving. Install the safety chains as described in SAFETY PROCEDURES. 4. Use safety chains to fasten the reach assembly or inner frame assembly and inner weldment of the mast so that they cannot move.

WARNING: Be careful when removing or installing snap rings. These snap rings are large and can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear eye and face protection during removal or installation.

5. Remove the snap rings, washers, thrust rollers and spacers. Install labels on the thrust rollers for correct installation during installation.

6. Remove the safety chains installed in Step 4. Lower the reach assembly or inner frame assembly for access to the chain anchors of the inner frame. Install safety chains so that they support the reach assembly or inner frame and the lift chains become loose. Move the key to the OFF position and disconnect the battery.

WARNING: Lift chains, hoses and cables can roll over the sheaves to fall and cause an injury if the !M ends are not fastened. Keep control of the ends of the lift chains, hoses and cables as they are removed. Use wire to temporarily connect the ends of the lift chains, hoses or cable to the masts.

NOTE: Removing the pins, at the chain anchors, will disconnect the lift chains without changing the chain adjustment. Always adjust the chains if new lift chains or other components are installed.

7. Hold the lift chains to keep them from falling and remove the pins in the chain anchors of the inner frame.

Disconnect the lift chains. Carefully fasten the ends of the lift chains so that they do not move over the chain sheaves.

Sheet 10: Mast and Reach Assembly

Figure 8-15 -Inner Frame 1. INNER FRAME 2. COVER 3. STOP 4. SHIM 5. BUSHING 6. LOAD ROLLER 7. SNAP RING 8. WEAR PLUG 9. SIDE ROLLER 10. LOCKWASHER 11. CAPSCREW 12. SPACER 13. THRUST ROLLER 14. WASHER 15. STOP SUPPORT 16. ADJUSTMENT SCREW 17. JAM NUT WARNING: The reach assembly or inner frame assembly is heavy and can cause an injury if it tips or falls. Make sure the reach assembly is stable during and after removal.

8. Install lifting eyes in the reach assembly or inner frame assembly for chains or slings. Fasten chains or slings to the lifting eyes. Use a crane to raise the reach assembly or inner frame assembly high enough to disconnect the hydraulic lines at the manifold block. Put tags on the fittings for correct connection during installation. Make sure to put caps on the open fittings and ports to keep dirt out of the system. Install labels for correct connection of the wires and disconnect the electrical connections at the selector valve.

CAUTION: Do not damage lift chains, hoses or electrical cables as the reach assembly is lifted out of the mast weldment.

9. Carefully lift the reach assembly or inner frame assembly out of the inner weldment. Carefully lower the reach assembly or inner frame assembly to the floor.

WARNING: Make sure that the reach assembly is stable and cannot fall to cause an injury. Make sure the safety chains are still installed (Step 1). If the forks are removed, put the reach assembly (or inner frame assembly) on the floor so that the mast side is on top.

Sheet 10: Mast and Reach Assembly NOTE: The side rollers must be adjusted while the reach assembly is out of the mast channels. Adjust the side rollers as described in CHECKS AND ADJUSTMENTS. Disassembly (See Figure 8-15) NOTE: It is usually not necessary to remove all the parts of the inner frame assembly. Remove only the necessary parts to do the repair. The thrust rollers are removed during removal of the inner frame assembly.

1. If necessary, remove the reach cylinders. See REACH CYLINDERS. 2. Remove the jam nuts and set screws for the load rollers.

3. If necessary, replace the wear plugs by pushing at the back of the wear plug. See Figure 8-16.

WARNING: Be careful when removing or installing snap rings. These snap rings are large and can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear eye and face protection during removal or installation.

4. Remove the snap rings from the stub shaft for the load roller.

5. Use a prybar to remove the load roller from the stub shaft for the load roller. See Figure 8-17.

6. Remove the capscrews that fasten the side roller brackets. Remove the side rollers and shim sets. Install labels for correct installation of the shim sets in the same positions. When the new side rollers are installed, the shim arrangement will normally be the same or similar.

7. If necessary, remove the cover for the REACH/TILT selector valve.

8. If necessary, remove the hydraulic lines and hoses.

9. If necessary, remove the REACH/TI LT selector valve. See REACH/TILT SELECTOR VALVE to repair the valve.

Figure 8-16 -Load Roller and Wear Plug Assembly 1.

2.

3.

4.

5.

6.

7.

LOAD ROLLER WEAR PLUG SNAP RING SET SCREW JAM NUT STUB SHAFT INNER FRAME

CAUTION: Do NOT use steam to clean the load bearings. Do not use compressed air on the bearings. The bearings are sealed and permanently lubricated. The air can force the lubricant out of the bearings.

Clean all of the parts of the inner frame with solvent. Dry the parts with compressed air. Inspect the parts of the inner

Sheet 10: Mast and Reach Assembly frame for damage and wear. Inspect all rollers for cracks, flat spots or bearings that do not turn freely. Replace any roller that shows wear or is damaged.

Assembly (See Figure 8-15) WARNING: The inner frame assembly is heavy and can cause an injury if it tips or falls. Make sure the innerframe assembly is stable before installing any parts.

WARNING: Be careful when removing or installing snap rings. These snap rings are large and can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear eye and face protection during removal or installation.

NOTE: If the scissor arms are not installed, install the inner frame in the mast before installing the scissor arm assembly. See INNER FRAME ASSEMBLY-INSTALLATION.

Figure 8-17 -Removing Load Roller 1. LOAD ROLLER WITH SNAP RING REMOVED 2. PRYBAR 3. MAST OR CARRIAGE COMPONENT(CARRIAGE SHOWN) Install all parts that were removed. If necessary, install the selector valve as described in REACH/TILT SELECTOR VALVE-INSTALLATION. Install all shim sets in the original positions as marked during removal. Use new snap rings.

Install the load rollers on the inner frame. Install the shims at each location as marked during disassembly.

Adjust the carriage side rollers during assembly. See ADJUSTMENTS in CHECKS AND ADJUSTMENTS. If the rod ends of the reach cylinders were removed, the reach cylinders must be adjusted after the reach assembly is completely assembled and installed in the mast. See ADJUSTMENTS in CHECKS AND ADJUSTMENTS. Installation (See Figure 8-15) NOTE: If the scissor arm assembly will be installed in the innerframe, it is easierto install afterthe innerframe is installed in the mast. See SINGLE REACH SCISSOR ARMS or DOUBLE REACH SCISSOR ARMS to install the scissor arm assembly.

NOTE: The side rollers must be adjusted while the reach assembly is out of the mast channels. Adjust the side rollers as described in CHECKS AND ADJUSTMENTS. 1. Install lifting eyes in the reach assembly or inner frame assembly for chains or slings. Fasten chains or slings to the lifting eyes. Use a crane to raise the reach assembly or inner frame assembly to align the load rollers with the channels of the inner weldment of the mast. Carefully lower the inner frame assembly into the mast channels. Continue to lower the assembly to a position to connect the hydraulic lines at the manifold block.

NOTE: Use safety chains on the inner frame and mast weldments to keep the inner frame and mast weldments from moving. Install the safety chains as described in SAFETY PROCEDURES.

Sheet 10: Mast and Reach Assembly 2. Use safety chains to fasten the carriage or inner frame assembly and inner weldment of the mast so that they cannot move.

WARNING: Lift chains, hoses and cables can roll over the sheaves to fall and cause an injury if the ends are not fastened. Keep control of the ends of the lift chains, hoses and cables as they are installed.

3. Connect the hydraulic hoses from the mast to the manifold block as marked during removal. Connect the electrical wires of the electrical cable to the selector valve as marked during removal.

4. Use new cotter pins and install the lift chains on the chain anchors of the inner frame.

NOTE: The lift chains must be adjusted if the nuts of the chain anchors at the mast were removed. Adjust the lift chains as described in CHECKS AND ADJUSTMENTS. 5. Install the thrust rollers as marked during removal. If the thrust rollers are replaced, install the correct size (74, 76 or 78 mm (2.88, 2.96 or 3.04 in) O.D.) thrust rollers. See CHECKS AND ADJUSTMENTS at the end of this section.

6. Remove the safety chains and the lifting eyes from the carriage or inner frame.

CAUTION: Do NOT operate the tilt or sideshift functions if the outer frame has been removed. Hydraulic oil can come out of the hoses.

7. After all hydraulic lines are connected, operate the functions to check for leaks and correct operation. Remove the air from the system as described in CHECKS AND ADJUSTMENTS. TRIPLEX MAST ASSEMBLY (See Figure 8-19 and Figure 8-21) Removal NOTE: If the mast assembly will be disassembled after it is removed from the truck, first remove the carriage assembly or the NR or NDR reach assembly as a complete unit. See CARRIAGE ASSEMBLY or REACH ASSEMBLY-REMOVAL AND INSTALLATION. If the reach assembly will be removed with the mast assembly, operate the REACH/RETRACT control handle to fully retract the forks. Install safety chains so that the forks cannot extend. Install the safety chains around the center plates of the scissor arm weldment and a crossmember of the mast. Make sure a safety chain does not touch the mount for the hose sheave, lift chains, chain or hose sheaves, hoses, tubes or fittings. If installed, operate the SIDESHIFT control handle to move the outer frame to the center position.

1. Remove the capscrew and nuts that fasten the wire guard and remove the guard. See Figure 8-18.

2. Remove the capscrews that fasten the rear leg to the overhead guard. See Figure 8-18. The overhead guard will be removed with the mast assembly.

Sheet 10: Mast and Reach Assembly

Figure 8-18 -Overhead Guard and Mast Guard 1.

2.

3.

4.

5.

6.

OVERHEAD GUARD LEG MAST CAPSCREW LEG CAPSCREW MAST GUARD CAPSCREW

CAUTION: Do NOT move the control handle for the reach, retract, tilt or sideshift functions. Oil will flow from the hoses for these functions.

3. Operate the LIFT/LOWER control handle to raise the inner weldment high enough to remove the four capscrews, the shims and the nut plates that fasten the bottom of the mast to the truck frame.

4. Install safety chains to keep the mast components from moving. Remove the capscrews, washers and clamps that fasten the lift cylinder hoses to the mast weldments. Do NOT disconnect any hydraulic fittings.

5. Remove the safety chains installed in Step 4. Do not damage hydraulic hoses as the mast lowers. Carefully operate the LIFT/LOWER control handle to fully lower the inner weldment. Make sure that all hydraulic pressure is removed from the system.

6. Mark the trunnion caps so they can be reassembled in the same position and on the same trunnion from which they are removed. Use chain to connect a crane or other lifting device to the top of the mast assembly. Operate the crane until it gives support to the weight of the mast assembly. Move the crane to a position so that the mast assembly will be lifted vertically. Make sure the chains will not damage the sheaves or other parts of the mast assembly. Make sure the chains and crane have the capacity to lift approximately 2000 kg (4500 Ibs). Use safety chains to fasten all the mast weldments together so that they cannot move. If installed, install a chain or sling to the reach or carriage assembly to keep the mast assembly from tipping during removal. Remove the four capscrews that fasten the trunnion caps.

7. Raise the mast assembly high enough to clear the trunnions. Move the mast assembly approximately 30 cm (1 ft) away from the truck for access to the hoses.

8. Install labels on the bulkhead hoses for correct connection during installation. Disconnect the mast and carriage or reach hoses from their fittings as required. Install caps on the fittings and hoses to prevent leakage.

9. Install labels on all plugs and wires for the electrical cable for correct connection during installation. Disconnect the plugs and wires so that the cable is completely disconnected from the truck. The plugs are near the cable tension device inside the electrical compartment above the battery.

10. Move the mast assembly away from the truck.

Sheet 10: Mast and Reach Assembly 11. Lower the carriage or reach assembly so that the safety chains are the support for the carriage or reach assembly and the lift chains do not have tension.

12. If the mast will be disassembled, put the mast on a level floor with the overhead guard on the bottom as a support. Install a support under the other end. Make sure the mast is level. Keep the safety chains on the mast assembly that were installed in Step 6.

13. If the mast will NOT be disassembled, put the mast on a level floor with the overhead guard on top.

Cleaning and Inspection WARNING: Cleaning solvents can be flammable and toxic, and can cause skin irritation. Wear protection for eyes and skin. When using cleaning solvents, always follow the recommendations of the manufacturer.

1. Clean the mast weldments with steam or solvent.

WARNING: Some parts can be damaged by welding and cause an injury. Get authorization and !M instructions from your Yale lift truck dealer before welding on the mast, reach or carriage assembly.

Sheet 10: Mast and Reach Assembly

Figure 8-19 -Triplex Mast Assembly 1.

2.

3.

4.

5.

INNER WELDMENT INTERMEDIATE WELDMENT OUTER WELDMENT FREE LIFT CYLINDER MAIN LIFT CYLINDER A. LOCK PLATE B. RETAINER 6. SHEAVE SUPPORT ASSEMBLY A. SPACER B. SNAP RING C. BALL BEARING D. CHAIN SHEAVE

Sheet 10: Mast and Reach Assembly E. SPACER (NS ONLY) F. SHAFT 7. FREE LIFT CHAIN 8. CHAIN ANCHOR 9. CLAMP 10. CHAIN SHEAVE ASSEMBLY (RH) A. CHAIN SHEAVE B. BALL BEARING C. SNAP RING 11. MAIN LIFT CHAIN 12. LOAD ROLLER 13. FREE LIFT HOSE SHEAVE 14. FLOW REGULATOR HOUSING 15. HYDRAULIC TUBE (MAIN LIFT) 16. HYDRAULIC HOSE (MAIN LIFT) 17. TRUNNION STUB SHAFT 18. TO TRUCK CONTROL VALVE 2. Inspect the sliding and rolling surfaces of the channels for damage (dents) and wear (grooves). Inspect all welds for cracks.

Free Lift Cylinder-Removal and Installation (See Figure 8-19, Figure 8-22 and Figure 8-22) NOTE: Cylinder seals can be replaced without removing the cylinder from the mast assembly.

NOTE: The following procedure describes how to remove the free lift cylinder without removing the reach or carriage and mast assembly from the lift truck. If the reach or carriage assembly has been removed, do only Steps 4 throughl2 to remove and install the cylinder.

1. Operate the REACH/RETRACT control handle to fully retract the forks. Use safety chains to fasten the parts of the reach assembly so that the forks cannot extend.

2. Raise the reach approximately 60 cm (2 ft). Use safety chains between the reach assembly and inner weldment to prevent the reach assembly from lowering. Operate the LIFT/LOWER control handle to retract the free lift cylinder.

3. Remove the load backrest extension as described in LOAD BACKREST EXTENSION-REMOVAL AND INSTALLATION. 4. Fasten the free lift chains so that they cannot move over the sheaves. Remove the cotter pins from the pins that fastens each free lift chain to the chain anchor at the free lift cylinder. Carefully remove these pins. This removal procedure will not change the chain adjustment.

5. If there are also hose and cable sheaves in the sheave support, disconnect the hoses at the free lift cylinder.

Install caps on the hydraulic fittings. Disconnect the spring of the cable tension device. See Figure 8-21.

6. Lift the sheave support assembly out of the free lift cylinder and put the lift chains, hoses, cable and sheave support over the carriage or reach assembly or fasten them out of the way.

7. Hold the LIFT/LOWER control lever in the LOWER position for approximately five seconds to fully retract the free lift cylinder rod and to remove all hydraulic pressure. It can be necessary to push the rod into the cylinder while the control lever is in the LOWER position.

WARNING: Make sure that the power is off and the keyis removed. Puta"DO NOT OPERATE"tag in the operator's compartment. Disconnect the battery and put a tag or lock on the battery connector.

8. Loosen, but do not remove, the nuts for the main lift chains at the chain anchors near the top of the outer weldment. The inner weldmentwill lower so that the free lift hose does not have tension.

9. Disconnect the hydraulic hose from the free lift cylinder and install caps on the fittings.

10. Remove the cylinder strap. Use a crane and sling to lift the free lift cylinder off the locating screw and out of the inner weldment. If the free lift cylinder must be disassembled, seethe HYDRAULIC SECTION. 11. Reverse the procedure to install the cylinder. Make sure the locating screw for the base of the free lift cylinder is

Sheet 10: Mast and Reach Assembly installed before installing the cylinder. Use a crane and sling to install the cylinder on the inner weldment.

12. Adjust the main lift chains. Check for hydraulic leaks and correct operation after the cylinder is installed. See CHECKS AND ADJUSTMENTS. Main Cylinders-Removal and Installation (See Figure 8-19) NOTE: It is necessary to remove the mast assembly from the truck to remove the main cylinders.

1. Remove the mast assembly as described in TRIPLEX MAST ASSEMBLY-REMOVAL. 2. Remove the safety chains that fasten the mast weldments together and use a prybar to carefully and slowly move the intermediate weldment approximately 75 mm (3 in) out of the outer weldment.

3. Install a sling and crane to support the cylinder. Remove the capscrews, washers and lock plate at the base of one main cylinder.

WARNING: Be careful when removing or installing snap rings. These snap rings are large and can come loose during removal or installation with enough force to cause an injury. Always use the correct snap ring pliers and wear eye and face protection during removal or installation.

4. Remove the snap ring, back-up washer, rubber bushing and shims (if applicable) that fasten the cylinder rod to the intermediate weldment. If shims are used, make a note of the shim arrangement. Normally, the shim arrangement for the replacement cylinder will be similar.

5. Remove the hose or tube between the main cylinder and the flow regulator. If necessary, use a prybar to carefully move the reach assembly or carriage assembly and mast weldments for access. Install a cap on the regulator fitting to prevent leakage.

6. Remove the main cylinder retainer, capscrews and washers.

7. Repeat the Steps 2 through 7 to remove the other main cylinder.

NOTE: Seethe HYDRAULIC SECTION to disassemble and repair the cylinder.

8. Reverse the procedure to install the main cylinders.

9. Push the cylinder toward the top of the mast assembly to move the main cylinder off the locating dowel pin.

Continue to push the cylinder so that the rod moves into the cylinder to allow removal from the intermediate weldment.

Sheet 10: Mast and Reach Assembly

Figure 8-20 -Triplex Hose Routing for Sideshift or Reach Carriage 1. CHAIN SHEAVE 2. HOSE SHEAVE 3. CABLE SHEAVE 4. CABLE TENSION DEVICE 5. TO TRUCK 6. ELECTRICAL CABLE FOR REACH ASSEMBLY 7. MANIFOLD BLOCK 8. TO REACH ASSEMBLY 9. HYDRAULIC HOSES 10. SHEAVE SUPPORT 11. TRUNNION STUB SHAFT Inner and Intermediate Mast Assemblies-Removal and Installation (See Figure 8-19, Figure 8-21, and Figure 8-22) 1. The load rollers and wear plugs must be removed to remove the inner or intermediate weldments. See LOAD ROLLERS AND WEAR PLUGS-REMOVAL AND INSTALLATION. 2. The lift chains, hoses and electrical cable must also be removed to remove the inner or intermediate weldments.

To remove the lift chains, hoses and sheaves, see TRIPLEX LIFT CHAINS-REMOVAL AND INSTALLATION, HOSES-REPLACE, TRIPLEX CHAIN SHEAVES-DISASSEMBLY AND ASSEMBLY and HOSES AND CABLE SHEAVES-REPLACE. 3. Use safety chains to fasten the intermediate weldment to the outer weldment. Use a crane or lifting device to support the inner weldment while sliding it out of the intermediate weldment.

4. Remove the safety chains that fasten the intermediate weldment to the outer weldment. Use a crane or lifting device to support the intermediate weldment while sliding it out of the outer weldment.

5. Reverse the removal procedure to install both the intermediate and inner weldments into the outer weldment.

Install the load rollers and wear plugs during assembly of the mast weldments.

Hoses-Replace (See Figure 8-21 and Figure 8-22) 1. To replace any hydraulic hoses, fully lower the carriage or reach assembly. Make sure that the system does not have hydraulic pressure. Hold the control lever (for each function) in the forward position for approximately five seconds to release the pressure. Make sure the hydraulic pump does NOT operate. Move the key to the OFF

Sheet 10: Mast and Reach Assembly position. Disconnect the battery and put a tag or lock on the battery connector.

NOTE: Access can be difficult for some fittings. If necessary, operate the system to move mast weldments or the carriage or reach assembly. Make sure to follow the SAFETY PROCEDURES after moving components BEFORE starting work. Also make sure the system does not have pressure as described in Step 1.

2. Disconnect hoses, drain any excess oil into a container and install caps to prevent dirt from entering the hydraulic system.

3. Replace the hose. Operate the system to remove all the air from the oil and to check for leaks.

Hose and Cable Sheaves Replace (See Figure 8-21 and Figure 8-22) WARNING: The mast weldments can move and cause an injury even if the mast assembly has been removed from the lift truck. Make sure the mast assembly is level to prevent the components from moving without being moved.

Use safety chains to prevent movement after components are in the correct position.

NOTE: The following procedures describe how to replace the hose and cable sheaves without removing the carriage or reach assembly or mast assembly from the lift truck. If the mast assembly has been removed, carefully move the carriage or reach assembly, inner or intermediate weldments using a prybar as necessary.

Free Lift Hose Sheave Remove the sheave, for the hose to the free lift cylinder, as follows: 1. Fully retract the forks if the reach assembly is installed. Move the key to the OFF position. Disconnect the battery and put a tag or lock on the battery connector. Install safety chains between the tops of the inner and outer reach weldments of the reach assembly to prevent reach operation.

2. Operate the LIFT/LOWER control lever to raise the inner weldment. Use safety chains to fasten the reach assembly or carriage assembly and inner weldment so that they cannot move and the bottom of the inner weldment is approximately 60 cm (2 ft) off the floor.

3. Lower the carriage or reach assembly so that the safety chains are the support for the carriage or reach assembly and inner weldment. The lift hose for the free lift cylinder must not have tension.

4. Remove the snap ring, washer, free lift hose sheave and spacer at the bottom of the intermediate weldment.

5. Follow the reverse procedure to install the hose sheave for the free lift cylinder.

Carriage or Reach Sheaves-Removal and Replacement Remove the sheaves, for the hoses and cable to the carriage or reach assembly as follows: 1. Fully lower the carriage or reach assembly. Fully retract the forks if the reach assembly is installed. Install safety chains between the tops of the inner and outer weldments of the reach assembly to prevent reach operation.

WARNING: The mast weldments can move and cause an injury. Make sure the mast assembly is level with the carriage or reach assembly side on top to prevent unexpected movement of the mast weldments.

CAUTION: Do NOT use steam to clean the lift chains, sheaves or load rollers. The sheaves and roller bearings are sealed and permanently lubricated. Do not use compressed air on the bearings. The air can force the lubricant out of the bearings.

2. Make sure that the system does not have hydraulic pressure. Hold the control lever (for each function) in the forward position for approximately five seconds to release the pressure. Make sure the hydraulic pump does NOT operate. Move the key to the OFF position. Disconnect the battery and put a tag or lock on the battery connector.

3. Fasten the carriage or reach assembly hoses. Install the reach assembly electrical cable to the top ofthe sheave support at the free lift cylinder. Disconnect or remove the hoses at the carriage or reach assembly. Install caps to prevent dirt from entering the hydraulic system.

4. Install tags on the connectors and wires of the electrical cable at the reach assembly for correct connection later.

Disconnect the electrical cable.

Sheet 10: Mast and Reach Assembly 5. Install tags on the hydraulic hoses at the reach assembly for correct connection later. Disconnect the hoses and install caps to prevent dirt from entering the hydraulic system.

Figure 8-21 -Hose and Cable Assemblies-Inner and Intermediate Weldments 1. HOSE SHEAVE 2. ELECTRICAL CABLE SHEAVE 3. SPACER 4. WASHER 5. CAPSCREW 6. CHAIN SHEAVE FOR MAIN LIFT 7. HOSE GUARD 8. SNAP RING 9. INTERMEDIATE WELDMENT 10. INNER WELDMENT 11. HOSE AND CABLE SHEAVE ASSEMBLY AT SHEAVE SUPPORT 12. ELECTRICAL CABLE (REACH ONLY) 13. TO SHEAVE SUPPORT AND CARRIAGE OR REACH ASSEMBLY 14. TENSION DEVICE FOR ELECTRICAL CABLE 15. MANIFOLD BLOCK 16. TO TRUCK 17. FREE LIFT CYLINDER

Sheet 10: Mast and Reach Assembly 18. HYDRAULIC HOSE FROM SHEAVE SUPPORT 19. HYDRAULIC HOSE TO CARRIAGE

Figure 8-22 -Hose and Cable Assemblies-Outer Weldment 1. HOSE BRACKET 2. TO FLOW REGULATOR 3. TO FREE LIFT CYLINDER 4. TENSION DEVICE 5. HOSE TO MANIFOLD BLOCK (EACH SIDE OF WELDMENT) 6. HOSE BRACKET (EACH SIDE OF WELDMENT) 7. TO REACH OR CARRIAGE ASSEMBLY 8. ELECTRICAL CABLE FOR REACH ASSEMBLY 9. TO LIFT TRUCK 10. HYDRAULIC HOSE (LIFT) 11. LIFT TRUCK FRAME 12. HOSE TO RIGHT MAIN CYLINDER

Sheet 10: Mast and Reach Assembly 13. TUBE TO LEFT MAIN CYLINDER 14. FLOW REGULATOR HOUSING 15. REGULATOR MOUNT PLATE 16. MAIN LIFT CYLINDERS 17. OUTER WELDMENT

Sheet 11: Battery and Charging System BATTERY AND CHARGING SYSTEM BATTERY AND CHARGING SYSTEM-GENERAL This section describes selection and maintenance of large batteries used in electric lift trucks. This information pertains to the service personnel that maintain industrial truck batteries.

SAFETY TIPS FOR HANDLING INDUSTRIAL TRUCK BATTERIES 1. WARNING: Disconnect the battery from the lift truck when doing maintenance and repair work.

Why -The live current may cause arcing or a short circuit with attendant damage to equipment or injury.

2. WARNING: Wear rubber apron, gloves, boots and goggles, when handling, checking, filling, charging or repairing batteries.

Why -To protect yourself against burns resulting from accidental spillage of electrolyte -a mixture of sulfuric acid and water.

3. WARNING: Keep open flames away from batteries - do not check electrolyte level with a cigarette lighter or match. USE A FLASHLIGHT OR PERMANENT LIGHT. Do not smoke or create sparks.

Why -The space between the underside of the cover and the top of the electrolyte in the cell usually contains a hydrogen oxygen mixture which is explosive when ignited.

4. WARNING: Be sure water is readily available in case electrolyte accidentally splashes on your skin or clothing.

Extreme care should be taken in flushing electrolyte from the eye. Use plain water only and obtain medical attention immediately.

Why -Volumes of water applied quickly and continuously will prevent serious injury to the skin. Quick medical attention is necessary to assure proper care and treatment.

5. WARNING: Apply strong neutralizer such as baking soda when acid is spilled on the floor and clean up promptly.

Why -Baking soda will neutralize the acid and make it safe to clean or flush from the floor.

6. WARNING: Take proper care in melting the sealing compound when preparing to seal a battery. Avoid puncturing the hard surface of partially melted compound with a screwdriver or other sharp tool. Compound may ignite if it is heated too rapidly.

Why -The hot liquid may squirt up and burn your hand, face or body. If it should catch fire it creates the hazard of an open flame. Burning consumes oil in the compound and impairs its useful characteristics.

Sheet 11: Battery and Charging System Figure 9-1 -Lead-Acid Industrial Truck Battery 7. Remove vent caps from nearby cells when preparing to assemble a repaired cell into the battery. Cover the vent holes with layers of damp cloth before using lead burning equipment on the intercell connectors in order to integrate the cell into the battery circuit. Also, use dark glasses to protect the eyes.

Why -To prevent a possible hydrogen oxygen concentration from exploding when a flame is lit.

8. Be sure to shut off the power when changing or repairing plugs or receptacles that are connected to the charging equipment. This will prevent a short circuit and arcing.

Why -A short circuit may injure you. Arcing may cause explosion and fire.

9. Before removing the terminal lugs from the receptacle when repairing a damaged or dirty plug or receptacle connected to a battery, the battery circuit must be opened or "broken".

Why -The leads which terminate in the receptacle are live or "hot" with the total voltage of the battery existing across the terminals. If the terminal lugs are accidentally touched together a short circuit or arcing will occur with its attendant danger.

10. WARNING: When mixing acid to prepare electrolyte, ALWAYS POUR ACID SLOWLY INTO WATER and never water into acid. Always store acid in plastic or glass container.

Why -If water should be added to acid it will not readily mix and will splash the acid due to the great difference in the specific gravity of the two liquids. The effect of splashed acid is dangerous.

11. WARNING: Always lift batteries with mechanical equipment such as a hoist, crane or lift truck. Move batteries horizontally with powertracks, conveyors or rollers. Make sure that hoist hooks, spreader bars and other tools are of ample strength and properly installed. Cover top of battery with rubber mat or other insulating material to prevent external short circuits from chains or cables falling on top of battery.

Why -Batteries are a heavy concentrated load and might easily cause painful strains or injury to your feet or hands.

Batteries may be seriously damaged or electrolyte spilled if the battery is dropped.

12. Make sure that charging plugs and receptacle are properly locked and all other connections tight, secure and free from friction.

Why -A loose connection may mean sparking or even arcing with attendant danger of gas explosion.

13. Allow only authorized personnel (qualified by training and experience) in the battery room.

Why -An untrained or inexperienced person may unknowingly break normal rules for proper handling, causing injury to themselves and damage to batteries and equipment.

14. Enclose all bare wires and buss bars in the battery room by wire guards, guard rails or other means of isolation from general plant traffic.

Why -Any open high current transmission equipment is a possible hazard to you, other workers and equipment.

15. Never lay metal tools such as wrenches or other material on top of an open battery.

Why -Sparking and short circuiting will occur and the battery will quickly be discharged or may explode.

16. Check batteries for cracks or leaks. Repair at once.

Why -Electrolyte will spill on floor or equipment, causing corrosion of the steel tray and related equipment.

Continuous flow of leaking electrolyte can cause a ground bath that reduces battery life and capacity.

17. When batteries are disposed of as scrap at the end of useful life, they should be sent to a authorized recycling center or salvage dealer.

Why -Even an old battery no longer capable of useful life may have enough residual voltage left to cause a spark if filled with electrolyte.

18. Familiarize yourself as completely as possible with batteries and the proper rules for their charging, handling and maintenance.

Sheet 11: Battery and Charging System Why -Full knowledge of batteries and the dangers of improper handling will pay dividends in the elimination of injuries and damage.

CAUTION: Keep vent plugs in the cells at all times, except when taking hydrometer readings, adjusting specific gravity and electrolyte levels, troubleshooting or assembling a repaired cell.

NOTE: Your company, industry and government safety regulations should be reviewed to help reduce accidents and damage to equipment.

NOTE: If batteries are not in use, keep them charged. Check specific gravities monthly and give a freshening charge (3 to 4 hours at the finish rate) if the gravities have fallen 30 points (.030) or more, otherwise, give freshening charge every three months.

BATTERY TROUBLESHOOTING PROBLEM Battery Overheats On Discharge

POSSIBLE CAUSE Over discharge Excessive load

Not fully charged prior to work assignment, resulting in over discharge Electrolyte levels low When overheating is confined to few cells, nearby operating equipment may be source Operating in high ambient temperatures Low Electrolyte Level

Broken or cracked jar Water additions neglected or cell missed in previous water addition.

Overcharging a. Voltage relay set for many cells b. Timer set for too many hours c. Voltage change rate relay operating

Specific Gravity Between Cells Not Uniform

Overfilled with water Operating cell with cracked jar Acid not adjusted properly after jar change Vent caps removed during operation Electrolyte leaking through sealing compound Operating battery with broken coil cover Neutralizing agent in cell

Unequal Cell Voltages

Unequal cell voltages Over discharge. Also more than .020 points spread in specific gravity from average Lack of equalizing charges Internal shunt

CORRECTION Limit discharge to 1.110 specific gravity.

Put more batteries into service. Set up more frequent charging schedule.

Determine cause of overload and correct.

Put more batteries into service if equipment requirements exceed battery capacity.

Needs more frequent and complete charging.

Add water as required. Do not assign battery to work if levels are below top of plates.

Install heat insulating material between equipment cells with air circulating space between.

Provide cool location for charging and good ventilation.

Replace jar.

Better maintenance supervision. Add water as required to all cells.

Adjust charging equipment. a.

Connect relay for proper number of cells. b.

Reduce time. c.

Reduce voltage value at which voltage relay operates.

Do not fill above high level -give equalizing charge and adjust acid.

Replace jar and adjust acid.

Adjust acid specific gravity.

Keep vent caps securely in place. Give equalizing charge and adjust acid.

Reseal and adjust acid.

Replace cover and adjust acid.

Keep vent caps in place at all times except when adding water. Keep battery clean.

Refer to Unequal Cell Voltages Give an equalizing charge and do not discharge below 1.110.

Give an equalizing charge periodically.

Make internal inspection of low voltage cell and correct cause. Check for split separator and moss short.

Sheet 11: Battery and Charging System BATTERY AND CHARGING SYSTEM BATTERY TROUBLESHOOTING PROBLEM Unequal Cell Voltages (Continued)

POSSIBLE CAUSE

CORRECTION

Dirty battery top

Neutralize and clean top of battery.

Cells operated with low electrolyte level

Add water as required. Give equalizing charge.

Low specific gravity of fully charged cell Adjust acid after equalizing charge.

Sediment space filled

Replace battery.

Half tap on cells for lower voltage circuit

Remove tap and connect load to battery terminals through resistance.

External source heating certain cells

Install heat insulating material between heat source and battery.

Impurities in cell

Add only distilled or approved water to electrolyte.

Take readings when charge rate is constant.

Variation in charge rate Battery Will Not Work Full Shift

Uneven cell voltages

Give an equalizing charge.

Low electrolyte levels

Refer to Low Electrolyte Level.

Battery not charged before work cycle

Check charging schedules. Do not assign discharged battery to work.

One or more jars leaking electrolyte

Replace broken jars.

Incorrect battery (number of cells) assigned to equipment

Install battery with correct voltage and capacity to equipment.

Fully charged specific gravity below normal

Adjust specific gravity to normal.

Impurities in electrolyte

Add only distilled or approved water to electrolyte.

Operator "riding the brake"

Discourage practice.

Using reverse in place of braking

Discourage practice.

Inexperienced operator

Instruct him on power conservation.

Load excessive

Use larger battery or reduce load.

Wheels, axles and bearings need grease Plan lubrication schedule.

Tires under inflated or wrong type

Plan periodic check of air pressure.

Brakes dragging

Adjust brakes properly.

Series field in motor shorted or grounded Replace field and remove ground.

Armature needs repair

Replace or repair armature.

Ground on equipment

Find ground and insulate.

Sheet 11: Battery and Charging System Excessive grades

Use larger battery or revise battery charge schedule.

Capacity or equipment assigned to job is inadequate

Reassign equipment.

LEAD-ACID BATTERIES A lead-acid battery converts chemical energy into electrical energy. The battery is discharged when the chemical reaction has occurred and the battery will not supply its rated voltage and current. A reverse chemical action must occur so that the battery can be used again. The batteries can be charged by an electric voltage and current from an outside source to provide the reverse chemical action. The lead-acid chemicals store the electrical energy until needed.

A lead-acid battery is made from several lead-acid batteries called cells. Each cell has positive and negative plates with dielectric spacers between each plate. All of the plates are in a solution of electrolyte.

Specific Gravity The strength of the electrolyte is measured in points of specific gravity. For example, a solution of sulfuric acid has a specific gravity of 1.835. Water has a specific gravity of 1.000. Electrolyte is 27% acid and 73% water and has a specific gravity of 1.275.

CAUTION: NEVER pour water into acid. The quick production of heat can cause the acid to boil and splash out of the container. ALWAYS pour acid into water when making a dilute solution of acid.

Figure 9-2 -Fully Charged Cell Chemical Reaction The cell generates a voltage (potential difference) when two different types of metal are in the electrolyte. The two metals in a lead-acid cell are lead peroxide (Pb03) for positive plates, and sponge lead (Pb) for negative plates. A potential difference of approximately two volts per cell is generated. The potential difference does not vary according to the size of the cell.

During the discharging of the cell, lead peroxide and sponge lead mixwith sulfuric acid to make lead sulfate (PbS04) on both plates. This action decreases the voltage in the cell. When the sulfuric acid is removed from the electrolyte, the specific gravity of the electrolyte decreases. The potential difference of a discharged cell is approximately 1.75 volts.

Sheet 11: Battery and Charging System

Figure 9-3 -Cell Discharging When a direct current is applied to a discharged cell, the lead sulfate is changed into lead and sulfuric acid. The lead goes to the positive plate and stays as lead and to the negative plate and stays as lead peroxide. The concentration of sulfuric acid in the electrolyte increases. The specific gravity of the electrolyte increases as the concentration of sulfuric acid increases. In a fully charged cell, the positive plate again contains the lead peroxide and the negative plate contains the sponge lead.

In a fully charged cell, the electrolyte has a specific gravity of 1.270 to 1.130. NEVER discharge a battery below a specific gravity of 1.130. The battery can have permanent damage if discharged below 1.130.

Figure 9-4 -Discharged Cell

Sheet 11: Battery and Charging System

Figure 9-5 -Cell Charging HOW TO SELECT THE BATTERY The battery needed to operate a period of eight hours depends on many conditions. Operations that require the lift truck to go up ramps or require the use of additional attachments increases the use of power from the battery. Some work conditions require that more than one battery must be used during a work period. The number of eight hour work periods per day is normally equal to the number of batteries needed. The capacity of the battery you need is found as follows: •

The size of the lift truck and the attachments.

•

The type of work. Heavy duty operation or normal operation for one eight hour work period.

•

The battery voltage you need is found as follows:

•

Will your lift truck operate on more than one voltage?

•

If you have more than one lift truck in operation, do the battery voltages need to be the same?

Lift trucks are available in various voltage ranges. The small "Motorized Hand" trucks are normally 12 to 24 volts.

Larger "Sit-down Rider" lift trucks are normally 24 to 48 volts.

Voltage of a Battery To reach the necessary battery voltage, the cells are connected in series. For example: •

24 volts 12 cell battery

•

36 volts 18 cell battery

•

48 volts 24 cell battery

Sheet 11: Battery and Charging System

Figure 9-6 -Cell Voltage Battery Ratings The ratings of batteries are measured in ampere-hours (AH) and kilowatt-hours (INVH) at a constant rate of discharge. The number and size of plates increases the amp-hour rating. A rating of six hours is the standard.

Ampere-hours is the measurement of battery capacity. To calculate ampere-hours, multiply amperes by hours. For example, 5 amperes times 5 hours is 25 ampere-hours. You cannot change the potential difference of a cell. You can increase the ampere-hour rating by increasing the number of plates in a cell, or by installation of larger plates. The constant rate of discharging can be compared to a measurement of the battery capacity and ampere-hours. For example, a battery with a rating of 600 ampere-hours during a work period of six hours will generate 100 amperes per hour for six hours. (The same battery cannot generate 300 amperes for two hours. The heat generated with the battery will damage the battery.)

Kilowatt Hours A kilowatt is 1000 watts. A watt is a measure of electric power. The capacity in kilowatt-hours is the total power generated by the battery. Watt-hours are measured by multiplying the voltage by ampere-hours. To measure the kilowatt-hours, divide the watt-hours by 1000. (volts x ampere x hours) = kilowatt hours of KWH 1,000 To calculate the kilowatt-hours for a battery that has a rating of 600 ampere-hours and a 48 volt system, use this formula.

48 x 600 =28'8 KWH ( Power available from a fully charged battery.)

1,000 All the electrical operations figure a specific watt-hours in electric energy. These operations include distances, loads, ramps, lifting heights, attachments, etc. The watt-hours can be converted to kilowatt-hours to indicate the battery needed for the operation. Always select the correct type of battery. Remember, a battery that has a rating of 300 ampere-hours will not do the same job as a battery that has a rating of 600 ampere-hours. Do not permit the specific gravity to go below the limits shown in the manual.

THE BATTERY AS A COUNTERWEIGHT On electric lift trucks that use the battery as part of the counterweight, the battery is part of the capacity of the lift truck to lift loads. The minimum weight of the battery is shown on the nameplate. If the battery is not the minimum weight, the capacity of the lift truck is reduced. If the battery used in the lift truck is less than the size of the battery compartment, blocks and spacers must be installed to hold the battery in position. The maximum allowable movement of a battery is 12.7 mm (0.5 in) from side to side and 12.7 mm (0.5 in) fore and aft. (Reference ANSI B-56.1.)

THE NEW BATTERY

Sheet 11: Battery and Charging System Inspect every new battery for damage. Make sure the electrolyte in each of the cells is at the correct level. Charge the battery for six hours or until the specific gravity is correct. Some new batteries may require cycling 7 to 10 times before the battery accepts a full charge. (Cycling is charging and then discharging the battery at a prescribed rate.

Refer to the instructions shipped with the battery.) Make sure the battery is correctly installed in the lift truck. Use a correct spreader bar with slings to lift and move the battery.

CAUTION: Always use a spreader bar and slings that lift vertically on the lifting eyes of the battery. DO NOT use a chain or sling without a spreader bar or you will damage the battery.

Use the correct blocks or spacers to hold the battery in position in the lift truck. Make sure that the battery compartment is clean and dry. All of the vents caps must be in position when the battery is in service. If the vent caps are not installed, the electrolyte will leak, causing corrosion of the battery case and in the battery compartment.

Figure 9-7 -Lifting the Battery BATTERY MAINTENANCE Battery maintenance must include a good battery charger, a clean battery, keeping the electrolyte at the correct level, and keeping a record of the battery.

1. Keep batteries clean and free of acid spills.

2. Do not over-discharge. Excessive discharge shortens battery life.

3. Do not overcharge. Overcharging produces corrosion of positive grids and excessive gassing, which loosens the active material of the plates.

4. Charge batteries in a well ventilated area to remove the explosive gases and acid fumes.

5. Maintain electrolyte at the proper level. If low, add water. Before charging, make sure tops of plates are covered; after charge, fill to recommended level. Do not add acid.

6. Keep batteries from freezing.

7. Keep batteries in a charged state.

8. Do not charge a battery with a charger that has an ampere-hour rating higher than that of the battery. This will give too high a charging current and excessive heating. Charging with a lower ampere-hour charger will cause no harm, but may require longer than 8 hours to fully charge.

Maintenance Records Always complete the Battery Inspection Report and the Daily Battery Report.

Sheet 11: Battery and Charging System NOTE: Follow the same sequence when you record the cell number. Always begin the record with a positive cell.

Follow a sequence so that the last cell is always the cell for the negative cable.

Record the beginning ampere reading of the charger each time the battery is charged. Any difference in the daily ampere reading can indicate a problem with the battery or the charger.

Figure 9-8 -Battery Inspection Report

Figure 9-9 -Daily Battery Record Cleaning the Battery Keep the battery compartment clean and dry. Use a clean cloth to wash the battery with water. Dry with compressed air.

CAUTION: Do not clean the battery with steam or hot water. Do not use a high pressure hose.

Remove any electrolyte from the battery compartment to prevent corrosion. If there is electrolyte on the top of the battery, apply a solution of bicarbonate of soda. Mix a solution containing 1.1 lb (0.5 kg) of soda for every 4.22 qts (4 litres) of water. Apply the solution, then flush the solution from the battery with clean water. Wash the battery and battery compartment as needed. Six months between cleaning is the maximum recommended interval.

NOTE: If the top of the battery is wet from electrolyte, check to see if the electrolyte level is too high or the battery charger is not operating correctly.

Adding Water Some water is lost from the electrolyte of each cell during the charge and discharge cycle when the battery is in service. Check the electrolyte level daily. Some service persons check some of the cells each day so that all of the cells are checked each week. If the level of the electrolyte goes below the level of the top of the separators for the

Sheet 11: Battery and Charging System plates, the cell can be damaged.

NOTE: Keeping the electrolyte level within the correct limits is the most important item of battery maintenance.

Always use distilled water. If you add distilled water, wait five minutes before measuring the specific gravity with a hydrometer. Do not add distilled water to a cell during the charging cycle. The electrolyte can flow out of the cell through the fill hole. Figure 9-10 shows a general rule for the incorrect electrolyte level. See the instructions from the manufacturer of your battery for the operating level of the electrolyte.

CELL HEIGHT Less than 38 cm (15 in) 38 -61 cm (15 -24 in) Greater than 61 cm (24 in)

DIMENSION "A" 3 mm (1/8 in) 6 mm (1/4 in) 12 mm (1/2 in)

Table 9-1 -Electrolyte Level

Figure 9-10 -Electrolyte Level Hydrometer TOP OF SEPARATORS Use a hydrometer to measure the specific gravity of the battery. Make sure there is enough electrolyte in the battery cells. A high level or low level of the electrolyte can change the specific gravity measurement. When the electrolyte level is low, the percent of sulfuric acid in the electrolyte increases. When the electrolyte level decreases by 3 mm (0.12 in) the specific gravity measurement can increase by 3 to 5 points.

When using the hydrometer, make sure there is enough liquid in the barrel to let the float move freely. The float must not touch the side, top, or bottom of the barrel for the correct method of reading the hydrometer.

Sheet 11: Battery and Charging System Figure 9-11 -Hydrometer Battery Temperature The temperature of the electrolyte will change the reading of the specific gravity. When the temperature increases approximately 6°C (10°F), the specific gravity will decrease by 0.003 points. Refer to Figure 9-12 for making specific gravity corrections.

SPECIFIC ELECTROLYTE CORRECTION GRAVITY TEMP. POINTS READING 1.210 31 °C (87°F) +0.003 1.210 27°C (80°F) +0.001 1.210 25°C (77°F) +0.000 1.210 18°C (64°F) -0.004 +0.001 for each 1.7°C (3°F) from the 25°C (77°F) Base Value Degrees C + 17.8 x 1.8 = Degrees F.

CORRECT VALUE 1.213 1.211 1.210 1.206

Table 9-2 -Specific Gravity Corrections

Figure 9-12 -Battery Thermometer Never charge or discharge a battery at a rate that will raise the temperature of the electrolyte above 50°C (120° F).

A temperature above this amount will damage the battery. The cells in the center of the battery are normally at the highest temperature. If the battery temperature is too hot, make sure the ventilation of the battery is increased and make sure that the charge or discharge rate is not too high. A recommendation for a battery in service is 8 hours of use (discharge), followed by 8 hours of cooling, followed by 8 hours of charging.

The normal electrolyte temperature is 25°C (77°F). At this temperature the electrolyte has a specific gravity of 1.285-1.295 with no correction for temperature. If the hydrometer you are using does not have a temperature correction, you will have to use a thermometer. Special battery thermometers are available that will indicate the correction factor directly and add or subtract the correct number of points.

WARNING: Batteries produce explosive hydrogen gas when charging. Always open the battery cover or hood and provide good ventilation when charging.

To charge the battery, a direct current must pass through the cells in the opposite direction to the discharging current. The ampere-hours must be equal to the discharging ampere-hours plus the energy lost as heat. This additional amount of charge will vary according to the battery and the temperature, but the average additional charge is 12%. When the battery is nearly charged, the final charging must be at a low rate. A charging rate that is too high will cause heating in the battery and a high loss of water from the electrolyte. The charging of the battery must be done correctly or the service life of the battery will be decreased.

NEVER discharge a battery below 1.130 to 1.110. Discharging a battery beyond the design limits will decrease the service life of the battery.

If lift truck operation results in only partial discharges (50% or less) and specific gravities are 1.210 to 1.220 or more at the end of the shift, recharging may be deferred and the battery used for another shift providing the work load is not expected to increase. Hydrometer readings and experience will disclose the frequency of charge intervals under

Sheet 11: Battery and Charging System these circumstances.

CAUTION: A battery should always be recharged immediately following a complete discharge. !M Never allow it to remain in a discharged condition, since permanent damage may result.

Types of Battery Charges 1. DAILY CHARGE -This charge is normally eight hours and will keep the battery fully charged if the battery is not discharged below the limit.

2. EQUALIZING CHARGE -This charge is at a low rate and balances the charge in all of the cells. The equalizing charge is normally given approximately once per week and is three hours at a low rate in addition to the regular charging cycle. The most accurate specific gravity measurements for a charged battery will be after an equalizing charge.

NOTE: Sometimes the capacity of a battery is not enough to complete a work period. Check for the following conditions: •

The battery is too small for the job.

•

The battery is not fully charged.

•

The battery charger is not operating correctly.

•

The battery is near the end of its service life.

Methods of Charging There are three methods of charging a battery.

1. GRADUAL CHARGE -This method uses a solid state automatic battery charger. The charging rate begins at 20-25 amps/100 amp-hours and decreases to less than 5 amps/100 amp-hours when the battery is 80% charged. The charging current decreases when the voltage across the cell increases during the charging cycle.

The increase in the voltage from the charger is approximately the same as the increase in the specific gravity in the cells.

2. MODIFIED CONSTANT VOLTAGE -This method uses a generator to generate a constant voltage that is controlled by a 3. resistor. When the charging current decreases, the voltage across the resistor causes an increasing voltage at the battery terminals. The charging is similar to the gradual charge. The resistor must be correctly set or the charging rate will be wrong.

4. TWO-RATE CHARGE - This method also uses a high charging rate at the beginning followed by a lower rate.

Two resistors control the charging rate. One resistor controls the charging rate at the beginning of the cycle and a second resistor reduces the charging rate when the voltage in the cells reach 2.37 volts. A relay automatically controls the second resistor.

Troubleshooting the Charger Battery chargers normally operate automatically without constant attention. It is necessary to make a periodic check to determine if the charger is operating correctly. Check for the following conditions: 1. Battery temperature is too high -The temperature in a battery will not normally rise more than 14°C (25° F) during an eight hour charging period. Higher temperatures indicate that the charging rate needs adjustment.

2. Continuous operation of the charger - Check the automatic controls on the charger. Check the charging rate. A low charging rate can be the problem.

3. Continuous operation of a charger at a high rate -Normally, the charging rate begins at a high rate and decreases as the battery becomes charged. If the rate does not decrease, the control need repair or adjustment.

WARNING: Always connect the positive cable to the positive terminal and connect the negative !M terminal. Any other connection will cause injury and damage.

WARNING: Always charge the battery at the end of the work period (shift). Never let the specific gravity reach a level less than the limits shown in the manual.

Sheet 11: Battery and Charging System WARNING: Always deenergize the charger before you connector disconnect the charger from !M the battery.

How to Know when the Battery is Fully Charged 1. During charging, the voltage increases slowly. When the battery is fully charged, the voltage level is constant.

2. Remove a vent cap and look in the opening. If you see bubbles in the electrolyte, the battery is either fully charged or in the final stage of charging.

3. The specific gravity reading is constant and within the limits of a charged battery. If the temperature increases after the battery is charged, the specific gravity will decrease a small amount.

4. Constant meter indications on the charger will indicate the end of the charging cycle.

Battery Charging Area To increase the service life and reduce maintenance, a special area is needed for charging the batteries. The following information should be considered when setting up an area.

1. Location of power supply.

2. Ventilation. Hydrogen gas comes from the batteries during charging.

3. Drains for cleaning the batteries.

4. Type and size of the batteries.

5. Type of lift truck.

6. Distances that the lift trucks must travel for service.

7. Safety regulations and instructions.

Equipment Needed •

A lifting device to remove the battery from the lift truck.

•

Racks to hold the batteries during charging and storage. These racks must be made of wood and must not be metal unless the metal racks are covered with an insulating material.

•

A battery charger that will charge your batteries.

•

Tools for maintenance.

•

An area with a drain for cleaning batteries and battery compartments.

•

Distilled water.

•

Air and water supplies for cleaning.

•

Maintenance records.

•

A work bench.

•

Spare parts and repair equipment.

•

Protective clothing and safety equipment for handling batteries.

•

Water sources for washing eyes and preventing acid burns.

•

Install a NO SMOKING sign in the service area.

•

Keep the charger in a clean, dry area with good ventilation.