PDF DOWNLOAD: Yale B815 (NR AD) Forklift Operating Manual

Sheet 1: Operating Instructions

OPERATING INSTRUCTlON OPERATING lNSTRUCTlONS - 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 with the forks trailing.

Familiarize yourself with the information contained on the nameplate which is located in the operator's compartment.

Information on this nameplate is shown in Figure 1-1 and as follows: A.

Serial Number

This is an identification number assigned to this particular truck 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 nameplate 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.

Sheet 1: Operating Instructions

Figure 1-1 - Nameplate Information

SAFETY LABELS A definition of the safety labels used on the motorized lift trucks is listed below.

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

WARNING: Identified by a Orange Label; Hazards or unsafe practices which MAY result in personal injury or death.

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 UNDERSTAND-ING OF THEIR USE, AS GIVEN BELOW, WILL AID THE READER. NOTE: An advisory procedure, practice, condition, etc. which is essential to emphasize.

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.

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

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.

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 5203717-03, 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, mast 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 to use without a legible, properly filled out nameplate.

Sheet 1: Operating Instructions 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, tilt and auxiliary 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 nameplate.

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 control handle for the opposite direction of travel. The lift truck will come to a stop and then accelerate in the opposite direction, unless the control lever is released. This is called plugging. When the control handle is released to neutral, the truck will brake to a stop. This action is called neutral braking.

•

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.

Sheet 1: Operating Instructions

•

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.

•

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 oft power, set brake, set coast control to oft (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 II.

Sheet 1: Operating Instructions

Figure 1-2 - Typical Narrow Aisle Electric Lift Truck OPERATING INSTRUCTIONS NOTE: This Daily Checklist is available for the Operator. Some items on this list may not be applicable to your truck. This convenient checklist 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-AD (reach), NDR-AD (double reach) and NS-AE (straddle) narrow aisle electric lift trucks have lifting capacities of 1362 kg (3,000 lbs) to 2270 kg (5,000 lbs) with a 609.6 mm (24 in) load center.

These trucks feature neutral braking, 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 Simplex and Triplex masts provide excellent visibility for these models.

No additions, omissions, changes 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.

Sheet 1: Operating Instructions 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.

Figure 1-3 - Narrow Aisle Electric Lift Truck 1. The Instrument Display is located near the steering tiller 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.

Figure 1-4 - Operating Controls

Sheet 1: Operating Instructions The Message Center is a 16 character, dot matrix, liquid crystal display (LCD) with green back light. There B. are four yellow and one red/yellow LED indicators. The 16 character, alpha-numeric 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.

Figure 1-5 - Instrument Display The Instrument Display Hourmeter switch is operator controlled and is used for on-demand display of C. 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.

The Drive Mode switch allows the operator to select the level of traction motor controller speed best suited D. to the application. Operation of the drive mode switch will cause the green indicators and corresponding drive modes to increase from Turtle to Mid to Rabbit. 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 and travel speed. When the key switch is turned to oft, the selected drive mode is retained. When the battery is disconnected the drive mode defaults to the Rabbit mode. The rates of acceleration and travel speeds are programmable and can be adjusted by a qualified service technician.

The LED Function Selection Lights are for the display of Status, Warning and Fault conditions. Status E. 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. Not all functions are used on each lift truck and the location of the functions may vary between lift truck models. 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. 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.

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 for 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. When the control handle is released to neutral, the truck will brake to a stop. This action is called neutral braking.

3. Steering Tiller - The steering tiller 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 Tiller 4. Key Switch - The key switch is a two position switch. The first position is OFF (marked 0). The second position is RUN (marked I). 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. Power is restored by pulling the knob upward to the extended position.

Figure 1-9 - Battery Power Disconnect 6. Brake Pedal and Operator Sensing Switch - The truck's brake is applied when the brake pedal is released.

The truck's brake is released when the pedal is pressed. Braking force can be controlled by the operator. The operator's right foot must press the operator sensing switch and the left foot must press 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 pressed (brake released). When the operator leaves the truck, the parking brake is automatically applied and power steering is turned off after 3 seconds. If the operator's right foot is pressing the operator sensing switch, but the left foot is raised off of the brake pedal (brake applied), the power steering turns off after 10 seconds, unless an auxiliary hydraulic function is selected.

1 2

BRAKE PEDAL OPERATOR SENSING SWITCH

Figure 1-10 - Brake Pedal 6. 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

Sheet 1: Operating Instructions this manual before operating the lift truck.

Figure 1-11 - Operating Manual SAFE MAINTENANCE PROCEDURES Your Yale industrial truck, as manufactured, meets all the applicable mandatory requirements of ANSI B56.1 Safety Standard for Powered Industrial Trucks.

All standard trucks conform to the Underwriters' Laboratories requirements for the 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 sure that 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

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.

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

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

12. 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

Sheet 1: Operating Instructions developed to the extent that it would create a hazard.

13. 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.

14. 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. Capacity, operation and maintenance instruction plates, tags or labels should be changed accordingly.

15. Capacity, operation and maintenance instruction plates, tags and labels should be maintained in legible condition.

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

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

18. 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: 10. 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 11. 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 12. 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.

Sheet 1: Operating Instructions 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. Press the brake pedal during towing to release the brake.

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 lift truck 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 sure that any 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.

Sheet 1: Operating Instructions 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.

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 oft, 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" over a period of time. This "self discharge" is due to 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 -8º C (+18º F). A fully charged battery with a specific gravity of 1.280 will freeze at -67º C (-87º F).

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.

Sheet 1: Operating Instructions 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 2: General Truck

GENERAL TRUCK AND LUBRICATION MAST SCREEN GENERAL This manual covers the repair and maintenance of the NR-AD (reach) NDR-AD (double reach) and NS-AE (straddle) narrow aisle electric lift trucks have lifting capacities of 1362 kg (3,000 lbs) to 2270 kg (5,000 lbs) 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.

FRAME The lift truck frame is a sturdy 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 9 MAST for the recommended removal and assembly for the LOAD BACKRESTS AND FORKS.

Figure 2-1 - NR Lift Truck MAST SCREEN A mast screen is provided to prevent fingers or hands from being placed into the mast area. The lift truck should never be operated without the mast screen. The mast screen may be removed for servicing the lift truck by removing the four attaching capscrews. Two of the capscrews retain the top of the mast screen to the overhead guard while the bottom two capscrews retain the mast screen to the lift truck frame. The operating manual holder is located on the mast screen.

ACCESS DOOR AND COVERS

Sheet 2: General Truck The drive unit access door is mounted on a hinge and secured by a single capscrew and latch at the rear of the lift truck. Turn the capscrew one-half turn to unlock the drive unit access door.

The battery compartment cover is made of molded plastic. It covers the compartment above the battery compartment. To remove the cover remove the five retaining screws one of which is common with the drive unit compartment cover.

The drive unit compartment cover is located over the drive unit compartment and adjacent to the steering tiller. The cover is attached with a single retaining screw and one screw that is common with the battery compartment cover.

To remove the cover remove the two screws and move the cover from its mounting points. To install the cover position the cover under the battery compartment cover and align with the mounting holes. Install the two screws.

Figure 2-2- NS Lift Truck The contactor panel area cover is located in the operator's compartment on the right hand side of the lift truck. It covers the contactor panel and the PMC controller. The bottom edge of this cover fits in a slot on the frame weldment. Two capscrews and self retaining "U" nuts retain the top of the cover to the frame. To remove the contactor panel area cover remove the two screws from the top of the cover and lift the cover out of the slot. To replace the cover install the bottom tab into the slot located in the frame. Align and install the two screws to retain the cover to the frame.

The floor plate located in the operator's compartment is not attached. To remove the floor plate lift the plate up off the frame 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 two supporting posts. The overhead guard weldment is attached to the mast with six capscrews and hardened washers. The bottom left hand 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 bottom right hand post slides into a slot provided in the frame and the top is attached to the overhead guard weldment with a capscrew and washer.

The overhead guard is furnished in three different sizes depending upon the battery compartment size. The length of the posts will also vary depending upon the size of the mast furnished with the lift truck.

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

Sheet 2: General Truck 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 lbf ft). Slide the right hand post into the slot located in the frame. Align the top of the post with the weldment and install the capscrew and lockwasher. Align the left hand post with the slot in the overhead weldment and slide the post into the opening. Align the lower portion of the post with the frame in the drive unit compartment and install the capscrew and washer to retain the left hand post.

BATTERY COMPARTMENT The battery compartment is furnished in five sizes depending on lift truck model and capacity. 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.

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

NOTE: Your company industry and government safety regulations should be reviewed to help reduce accidents and damage to equipment.

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 127 mm (050 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 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 nameplate. The spreader bar must not be made of metal or it must have insulated straps.

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.

1.

2.

3.

4.

5.

6.

BATTERY BATTERY DISCONNECT ROLLERS BATTERYSTAND RATCHET LOCK LEVER BATTERY PULLER

Figure 2-3 - Changing the Battery 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 nameplate. 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.

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

2. 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.

3. Make sure the weight of the replacement battery is within the maximum and minimum weight shown on the

Sheet 2: General Truck nameplate.

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

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.

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.

Figure 2-4 - Inspecting Tires

Table 2-2-Tire Sizes 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 proper tools 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.

WARNING: The lifting and carrying of solid tires is not recommended because their weight could be in excess of 45kg (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.

Sheet 2: General Truck 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.

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 2-5. Align the wheel and tire assembly removed from the truck on top of the new tire. Make certain the wheels are aligned. Make certain the tires are level. Position a press ring on top of the wheel hub.

1. 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 2-6 and Figure 2-7.

INSTALL THE WHEELS ON THE LIFT TRUCK

1. Install the tire and wheel on the hub. Tighten the lug nuts to 136 Nm (100 lbf 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 lbf ft) torque. When the nuts stay tight for eight hours the interval for checking the torque can be extended to 350 hours.

1 2 3 4

PRESSRING OLD TIRE NEWTIRE WHEELHUB

Figure 2-5- Position Tire on Wheel

Figure 2-6- 1 2 x 5.5 Solid Tire Pressed onto Wheel

Sheet 2: General Truck

Figure 2-7- 13.5x5.5 Solid Tire Pressed onto Wheel 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 2-8.

1.

2.

3.

4.

5.

6.

7.

AXLESHAFT WASHER BRACKET AXLESLEEVE BEARING LOADWHEEL 7 NUT

Figure 2-8 - Tandem Load Wheels 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.

Sheet 2: General Truck SINGLE LOAD WHEELS Removal-Single Load Wheels NOTE: Single load wheels are optional.

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

2. Using a drift drive the roll pins through the top of the base arm until the axle is released.

3. Remove the axle spacers and load wheel. Remove the roll pins from the axle. Remove the bearings from the load wheel.

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

2. Align the spacers and position the new load wheel. Install the axle through the base arm. See Figure 2-9.

1.

2.

3.

4.

5.

6.

ROLLPIN AXLE SPACER BEARING LOAD WHEEL ASSEMBLY BASEARM

Figure 2-9 Single Load Wheels 3. Align the slots in the axle with the roll pin holes in the base arm. Install the roll pins until they are flush with the top of the base arm.

4. Remove the blocks from under the lift truck.

CASTER AND CASTER WHEELS Description The caster is 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 by four capscrews and lockwashers. 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.

Sheet 2: General Truck

1. SWIVELPLATE 2. THRUST BEARING 3. 0-RING 4. ROLLER BEARING 5. GUARDWASHER 6. NUT 7. COTTERPIN 8. LUBE FITTING 9. LOCkWASHER 10. SELF-LOCkING NUT 11. GUARDWASHER 12. ROLLER BEARING 13. WHEEL 14. AXLESHAFT 15. iS CAPSCREW 16. SWIVELFORk Figure 2-10 - Caster Wheels Removal-Caster 1. Put the rear of the lift truck on blocks. See HOW TO RAISE THE DRIVE/STEER TIRE 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 the four capscrews and lockwashers that retain the caster to the articulating axle weldment. Remove the caster.

Installation-Caster 1. Align and install the replacement caster on the articulating axle weldment using the capscrews and lockwashers.

Tighten the capscrews to 68 Nm (50 lbf ft) torque.

2. 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 TIRE 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 the cotter pin, axle nut, lockwasher and guard washers from each caster wheel. Remove each caster wheel.

Sheet 2: General Truck 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 the guard washers at each bearing of each wheel. Install each wheel, lockwasher and nut. Rotate each wheel as the nut is tightened. Tighten each nut to remove all clearance. There will be a resistance to the rotation of the wheel. Loosen the nut to the first alignment to install the cotter pin. Install a new cotter pin through each nut.

3. Apply grease to the lube fittings on the caster with the recommended grease listed in the LUBRICATION SCHEDULE, this section.

4. Remove the blocks from under the lift truck.

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, at the following 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 2-11 - Drive Unit Articulation Stops Nameplate

Table 2-3 - Articulation Chart NOTE: The articulation stop settings are also listed on the nameplate.

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

2. Disconnect the battery.

Sheet 2: General Truck 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 lbf ft).

6. Close and lock the compartment door. CASTER SIDE ADJUSTMENT

Figure 2-12 - 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 a Standard Parts Manual through your Yale 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.

Sheet 2: General Truck 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 safety devices must be properly installed before testing or operation of the truck. Failure to comply with this warning could result in serious injury to the mechanic and/or the operator.

CAUTION: Never use steam to clean the electronic control or electrical parts. In dusty areas, 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 1.

2.

3.

4.

5.

6.

7.

8.

Master Drive Unit Bearing 2 Articulation Shaft 1 Caster Wheel Assembly 4 Thrust Rollers - Reach Frame/Fork Carriage Reach Cylinder Pivot Pins - Upper and Lower Reach Arms - NR 6 Reach Arms-NDR 12 Articulating Chain Anchors - NS (Triplex Mast)

No. of Fittings

2 4 2

Apply lithium base, multi-purpose No. 2 grease to the following surfaces: 9. Mast Load Roller Wear Plugs Sliding Surfaces

Sheet 2: General Truck 10.

Reach Load Roller Radial and Thrust Wear Surfaces

Apply silicone spray lubricant to all of the following friction points: 11. Lift Chain Sheaves Apply engine oil (SAE 30) to all friction points of the following: 12. Master Drive Unit Chain Assembly 13. Upper Steering Chain and Sprockets 14. Lift Chains-Wipe oft 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: 15. Articulation Stop Hardware 16. Articulation Shaft Retaining Bolt and Ends of Shaft 17. Drive Wheel Lug Nuts 18. Load Wheel Axle Bolts 19. Brake Rods and Brake Drum Splines 20. Door Latch Capscrew and Hinge Pin 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 Oil Level - Remove and wipe dipstick. With forks fully lowered and oil at normal operating temperature, (above 1000F), measure oil level with dipstick. Add hydraulic oil, if necessary, to the "full" mark on the dipstick.

Remove and clean breather/filler 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 be at the bottom edge of the hole. If low, fill with SAE 80W-go 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 2.6 litres (0.69 gallons) for AD/AE 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 breather/filler assembly. 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

Figure 2-13 - 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 2.6 litres (0.69 gallons) for AD/AE models.

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

Sheet 2: General Truck

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

Sheet 2: General Truck

Sheet 2: General Truck

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

2. Use Magnaglo or equivalent Fatigue Crack Detector to test 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 260 C (790 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 260 C (790 F). Refer to Service Bulletin SE-i 077 for procedure to measure hydraulic drift.

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

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

GEAR OILS

Sheet 2: General Truck

BRAKE FLUID

GREASE

Sheet 2: General Truck

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 2-13.

Threads, Nomenclature The thread design is specified by a series of numbers and letters for inch and metric fasteners. See Figure 2-14. 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 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 2-14 - Thread Design

Sheet 2: General Truck

Table 2-6- Bolts and Screws

Sheet 2: General Truck

Table 2-7 - Studs and Nuts

Sheet 2: General Truck

Table 2-8 - Torque Nuts

Sheet 2: General Truck

Table 2-9 - Torque Nuts with Nylon Inserts

Sheet 2: General Truck

Table 2-10 - General Guide to Torque Values

Sheet 2: General Truck

Table 2-11 - General Guide to Torque Values

Sheet 2: General Truck

Table 2-12 - Recommended Maximum Torque Values for Hydraulic Fittings

Sheet 2: General Truck

Table 2-13 - Conversion Table for Metric and English Units

Sheet 3: Electrical System

ELECTRICAL SYSTEM INTRODUCTION GENERAL The electrical control system consists of the following major components: Main Interface Board (MIB) Proportional Electro-Hydraulic Valve SEM Traction Motor Controller Dash Display Assembly Multi-function Control Handle Assembly Contactor Panel Assembly WIRING SCHEMATICS AND DIAGRAMS are located at the end of this section.

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

Figure 3-1 - Logic Diagram COMPONENT REPAIR AND TESTING GENERAL 1. To check for wire connections to the frame disconnect the battery connector completely and use an ohmmeter to check the circuits. Check for resistance of 50,000 ohms or more between each terminal of the lift truck portion of the battery connector and a clean connection point on the frame of the lift truck. There should be no electrical connections to the frame of the lift truck. Wires or terminals without insulation can cause electrical connections

Sheet 3: Electrical System to the frame. Isolators used to insulate circuit boards from the frame that are missing broken or installed incorrectly can also cause these connections.

2. Check for voltage between each terminal of the connector on the battery and a clean metal connection on the frame of the lift truck. It is normal to measure some voltage between the battery and the frame even if the resistance checks are correct. If voltage is detected use an ammeter to measure current flow. The current must not exceed 100 milliamperes. Current in excess of 100 milliamperes can cause a problem.

If voltage is detected at the frame check to be sure the battery is clean and is not defective. Clean the battery and battery compartment as required. A build-up of carbon dust in the electric motors can also cause measurable voltage at the frame. Wear appropriate safety equipment and remove carbon dust from motors using dry compressed air.

CONTACTOR PANEL ASSEMBLY Description/Features The contactor panel assembly is located behind the operator's compartment cover on the right side of the truck. The contactor panel assembly contains the following major components: Traction Contactor Lift Pump Contactor Steer/Auxiliary Pump Contactor 3 Power Fuses 4 Control Fuses "ER" (enable relay) "HR" (hourmeter relay) "EE" trucks only Sidactor (for dash display protection) 6 Amp Diode (for reverse polarity protection) Components used in the contactor panel assembly are common to both the 24 volt truck and the 36 volt truck options.

Removal 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 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 by separating 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. Remove the socket head capscrews retaining the operator's compartment cover to the frame. Remove the cover for access to the contactor panel assembly.

Sheet 3: Electrical System

1.

2.

3.

4.

5.

6.

7.

TRACTION CONTACTOR LIFT PUMP CONTACTOR POWERFUSES POWER STEER CONTACTOR TRACTION CONTROL ENABLE RELAY CONTROL FUSES

Figure 3-2- Contactor Panel and Traction Controller 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 (center 2 terminals). DO NOT use a screwdriver to discharge the traction motor controller.

1. Discharge the controller by connecting a load across terminals B+ and B-. Disconnect the plug to the main wiring harness.

NOTE: The contactor panel assembly does not normally have to be removed from the lift truck. The steps listed above must be done to service any item that is attached to the contactor panel assembly.

2. To remove the panel assembly tag and disconnect the power wires to the contactors and the fuses.

3. Unplug the control wires from the main wire harness at the X-5 connector.

4. Remove the capscrew flat washer lockwasher and nut retaining the top of the panel assembly to the frame.

Remove the two nuts lockwashers and flat washers retaining the bottom of the panel assembly to the frame.

Remove the contactor panel assembly.

Installation 1. Align the contactor panel with the mounting holes in the frame. Install the two flat washers lockwashers and nuts on the bottom of the panel assembly. Install the capscrew flat washer lockwasher and nut to retain the top of the panel assembly.

Sheet 3: Electrical System 2. Install the power wires and fuses. Refer to WIRING SCHEMATICS AND DIAGRAMS at the end of this section for wiring details.

3. Reconnect the control wires.

4. Connect the battery.

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

CONTACTORS Description/Features Contactors are switches controlled by electromagnets (coils) that close and open a power circuit. The MlB and traction motor controller have internal electronic drivers to control the current to the coils of the contactors. The electro-magnetic field in the coil moves the armature against spring pressure to close the contact. When the coil is de-energized the spring pressure moves the armature and opens the contacts. When a spring holds the contacts of a switch open the switch is called normally open (NO). If a spring holds the contacts of a switch closed the switch is called normally closed (NC).

Figure 3-3 - Typical SPNO Contactor Assembly The contactor contacts are made of special silver alloy. The contacts will normally look black and rough from normal operation. This condition does not cause problems with the operation of the lift truck. Cleaning is not necessary. DO NOT USE A FILE ON THE CONTACTS. DO NOT LUBRICATE THE CONTACTS. Replace the contacts when the silver alloy is worn away to the base support metal.

The traction lift pump and steer pump contactors are SPNO (single pole normally open) contactors. SPNO contactors have one set of normally open contacts. See Figure 3-3.

Auxiliary Switch On non-"EE" rated trucks there is an auxiliary switch mounted on the lift pump contactor. A mechanical connection between the lift pump contactor and the auxiliary switch causes the contacts of the auxiliary switch to close when the lift pump contactor is closed.

The lift pump contactor auxiliary switch is used to send a signal to the dash display whenever the lift pump is activated. When the signal is present pump hours accumulate on the dash display hourmeter.

NOTE: The lift pump contactor auxiliary switch is not present on "EE" rated trucks. On "EE" rated trucks a hourmeter relay is used to send a signal to the dash display. Refer to RELAYS for additional information on the hourmeter relay.

Testing WARNING: Parts of this procedure requires working on the lift truck with full electrical current present. Do not wear any rings, a watch or any other jewelry while working around the contactor panel assembly. When manually closing a

Sheet 3: Electrical System contactor with the power connected, use a properly insulated tool.

1. Remove the operator's compartment cover.

2. Check the condition of the battery. If it is not fully charged, charge or replace the battery with a fully charged battery before continuing.

3. Visually check to see if the contactor closes when the circuit is energized. If the contactor closes, skip to Step 9 If the contactor does not close, proceed to Step 4.

4. Connect a voltmeter across the coil terminals. Verify that the correct voltage is being applied to the coil with the circuit energized. See Table 3-1.

Table 3-1 - Contactor Coil Voltages 5. Check the contactor for loose, broken or corroded connections at the contactor.

6. Check the mechanical function of the contactor. Use an insulated tool, such as an electricians screwdriver to manually close the contactor tips. Check for looseness or binding of the moving parts of the contactor. The parts should move freely, but the parts must not be so loose that the movement is sloppy.

7. Visually check the tips for pitting, burning or wear.

8. If a external suppressor is attached to the coil, remove the suppressor. Check the resistance of the contactor coil. Compare the reading against the values for the type of contactor being tested. See Table 3-3, Page 3-7 for coil resistance values. Readings not within the listed limits indicate the following: High Resistance ... Corrosion or an open coil Low Resistance ... Shorted or a burnt coil NOTE: No external suppressors are used on contactor coils which are controlled by the MIB or the traction motor controller. The MIB and traction motor controller have internal suppressors for these contactor coils.

9. If the contactor closes but the truck does not work properly, check the electrical function of the high current section of the contactor (the tips and buss bars). With the lift truck battery connected and all switches closed, connect a volt ohmmeter across the high current terminals of the contactor.

Check the voltage drop across the contactor tips. Set the voltage scale of the meter to the lowest range higher than battery voltage (50 volts for a 36 volt battery, etc.). On SPNO contactors, read the voltage across the contactor with the tips open. Battery voltage should drop to zero or near zero as the tips close.

A voltage drop of 2 volts or more across the closed tips indicates a poor contact or high resistance. Check for burned or worn tips, incorrect size or mismatched tips and for an incorrect gap setting on contactors with adjustable point gaps.

Removal 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 (center 2 terminals). DO NOT use a screwdriver to discharge the traction motor controller.

1. Disconnect the battery and separate the connectors.

Sheet 3: Electrical System 2. Refer to CONTACTOR PANEL ASSEMBIJ REMOVAL for access to the contactors.

3. Tag and disconnect the wires and/or buss bars to the contactor.

4. Remove the capscrews, flat washers and lockwashers retaining the contactor to the contactor panel assembly.

For the pump contactor, remove the capscrews, lockwashers, flat washers and nuts.

Installation 1. Align the contactor to the contactor panel assembly. Install the contactor using the capscrews, flat washers and lockwashers.

2. Connect the wires and/or buss bars to the contactor. Refer to WIRING SCHEMATICS AND DIAGRAMS at the end of this section for wiring details.

1. ENCLOSURE SHROUD 2. CAPSCREW 3. INSULATOR 4. FIXED CONTACT 5. CAPSCREW 6. COVER 7. RETURN SPRING 8. MOVING CONTACT 9. BASE 10. PLUNGER 11. COILANDFRAME Figure 3-4 - Typical "EE" Contactor

Sheet 3: Electrical System 1. Install the operator's compartment cover. Refer to CONTACTOR PANEL ASSEMBLY INSTALLATION. 2. Connect the battery and test the operation of the truck.

"EE" Contactors When "EE" contactors are used, additional steps are required to service the contactors as the contactors are covered by an enclosure shroud.

1.

2.

3.

4.

Remove the capscrews retaining the enclosure shroud to the contactor. Remove the shroud.

Remove the insulator.

Service the contactor.

Install the insulator.

5. Position the enclosure shroud over the contactor and fasten the shroud to the coil and frame assembly.

FUSES The fuses for these lift trucks are located on the contactor panel assembly. To access the contactor panel assembly.

Refer to CONTACTOR PANEL ASSEMBLY/REMOVAL and remove the operator's compartment cover.

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.

When the lift truck has the provision for "EE" the fuses FU1, FU2 and FU3 are enclosed in a fuse box on the contactor panel assembly. For access to the fuses, see Figure 3-5. Remove the capscrews and lockwashers retaining the floor insulator, wall insulator and the fuse box enclosure to the base plate to test or remove the fuses.

The fuses may be checked for continuity if it cannot be determined visually that a fuse has failed. Make certain to replace any failed fuse with one of the same amperage when replacing a fuse. See Table 3-2.

Table 3-2 - Fuses

Sheet 3: Electrical System

1. INSULATOR-TERMINAL 2. ENCLOSURE-FUSE BOX 3. NUT 4. LOCKWASHER 5. SPACER 6. LOCKNUT 7. FUSE 100 AMPS 8. SCREW 9. WASHER 10. TERMINAL POST 11. CAPSCREW 12. INSULATOR-FLOOR 13. SPACER 14. WASHER 15. NUT 16. FUSE 400 AMPS 17. FUSE 325 AMPS 18. INSULATOR-WALL 19. LOCKWASHER 20. CAPSCREW Figure 3-5- Enclosed Fuse Box "EE" Application RELAYS Description/Features The "ER" (enable relay) is found on all NR/NDR/NS model lift trucks. The "HMR" (hourmeter relay) is present only on "EE" rated trucks. Both relays are mounted on the contactor panel assembly.

NOTE: On non-"EE" rated trucks, there is an auxiliary switch mounted on the lift pump contactor. Refer to CONTACTORS, AUXILIARY SWITCH for additional information.

Enable The enable relay is controlled by the MIB. The enable relay supplies battery volts to the lift pump contactor coil, the power steering contactor coil, the hydraulic control valve coils, the selector valve coils and to certain MIB input switches. The relay will de-energize these circuits if certain fault conditions occur. Refer to MIB codes 70, 71, 72 and 73.

Hourmeter The "HMR" (hourmeter relay) is used to send a signal to the dash display whenever the lift pump is activated. When

Sheet 3: Electrical System the signal is present, pump hours accumulate on the dash display hourmeter. The "HMR" (hourmeter relay) is present only on "EE" rated trucks.

Figure 3-6 - "ER" and "HMR" Relays

Table 3-3- Hydraulic Control Valve/Relay Coil Resistance Values Coil testing The "ER" and "HMR" relay coils can be tested for resistance across terminals 85 and 86. See Figure 3-6 for test point locations. Replace any relay which has a coil resistance value outside of specifications. See Table 3-3 for coil resistance values.

NOTE: The "ER" (enable relay) and "HMR" (hourmeter relay) are both single pole, double throw (SPDT) type relays.

They are manufactured by either The Bosch Company or Potter & Brumfield. When testing these relays, it is important to identify the manufacturer due to different coil resistance values. The name of the manufacturer is stamped on the relay.

Contact testing The normally open contacts of the "ER" and "HMR" relays are checked at terminals 30 and 87. Check for a voltage drop across the N.O. contacts with the relay energized. Replace any relay which has a voltage drop exceeding 2 volts. See Figure 3-6 for test point locations.

Removal and Installation To remove the relays, tag and disconnect the wires. Remove the capscrews and lockwashers retaining the relay to

Sheet 3: Electrical System the contactor panel assembly or the mounting bracket.

Replace the relays by aligning the relay with the mounting holes in the contactor panel assembly or mounting bracket and installing the capscrews and lockwashers.

HEIGHT LIMIT SWITCH Removal 1. Move the lift truck to a safe level area. Raise the mast high enough to obtain access to the height limit switch.

SAFETY CHAIN THE MAST. See - Section 8. Turn the key switch oft and remove the key. Put a "DO NOT OPERATE" tag on the multi-function 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: Do not raise the frame of the truck with the forks raised. The stability of the truck is reduced. Raising the frame of the truck with the forks raised could cause it to tip over. Tipping of the truck can cause personal injury or property damage.

WARNING Disconnect the battery and separate he connector before opening the compartment 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. Disconnect the X-11 plug.

4. Remove the two capscrews retaining the cover to the switch body. Pry the cover from the switch.

5. If the switch must be replaced, tag and disconnect the wires.

6. Remove the switch by removing the mounting capscrews, lockwashers and nuts.

Testing 1. Remove wires #56 and #74 from the switch and check the resistance between switch terminals 7 and 8.

2. Replace any switch that does not read continuity between switch terminals 7 and 8 with the switch not activated and no continuity with the switch activated.

NOTE: The switch is not activated (switch arm out) when the inner mast is elevated. The switch is activated (switch arm depressed) when the inner mast is lowered.

Installation 1. Position the new switch on the bracket. Install the mounting capscrews, lockwashers and nuts.

2. Connect wire #56 to terminal 8 and wire #74 to terminal 7.

3. Install the cover using the two capscrews.

4. Connect the X-11 plug.

5. Remove the safety chains from the mast. Connect the battery, install the key and check the mast for proper operation.

6. Remove the blocks from under the drive wheels. Remove the "DO NOT OPERATE" tag from the multi-function control handle.

7. Verify that the switch is activated with the inner mast lowered and not activated with the inner mast elevated.

Check wire #74 at the X-11 plug. Battery volts should be present at wire #74 with the inner mast elevated. Near 0 volts should be present at wire #74 with the inner mast lowered.

8. Check the truck for proper operation. Maximum travel speed must be limited with the mast elevated above free lift.

KEY SWITCH

Sheet 3: Electrical System Removal 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 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 the battery and separate the connectors.

3. Remove the hydraulic tank dipstick.

4. Remove the battery compartment cover for access to the wiring to the key switch.

5. Tag and disconnect the electrical wires to the key switch.

6. Remove the nut retaining the key switch to the mounting bracket and remove the key switch.

Installation 1. Position the new switch in the mounting bracket. Install the nut to retain the key switch.

2. Install the electrical wires to the key switch. Refer to WIRING SCHEMATICS AND DIAGRAMS at the end of this section for wiring details.

3. Install the battery compartment cover.

4. Install the hydraulic tank dipstick.

5. Connect the battery.

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

BATTERY DISCONNECT SWITCH Removal 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 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 the battery and separate the connectors.

3. Remove the hydraulic tank dipstick.

4. Remove the battery compartment cover for access to the wiring to the battery disconnect switch.

5. Tag and disconnect the electrical wires to the battery disconnect switch.

6. Pull the battery disconnect switch up to the "ON" position.

7. Rotate the red knob to align the hole in the housing with the hole in the shaft.

8. Insert a 4.0 mm (0.15 in) diameter rod through the hole in the housing and into the hole in the shaft, to prevent the shaft from rotating.

9. Rotate the red knob counterclockwise to remove it.

10. Remove the two screws retaining the battery disconnect switch to the mounting bracket and remove the switch.

Sheet 3: Electrical System Installation 1. Ensure the replacement battery disconnect switch is in the "ON" (up) position and that the red knob is removed.

2. Position the new battery disconnect switch in the mounting bracket. Install the two screws retaining the battery disconnect switch to the mounting bracket.

3. Install the red knob by threading it clockwise. Insert a 4.0 mm (0.15 in) diameter rod through the hole in the housing and into the hole in the shaft, to prevent the shaft from rotating while installing the knob. Remove the rod from the housing once the red knob is tightened securely.

4. Install the electrical wires to the battery disconnect switch.

5.

Install the battery compartment cover.

6. Install the hydraulic tank dipstick.

7. Connect the battery.

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

PROPORTIONAL ELECTRO-HYDRAULIC CONTROL VALVES There are four electrically operated proportional valves located on the main hydraulic control valve. These proportional valves are controlled by solenoids. Valve openings are controlled by varying the electrical current in the valve coils.

The instructions for testing, removal and replacement of the proportional valves is covered in Section 7 HYDRAULIC SYSTEM.

Figure 3-7 - Proportional Electro-Hydraulic Valve Manual Lowering WARNING: Always verify that no one is under or near the lift mechanism or load during the manual lowering procedure. Verify that there are no obstructions beneath the lift mechanism or load. If the mast does not lower when the manual lowering valve is activated, deactivate the valve immediately and determine the cause.

A provision is provided on the lowering valve to allow manual lowering of the forks if necessary. Manual lowering is accomplished by inserting a 1/8" allen 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 3-8. Be sure to return the screw to the 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.

Sheet 3: Electrical System

1. AUXILIARY UP 2. AUXILIARY DOWN 3. LIFT 4. LOWER Figure 3-8 - Hydraulic Control Valve Operation The four electrically operated proportional valves located on the main hydraulic control valve are controlled by solenoids. These solenoids can be checked for resistance by removing the leads to the solenoids and tested using a volt ohmmeter. See Table 3-3, Page 3-7 for coil resistance values.

If a reading other than those listed are obtained, replace the solenoid. See Section 7 for information on removing and installing the solenoids.

SELECTOR VALVES (Used on REACH model trucks only.)

If the lift truck has provisions for tilt, sideshift and reach there are solenoids used to operate these functions located on selector valves. One selector valve assembly, containing two selector valves and two solenoids is located on the mast assembly and used to select between reach or tilt. See Figure 3-9. A second selector valve assembly, also containing two selector valves and two solenoids is located on the reach assembly and used to select between tilt and sideshift. See Figure 3-10. The second selector valve assembly is only fitted on reach model trucks equipped with an optional sideshifter.

When tilt is selected by the operator at the multi-function control handle, neither of the two selector valve assemblies is energized. When reach is selected, the coils are energized on the reach selector valve. When sideshift is selected the coils on the optional sideshift selector valve are energized.

Testing/Removal/lnstallation Solenoids can be checked for resistance by removing the leads to the solenoids and tested using a volt ohmmeter.

See Table 3-3, Page 3-7 for coil resistance values. If a reading other than those listed are obtained, replace the solenoid. See Section 8 for information on removing the sideshift and reach solenoids.

Sheet 3: Electrical System

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HYDRAULIC FITTING SOLENOID VALVE BODY HOSE INNER FRAME PORT TUBES CHECK VALVE ASSEMBLY

Figure 3-9 - Reach Selector Valve

1. SOLENOID 2. VALVE BODY Figure 3-10 - Sideshifter Selector Valve MULTI-FUNCTION CONTROL HANDLE Description/Features The multi-function control handle is located in the operator's compartment. The handle is spring-loaded to return to the center (neutral position) when pressure on the handle is removed. The traction and hydraulic functions of the truck are controlled with the multi-function handle. The traction functions are selected by moving the multi-function control handle from side to side. The hydraulic functions are controlled by moving the multi-function control handle

Sheet 3: Electrical System from front to rear. See Figure 3-11. The handle is equipped with a horn button and can be equipped with up to three auxiliary selection buttons. The auxiliary selection buttons operate the extend/retract, tilt and sideshift, depending on how the truck is equipped. See Figure 3-11 for the location of the components on the multi-function control handle.

Operation The handle can be adjusted to three different positions for operator comfort. The handle is adjusted by pressing the handle downward on the shaft and turning the handle to the desired position. Move the multi-function control handle to the left to cause the lift truck to travel in a forward direction. Move the handle to the right to cause the lift truck to travel in the reverse direction.

Disassembly 1. Move the lift truck to a safe level area. Turn the key switch oft and remove the key. Put a "DO NOT OPERATE" tag on the multi-function 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 the battery and separate the connectors.

3. Remove the hydraulic tank dipstick and the battery compartment cover.

Figure 3-11 - Operation of the Multi-Function Control Handle 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.

4. 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 (center 2 terminals). DO NOT use a screwdriver to discharge the traction motor controller.

5. Disconnect X-7, X-8 and X-9 plugs from the connectors.

Sheet 3: Electrical System 6. Remove the multi-function control handle by disconnecting the X-7 connector and then removing the roll pin retaining the handle to the handle weldment. Remove the handle, disk and springs.

7. The top cover of the handle is retained with two screws. Remove the cover, membrane, buttons and switch retainer. Remove switches, as required, complete with the wires attached.

8. Use Amp Connector Extraction Tool P/N 5180968-81 to remove the pin connectors on the ends of the switch wires from the X-7 amp connector. Make note of the color and wire position before removal. Fasten a piece of string to the wires before pulling them through the handle. Fasten the wires of the new switch to the string and use the string to pull the wires through the handle. Install the wires in the X-7 amp connector as earlier noted.

Refer to WIRING SCHEMATICS AND DIAGRAMS at the end of this section for wiring details. Install the switch retainer, buttons, membrane and top cover. Install the two screws retaining the top cover.

CAUTION: Pulling the potentiometer gear from the potentiometer assembly can cause damage to the potentiometer.

9. To remove either one or both of the potentiometers, tag and disconnect the electrical wires. Loosen the setscrew holding the gear to the potentiometer shaft and remove the potentiometer gear. Use a screwdriver positioned in the slot of the potentiometer shaft to hold the potentiometer shaft while pulling the gear. Pulling on the potentiometer gear without holding the potentiometer shaft can damage the potentiometer. Remove the nut and lockwasher retaining the potentiometer to the mounting plate or bracket. Remove the potentiometer.

10. To remove a forward, reverse or neutral micro switch, tag and disconnect the electrical wires. Remove the capscrews, lockwashers and nut plates retaining the switch. Remove the switch and the insulator.

11. To separate the handle weldment and the cam and gear sector from the lever cam with gear section, remove the roll pin, back-up washer and the cam with gear sector. Remove the handle weldment from the lever cam with gear section.

WARNING: Be careful when removing or installing snap rings. 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.

12. Remove the snap ring retaining the torsion spring on the bottom of the mounting plate. Remove the back-up washer and torsion spring. Remove the shoulder screw from the bottom of the lever cam with gear section.

Remove the snap ring retaining the lever cam with gear section to the mounting plate. Remove the back-up washer and the lever cam with gear section with the bracket. Separate the bracket from the lever cam with gear section by removing the two capscrews (one socket head and one flat head) and single lockwasher. Inspect the bushings in the lever cam with gear section and remove the bearings if they are damaged or worn.

13. Remove the mounting plate by removing the two capscrews, lockwashers, flat washers and nuts retaining the mounting plate to the lift truck frame Assembly 1. Install the mounting plate on the lift truck frame using the two capscrews, lockwashers, flat washers and nuts.

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. Install the bushings in the lever cam with gear section. Install the bracket on the lever cam using the two capscrews (one socket head and one flat head). Position the lockwasher under the head of the socket head capscrew. Install the lever cam with gear section on the mounting plate. Install the back-up washer and snap ring to retain the lever cam to the mounting plate. Install the shoulder screw in the lever cam. Install the torsion spring, back-up washer and snap ring on the bottom of the mounting plate.

3. Align the handle weldment with the lever cam and install the handle weldment. Position the cam with gear sector, torsion spring and back-up washer on the handle weldment and install the roll pin.

4. Align the insulator, switch and nut plate in position on the mounting plate or bracket and install the capscrews and lockwashers to retain the switches.

5. Locate the conical spring on the handle weldment and the disk on the multi-function control handle. Insert the smaller spring in the handle. Align the multi-function control handle and install on the handle weldment. Install the roll pin retaining the multi-function control handle.

Sheet 3: Electrical System 6. Adjust each switch so it activates when the multi-function control handle is moved in the appropriate direction and does not activate when in neutral. When the switches are activated, the switch arm must not bottom out against the body of the switch or bind the multi-function control handle assembly. Properly adjusted switches will activate when the end of the multi-function control handle is moved approximately ½" to ¾" from the neutral position. See Figure 3-12.

Figure 3-12 - Multi-function Control Handle Switch Adjustment CAUTION: If the forward, reverse or hydraulic neutral switch is not adjusted properly, the MIB may not allow the set up of the corresponding potentiometer. All switches must be open when the multi-function control handle is in neutral and the appropriate switch must close when the multi-function control handle is moved ½" to ¾" from the neutral position.

7. Install and adjust the potentiometers. Refer to TRACTION AND HYDRAULIC POTENTIOMETER, INSTALLATION and ADJUSTMENT. 8. Install all the electrical wires and connect the X-7, X-8 and X-9 plugs to the connectors. Refer to WIRING SCHEMATICS AND DIAGRAMS at the end of this section for wiring details. Make certain that the switches and potentiometers work properly when the multi-function control handle is moved.

9. Calibrate the MIB to the potentiometer. Refer to MIB CALIBRATION. CAUTION: Whenever adjusting or replacing a potentiometer the MIB must be calibrated to the potentiometer.

10. Install the battery compartment cover.

Sheet 3: Electrical System

1. COVER 2. MEMBRANE 3. BUTTON 4. SWITCH ASSEMBLY 5. SWITCH RETAINER 6. BODY AND SLEEVE 7. TOLERANCE RING 8. SCREW 9. HORN SWITCH 10. SCREW Figure 3-13 - Multi-function Handle - Exploded View

Sheet 3: Electrical System

1. CONTROLHANDLE 2. ROLL PIN 3. COMPRESSION SPRING 4. CONNECTOR 5. TY-WRAP 6. LEVER CAM WITH GEAR SECTION 7. MOUNTING PLATE WITH PINS 8. CONTROL HANDLE DISK 9. CONICAL SPRING 10. ROLL PIN 11. HANDLE WELDMENT 12. POTENTIOMETER ASSEMBLY 13. SPURGEAR 14. BACK-UP WASHER 15. TORSION SPRING 16. CAM WITH GEAR SECTOR 17. RETAINING RING 18. BUTTON HEAD SCREW 19. LOCKWASHER

Sheet 3: Electrical System 20.

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ROUND HEAD SCREW LOCKWASHER MICROSWITCH INSULATOR NUT PLATE ASSEMBLY SOCKET HEAD SCREW FLAT HEAD SCREW MOUNTING BRACKET RETAINING RING BACK-UP WASHER BUSHING SOCKET HEAD SCREW

Figure 3-14 - Multi-Function Control Handle Assembly - Exploded View TRACTION AND HYDRAULIC POTENTIOMETER Testing Potentiometer's operation can be verified by disconnecting the wiring and checking resistance. Use an analog volt ohmmeter. Watch the needle on the meter while slowly rotating the potentiometer shaft. Look for a smooth sweep of the needle from minimum to maximum values. Replace any potentiometer with erratic readings or operation.

Table 3-4- Potentiometer Specifications Installation 1. Install the potentiometer through the mounting hole. Fasten the potentiometer securely to the bracket using the lockwasher and nut.

CAUTION: Potentiometers can be supplied with or without rotational stops. Potentiometers with internal rotational stops will be damaged if they are rotated beyond the stops.

2. Install the gear on the potentiometer. Do not tighten the setscrew in the gear at this time. If the setscrew is tightened before the potentiometer is centered, the potentiometer can be damaged.

Adjustment CAUTION: The wires to the potentiometer must be disconnected during Step 1.

1.

Adjust the potentiometer for mid-range. For the traction potentiometer, compare the resistance measured between potentiometer wires 21 and 22 with the resistance measured between potentiometer wires 22 and 23.

For the hydraulic potentiometer, compare the resistance measured between potentiometer wires 31 and 32 with the resistance measured between potentiometer wires 32 and 33.

The potentiometer is at the mid-range position when the resistance readings are equal within 100 ohms. Rotate the potentiometer shaft while holding the gear in the neutral position for the correct resistance readings. Tighten the setscrew in the gear at this time.

NOTE: Failure to properly center the potentiometer may cause a fault code to occur. The fault code can occur

Sheet 3: Electrical System immediately or intermittently.

2.

Connect the wire connector to the truck wire harness.

Table 3-5 - Potentiometer Wiring 3.

Calibrate the MIB to the potentiometer. Refer to MIB CALIBRATION.

CAUTION: Whenever adjusting or replacing a potentiometer the MIB must be calibrated to the potentiometer.

Figure 3-15-Traction and Hydraulic Pot Specifications

Sheet 4: Electrical System MAIN INTERFACE BOARD (MIB) DESCRIPTION/FEATURES

The main interface board (MIB) is a printed circuit board that directs communication between the electrical components of the truck. The MIB provides inputs and outputs to the multi-function control handle, variable valves, solenoid valves, contactor coils, relay coils, throttle speed limit switch, brake switch, operator sensing switch and the dash display. Pushbuttons on the MIB provide for service level diagnostics and set-up capability. A four-digit LED display on the MIB shows real-time truck function "STATUS", "WARNINGS" and "FAULTS". See STATUS, WARNING AND FAULT CODE TROUBLESHOOTING.

Figure 3-16 - Main Interface Board (MIB) OPERATION When the key switch is in the "ON" position and the operator is not on the truck the MIB should display "0200" and the dash display should read "POWER ON". If the operator is present on the truck and the brake pedal is pressed (operator sensing switch and brake switch closed) the MIB should display "0300" and the dash display should read "READY".

NOTE: When the operator enters the operators compartment the operator sensing switch (under right foot) and the brake switch (under left foot) must both be closed to change the MIB display to "0300" and the dash display to "READY". Afterwards either of the two switches may be opened at any one time as long as both switches are not opened simultaneously.

If the operator steps off the truck and the key switch remains in the "ON" position the MIB will display "0200" and the dash display will read "POWER ON" (after a 3 second delay).

LED DISPLAY The four-digit LED display is capable of displaying two truck function status warning or fault codes simultaneously.

Refer to MIB STATUS, WARNING AND FAULT CODES for a comprehensive explanation of each code. One code is displayed by the left two digits and the other code is displayed by the right two digits. It is important to read the left two digits as one code and the right two digits as a separate code. The LED display is also used during the calibration procedure. Refer to MIB ADJUSTMENTS. During normal operation the left two digits show the "STATUS" code of the truck and the right two digits show "00".

Whenever a truck function is selected the left two digits are updated to display the selected function.

The two digits on the right side of the display are used to display either a "WARNING" code or a "FAULT" code. If neither a "WARNING" code nor a "FAULT" code is present the right two digits continue to display "00". If multiple faults are present the highest priority "FAULT" code is displayed. After the highest priority fault is repaired the next highest priority "FAULT" code will be displayed.

If a "WARNING" code and a "FAULT" code are received at the same time the left two digits will display the "WARNING" code the right two digits will display the "FAULT" code and the "STATUS" code will not be displayed.

Always troubleshoot the code shown on the right side of the display first.

Codes are displayed as follows: "STATUS" codes "WARNING" codes "FAULT" codes →

→ numbers 01 to 16. → numbers 34 to 38. numbers 40 to 85.

Sheet 4: Electrical System

Figure 3-17 - MIB Pushbuttons A, B, C, and D and LED Display MIB REMOVAL The main interface board (MIB) is located under the battery compartment cover. For access to the MIB, remove the battery compartment cover. The MIB is not a repairable item and must be replaced if troubleshooting determines the MIB to be faulty.

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.

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 under the drive wheels to keep the lift truck from moving. See Section 1 - HOW TO PUT A LIFT TRUCK ON BLOCKS. 2. Disconnect the battery and separate the connectors.

3. Remove the battery compartment cover for access to the main interface board (MIB).

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 (center 2 terminals). DO NOT use a screwdriver to discharge the traction motor controller.

4. Discharge the controller by connecting a load across terminals B+ and B-. Disconnect the two plugs from the main interface board (MIB).

5. Remove the capscrews and lockwashers retaining the MIB to the lift truck frame.

6. Lift the MIB high enough to access the connectors on the bottom of the MIB. 7. Use a screwdriver in the slot of the lock on the connector to release the male plug. Pull and hold the lock away from the latch while pulling the J plug from the MIB. See Figure 3-18. Disconnect both the J1 and J2 plugs from the MIB. The MIB can now be removed from the lift truck.

NOTE: The MIB is not a repairable item and must be replaced if there is a problem with the board itself.

MIB INSTALLATION WARNING: Disconnect the battery and separate he connector before opening the compartment 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.

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 under the drive wheels to keep the lift truck from moving. See Section 1 - HOW TO PUT A LIFT TRUCK ON BLOCKS. 2. Disconnect the battery and separate the connectors.

3. Align the plugs with the connectors located on the bottom of the MIB. Connect the two plugs J1 and J2 to the bottom of the main interface board. Make certain that the lock on each plug is engaged with the latch.

Sheet 4: Electrical System 4. Align the new main interface board with the holes in the lift truck frame and install the capscrews and lockwashers.

5. Before installing the battery compartment cover, the MIB must be programmed for the lift truck that it is being installed in. The MIB must also be calibrated to the traction and hydraulic potentiometers. Refer to MAIN INTERFACE BOARD ADJUSTMENTS. 6. Install the battery compartment cover and connect the battery. Remove the blocks from under the drive wheels, remove the "DO NOT OPERATE" tag and install the key.

Figure 3-18 - MIB "J" Connector MAIN INTERFACE BOARD (MIB) ADJUSTMENTS GENERAL The MIB must be calibrated whenever any of the following occur: •

A new MIB is installed or a MIB is transferred from one truck to another.

•

Traction potentiometer is adjusted or replaced.

•

Hydraulic potentiometer is adjusted or replaced.

•

Troubleshooting indicates that any of the above components may be out of adjustment.

CAUTION: Turning the key switch off or disconnecting the battery when the MIB is being calibrated will result in the MIB returning to the run mode without saving any new values.

DEFAULT VALUES Every MIB installed in a new truck by the factory is programmed with the recommended factory default values for that model truck. In addition, the MIB is calibrated to the specific traction and hydraulic potentiometers on the truck.

Whenever a replacement MIB is installed in a truck, the appropriate model code must be programmed into the MIB. This automatically sets the recommended factory default values for all functions except functions 30 through 34.

Functions 30 and 31 are programming utilities and do not require value entries. Function 33 is not used. Functions 32 and 34 are used to calibrate the traction and hydraulic potentiometers. The replacement MIB must be manually calibrated to the specific traction and hydraulic potentiometers installed on the truck.

NOTE: The MIB must be calibrated to the traction and/or hydraulic potentiometer whenever a traction or hydraulic potentiometer is adjusted, repaired or replaced.

CHECKING THE MODEL CODE AND SET-UP STATUS Turn the key switch to the "ON" position. Press button "A" on the MIB. Refer to Figure 3-17. The LED display will

Sheet 4: Electrical System show either "Fnn0" or "FnnA", where 'nn' indicates the model code number currently programmed into the MIB and the "0" or "A" indicates the MIB program status. A model code of "00" indicates that the MIB has not been programmed for any truck model. See Table 3-6 for model code information.

The MIB program status is shown as "0" or "A". The "0" indicates that the settings correspond to the default values for the truck model listed ('nn'). The "A" stands for "altered", and indicates that one or more of the function values have been set to a value other than the default value for the truck model listed.

NOTE: A fault code can occur if the truck model is not selected properly or if the traction and/or hydraulic potentiometers are not properly calibrated to the MIB. Pressing button "C" or "D" will show the software version (i.e. "C500" for version 5.00).

MIB CALIBRATION PROCEDURE The four-digit LED display on the MIB is used during the calibration procedure to display the function number and the function value.

The function number is displayed by the left two digits.

The function value is displayed by the right two digits.

During normal operation, the left two digits show the status code of the truck and the right two digits show 00, or a warning or fault code, as applicable. During the set-up procedure, the LED is used to display function number and function value information.

Step 1 - Entering the Set-up Mode NOTE: To exit the set-up procedure at any time without saving new values, turn the key switch to the "OFF" position.

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

2.

Refer to Figure 3-17 for the location of the MIB buttons. Press and hold buttons "A" and "C" simultaneously until the LED display shows a series of dashes"- - -", then release. Upon release, the left two digits will display function number "01" and the right two digits will display the corresponding function value. Function number "01" is the truck model code function. The function value shown should correspond to one of the truck model code values shown in Table 3-6.

Table 3-6 - Truck Model Code Function Values NOTE: A value of 00 indicates a new MIB with no program or a MIB which has had the program erased.

3. If the model code is incorrect or the MIB is to be reset to the factory default settings, proceed to Step 2, ERASING THE MODEL CODE. If the model code is correct, proceed to Step 4, CALIBRATING THE HYDRAULIC POTENTIOMETER RANGE.

Sheet 4: Electrical System Step 2 - Erasing the Model Code 1. Select function number 31 by pressing and holding button "A", then pressing button "C" or "D" until the left two digits of the LED show 31. Release button "A" when the desired function number is reached.

CAUTION: After erasing the model code it will be necessary to perform Steps 3 through 6 before the lift truck will be operational.

2. Verify that the LED display shows "3150".

3. Change the function value (the right two digits) to a value of 75. The function value is changed by pressing either button "C" or "D" until the desired value is obtained.

4. Press and hold button "B". Press button "D" to erase the model code and all programmed values. Release both buttons. The MIB display will show "0110" to indicate that Function 01 has reset to the starting value of 10 corresponding to the first model code function value in sequence (NRO35AD). Proceed to STEP 3 to change the model code function value, as required.

Step 3 - Setting the Model Code 1. Change the function value (the right two digits) to the value assigned for the correct truck model, as required. See Table 3-6. The function value is changed by pressing either button "C" or "D" until the desired value is displayed.

Step 4 - Calibrating the Hydraulic Potentiometer Range 1. Center the hydraulic potentiometer manually using an ohmmeter before proceeding. Refer to HYDRAULIC POTENTIOMETER, ADJUSTMENT. 2. Select function number 32 by pressing and holding button "A", then pressing button "C" or "D" until the left two digits of the LED show 32. Release button "A" when the desired function number is reached. The MIB display should show "3210".

3. Press button "D" until the function value is decreased to zero. Once the value reaches zero, press button "D" at least one more time.

4. Verify that the MIB display shows "3200".

5. Move the multi-function control handle to the full speed lift position. Hold for 2 seconds.

6. Move the multi-function control handle to the full speed lower position. Hold for 2 seconds.

7. Repeat Step 5.

8. Repeat Step 6.

9. Return the multi-function control handle to the neutral position.

10. Press button "C" to increase the function value (the right two digits) to any value greater than "00".

11. Press and hold button "B". Move the multi-function control handle through the full range of full speed lift to full speed lower while holding button "B". Notice that the function value digits (right two digits) remain at the value set in Step 10 above, but that the left two digits change as the control handle is moved. Notice also that the decimal point between each digit will light to indicate that the neutral switch has closed.

Check the calibration by watching the left two digits, while holding button "B" and cycling the control handle through the full range of lift and lower. The left two digits should be nearly zero in the neutral position. When the handle is moved to the full speed lift position, the left two digits should increase to a value of at least 94, ideally 99 (the value "A0" represents a value of 100 and is acceptable). Similarly, when the handle is moved to the full speed lower position, the left two digits should increase to a value of at least 94, ideally 99 (the value "A0" represents a value of 100 and is acceptable). If the left two digits do not exceed 94 when the control handle is moved to the full speed (lift or lower) position, the calibration must be repeated. If the proper values cannot be obtained, check the potentiometer or switch.

Step 5 - Calibrating the Traction Potentiometer Range 1. Put blocks under the drive wheels to keep the lift truck from moving. See Section 1 - HOW TO PUT A LIFT

Sheet 4: Electrical System TRUCK ON BLOCKS. 2. Center the traction potentiometer manually using an ohmmeter before proceeding. Refer to TRACTION POTENTIOMETER, ADJUSTMENT 3. Select function number 34 by pressing and holding button "A", then pressing button "C" or "D" until the left two digits of the LED show 34. Release button "A" when the desired function number is reached. The MIB display should show "3410".

4. Press button "D" until the function value is decreased to zero. Once the value reaches zero, press button "D" at least one more time.

5. Verify that the MIB display shows "3400".

6. Press the brake pedal.

CAUTION: The brake pedal must remain pressed during the traction potentiometer calibration procedure.

7. Move the multi-function control handle to the full speed forward position. Hold for 2 seconds.

8. Move the multi-function control handle to the full speed reverse position. Hold for 2 seconds.

9. Repeat Step 7.

10. Repeat Step 8.

11. Return the multi-function control handle to the neutral position.

12. Press button "C" to increase the function value (the right two digits) to any value greater than "00".

13. Press and hold button "B". Move the multi-function control handle through the full range of full speed forward to full speed reverse while holding button "B". Notice that the function value digits (right two digits) remain at the value set in Step 12 above, but that the left two digits change as the control handle is moved. Notice also that the decimal point on the far left of the display will light to indicate that the reverse switch has closed, and that the decimal point in the center will light to indicate that the forward switch has closed.

Check the calibration by watching the left two digits, while holding button "B" and cycling the control handle through the full range of forward and reverse. The left two digits should be nearly zero in the neutral position. When the handle is moved to the full speed forward position, the left two digits should increase to a value of at least 89, ideally 99 (the value "A0" represents a value of 100 and is acceptable). Similarly, when the handle is moved to the full speed reverse position, the left two digits should increase to a value of at least 89, ideally 99 (the value "A0" represents a value of 100 and is acceptable). If the left two digits do not exceed 89 when the control handle is moved to the full speed (forward or reverse) position, the calibration must be repeated. If the proper values cannot be obtained, check the potentiometer or the switches.

Step 6 - Exiting the Set-up Mode and Saving the New Values CAUTION: Failure to perform this step will result in the loss of all new settings.

1. Select function number 30 by pressing and holding button "A", then pressing button "C" or "D" until the left two digits of the LED show 30. Release button "A" when the desired function number is reached. The MIB display should show "3050".

2. Verify that the MIB display shows "3050".

3. Press and hold button "B", then press button "C".

4. Release both buttons. After several seconds the dash display will change from MIB SET-UP MODE to the current truck status (POWER ON, READY, etc.). This indicates that the new values have been saved and that the set-up mode has been exited.

NOTE: To exit without saving new values, turn the key switch to the "OFF" position.

5. Verify the correct operation of all traction and hydraulic functions.

CUSTOMIZING MIB FUNCTIONS

Sheet 4: Electrical System Certain function values can be customized, as required. The following pages contain detailed descriptions of each function number.

Refer to Table 3-19 through Table 3-28 for specific minimum and maximum values available for each function, corresponding to the specific truck model.

Settings can be returned to the existing values by exiting without saving the new values. To exit without saving new values, turn the key switch to the "OFF" position. The settings can be returned to the factory default values by setting Function 01 to the correct value for the specific lift truck model. Refer to MIB CALIBRATION PROCEDURE. WARNING: Program changes will affect lift truck performance and operation. If function values are changed, make sure all operators of the lift truck know that the truck may now operate differently.

WARNING: Each function has a range of values (minimum/maximum), specific to each model truck. Adjustment of functions to a value outside the specific range for the truck model can cause the truck to operate differently than normal. Do not set any function to a value outside the minimum/maximum range for the truck. Function values set incorrectly can cause personal injury or damage to the truck.

Function values are customized as follows: 1. Turn the key switch to the "ON" position.

2. Refer to Figure 3-17 for the location of the MIB buttons. Press and hold buttons "A" and "C" simultaneously until the LED display shows a series of dashes"- - -", then release. Upon release, the left two digits will display function number "01" and the right two digits will display the corresponding function value. Function number "01" is the truck model code function. The function value for function number "01" should correspond to the value for the specific truck model, as shown in Table 3-6.

3. Select the function number to be customized by pressing and holding button "A", then pressing button "C" or "D" until the left two digits of the LED show the desired function number. Release button "A".

4. Change the function value (the right two digits) to the desired value, taking care to ensure that the value is within the acceptable range for the specific truck model. The function value is changed by pressing either button "C" or "D" until the desired value is obtained.

5. Repeat the steps above for each function to be adjusted.

CAUTION: Failure to exit the set-up mode properly will result in the loss of all new settings.

6. Exit the Set-up Mode and save the new values. Select function number 30 by pressing and holding button "A", then pressing button "C" or "D" until the left two digits of the LED show 30. Release button "A" when the desired function number is reached. The MIB display should show "3050".

7. Verify that the MIB display shows "3050".

8. Press and hold button "B", then press button "C".

9. Release both buttons. After several seconds the dash display will change from MIB SET-UP MODE to the current truck status (POWER ON, READY etc.). This indicates that the new values have been saved and that the set-up mode has been exited.

NOTE: To exit without saving new values, turn the key switch to the "OFF" position.

10. Verify the correct operation of all traction and hydraulic functions.

MIB FUNCTION DESCRIPTIONS Function 01 - Model Code Default Values This function permits the programming of MIB factory default values for each model truck. Setting this function to the value corresponding to the specific truck model will program MIB function numbers 2 through 29 to the corresponding factory default values. See Table 3-6 for a list of settings for each model truck. Refer to MIB SET-UP PROCEDURE for detailed instructions for programming the MIB.

Sheet 4: Electrical System CAUTION: Function 01 will not program values for the traction potentiometer (Function 34) or hydraulic potentiometer (Function 32). These components must be manually calibrated to the MIB. Refer to MIB SET-UP PROCEDURE for detailed instructions.

Function 02 - Lift - Minimum Rate This function adjusts the slowest speed the forks lift with the multi-function control handle in the slow lift position (pump motor first starts).

Increasing this value will increase the slowest speed the forks lift. Decreasing this value will decrease the slowest speed the forks lift. Decreasing this value below the default value can increase the distance the multi-function control handle has to be moved to start lift.

Function 03 - Lift - Maximum Rate This function adjusts the fastest speed the forks lift with the multi-function control handle in the fast lift position.

The factory default value allows maximum lift speed. Increasing this value from the default value will not increase lift speed, but will allow maximum lift speed to occur at a point closer to the neutral position of the multi-function control handle. Decreasing this value will decrease maximum lift speed. After programming the minimum value allowed, an additional reduction in lift speed can be realized by decreasing the value of Function 02, if desired.

Function 04 - Lower - Minimum Rate This function adjusts the slowest speed the forks lower with the multi-function control handle in the slow lower position (lowering valve is first activated).

Increasing this value will increase the slowest speed the forks lower. Decreasing this value will decrease the slowest speed the forks lower. Decreasing this value below the default value can increase the distance the multi-function control handle has to be moved to start lowering.

Function 05 - Lower - Maximum Rate This function adjusts the fastest speed the forks lower with the multi-function control handle in the fast lower position.

The factory default value allows maximum lower speed. Increasing this value from the default value will not increase lower speed but will allow maximum lowering speed to occur at a point closer to the neutral position of the multi-function control handle. Decreasing this value will decrease maximum lower speed. After programming the minimum value allowed, an additional reduction in lower speed can be realized by decreasing the value of Function 04, if desired.

Function 06 - Extend - Minimum Rate This function adjusts the slowest speed the forks extend with the multi-function control handle in the slow extend position (auxiliary valve is first activated).

Increasing this value will increase the slowest speed the forks extend. Decreasing this value will decrease the slowest speed the forks extend. Decreasing this value below the default value can increase the distance the multi-function control handle has to be moved to start extend.

Function 07 - Extend - Maximum Rate This function adjusts the fastest speed the forks extend with the multi-function control handle in the fast extend position.

Increasing this value will provide faster speeds. Decreasing this value will provide slower speeds. After programming the minimum value allowed, an additional reduction in extend speed can be realized by decreasing the value of Function 06, if desired.

Function 08 - Retract - Minimum Rate This function adjusts the slowest speed the forks retract with the multi-function control handle in the slow retract position (auxiliary valve is first activated).

Increasing this value will increase the slowest speed the forks retract. Decreasing this value will decrease the slowest speed the forks retract. Decreasing this value below the default value can increase the distance the multi-function control handle has to be moved to start retract.

Sheet 4: Electrical System Function 09 - Retract - Maximum Rate This function adjusts the fastest speed the forks retract with the multi-function control handle in the fast retract position.

Increasing this value will provide faster speeds. Decreasing this value will provide slower speeds. After programming the minimum value allowed, an additional reduction in extend speed can be realized by decreasing the value of Function 08, if desired.

Function 12 - Tilt Down - Minimum Rate This function adjusts the slowest speed the forks tilt down with the multi-function control handle in the slow tilt down position (auxiliary valve is first activated).

Increasing this value will increase the slowest speed the forks tilt down. Decreasing this value will decrease the slowest speed the forks tilt down. Decreasing this value below the default value can increase the distance the multi-function control handle has to be moved to start tilt down.

Function 13 - Tilt Down - Maximum Rate This function adjusts the fastest speed the forks tilt down with the multi-function control handle in the fast tilt down position.

Increasing this value will provide faster speeds. Decreasing this value will provide slower speeds. After programming the minimum value allowed, an additional reduction in tilt down speed can be realized by decreasing the value of Function 12, if desired.

Function 14 - Sideshift Right-Minimum Rate This function adjusts the slowest speed the forks sideshift to the right with the multi-function control handle in the slow sideshift right position (auxiliary valve is first activated).

Increasing this value will increase the slowest speed the sideshift moves right. Decreasing this value will decrease the slowest speed the sideshifter moves right. Decreasing this value below the default value can increase the distance the multi-function control handle has to be moved before sideshift right occurs.

Function 10 - Tilt Up - Minimum Rate This function adjusts the slowest speed the forks tilt up with the multi-function control handle in the slow tilt up position (auxiliary valve is first activated).

Increasing this value will increase the slowest speed the forks tilt up. Decreasing this value will decrease the slowest speed the forks tilt up. Decreasing this value below the default value can increase the distance the multi-function control handle has to be moved to start tilt up.

Function 11 - Tilt Up - Maximum Rate This function adjusts the fastest speed the forks tilt up with the multi-function control handle in the fast tilt up position.

Increasing this value will provide faster speeds. Decreasing this value will provide slower speeds. After programming the minimum value allowed, an additional reduction in tilt up speed can be realized by decreasing the value of Function 10, if desired.

Function 15 - Sideshift Right-Maximum Rate This function adjusts the fastest speed the forks sideshift to the right with the multi-function control handle in the maximum-speed, sideshift right position.

Increasing this value will provide faster speeds. Decreasing this value will provide slower speeds. After programming the minimum value allowed, an additional reduction in sideshift right speed can be realized by decreasing the value of Function 14, if desired.

Function 16 - Sideshift Left-Minimum Rate This function adjusts the slowest speed the forks sideshift to the left with the multi-function control handle in the slow sideshift left position (auxiliary valve is first activated).

Sheet 4: Electrical System Increasing this value will increase the slowest speed the sideshifter moves left. Decreasing this value will decrease the slowest speed the sideshifter moves left. Decreasing this value below the default value can increase the distance the multi-function control handle has to be moved before sideshift left occurs.

Function 17 - Sideshift Left-Maximum Rate This function adjusts the fastest speed the forks sideshift left with the multi-function control handle in the maximum-speed, sideshift left position.

Increasing this value will provide faster speeds. Decreasing this value will provide slower speeds. After programming the minimum value allowed, an additional reduction in sideshift left speed can be realized by decreasing the value of Function 16, if desired.

Function 18 - Auxiliary Hydraulic Function - Starting Rate This function adjusts the starting rate, or rate of acceleration, of the hydraulic valve for the auxiliary hydraulic function.

Increasing the starting rate value increases the time it takes for the auxiliary hydraulic function to accelerate to the selected speed (accelerates more slowly). Decreasing the starting rate value decreases the time it takes for the auxiliary hydraulic function to accelerate (accelerates more quickly).

Function 19 - Auxiliary Hydraulic Function - Stopping Rate This function adjusts the stopping rate, or rate of deceleration, of the hydraulic valve for the auxiliary hydraulic function.

Increasing the stopping rate value increases the time it takes for the auxiliary hydraulic function to stop (decelerates more slowly). Decreasing the stopping rate value decreases the time it takes for the auxiliary hydraulic function to stop (decelerates more quickly).

Function 20 - Maximum Travel Speed - Mast Elevated This function adjusts the maximum travel speed (speed limit) of the truck with the mast elevated above free lift.

WARNING: Never adjust Function 20 to a value greater than the value specified for the truck model. Refer to Table 3-19 through Table 3-28 for specific maximum values. Lift trucks can tip over even at very slow speeds. A lift truck is less stable with the forks elevated. Tip over can cause personal injury or property damage.

Decreasing the maximum travel speed value lowers the speed of the truck with the mast elevated.

Function 21 - Model Code - MTVFD WARNING: Do not customize this function. This function must remain at the default value. Values other than the default value can cause improper operation of the lift truck. Improper lift truck operation can cause personal injury or property damage.

Function 22 - Model Code - MTVRD WARNING: Do not customize this function. This function must remain at the default value. Values other than the default value can cause improper operation of the lift truck. Improper lift truck operation can cause personal injury or property damage.

Function 23 - Power Steering Contactor - Minimum Current WARNING: Do not customize this function. This function must remain at the default value. Values other than the default value can cause improper operation of the lift truck. Improper lift truck operation can cause personal injury or property damage.

Function 24 - Power Steering Contactor - Maximum Current WARNING: Do not customize this function. This function must remain at the default value. Values other than the

Sheet 4: Electrical System default value can cause improper operation of the lift truck. Improper lift truck operation can cause personal injury or property damage.

Function 25 - Lift Pump Contactor - Minimum Current WARNING: Do not customize this function. This function must remain at the default value. Values other than the default value can cause improper operation of the lift truck. Improper lift truck operation can cause personal injury or property damage.

Function 26 - Lift Pump Contactor - Maximum Current WARNING: Do not customize this function. This function must remain at the default value. Values other than the default value can cause improper operation of the lift truck. Improper lift truck operation can cause personal injury or property damage.

Function 27 - Auxiliary Function Coils - Minimum Current WARNING: Do not customize this function. This function must remain at the default value. Values other than the default value can cause improper operation of the lift truck. Improper lift truck operation can cause personal injury or property damage.

Function 28 - Auxiliary Function Coils - Maximum Current WARNING: Do not customize this function. This function must remain at the default value. Values other than the default value can cause improper operation of the lift truck. Improper lift truck operation can cause personal injury or property damage.

Function 29 - Steering Pump Time Delay WARNING: Do not customize this function. This function must remain at the default value. Values other than the default value can cause improper operation of the lift truck. Improper lift truck operation can cause personal injury or property damage.

Function 30 - Exit and Save New Values This function is used as a utility for saving changes made to MIB settings and exiting from the MIB set-up mode. No customization for this function is applicable.

Function 31 - Erase This function is used as a utility for erasing model code information during the MIB calibration. No customization for this function is applicable.

Function 32 - Hydraulic Potentiometer - Set-up This function is used as a utility for setting the hydraulic potentiometer range during MIB calibration. No customization for this function is applicable.

Function 33 - NOT USED Function 34 - Traction Potentiometer - Set-up This function is used as a utility for setting the traction potentiometer range during MIB calibration. No customization for this function is applicable.

Functions 35-56 - NOT USED Function 57 - Auxiliary Hydraulic Function Damping This function is used as a utility for timing auxiliary hydraulic function damping.

WARNING: Do not customize this function. This function must remain at the default value. Values other than the

Sheet 4: Electrical System default value can cause improper operation of the lift truck. Improper lift truck operation can cause personal injury or property damage.

Function 58 - Hydraulic Lift Function - Starting Rate This function adjusts the starting rate, or rate of acceleration, of the hydraulic valve for the hydraulic lift function.

Increasing the starting rate value increases the time it takes for the hydraulic lift function to accelerate to the selected speed (accelerates more slowly). Decreasing the starting rate value decreases the time it takes for the hydraulic lift function to accelerate (accelerates more quickly).

Function 59 - Hydraulic Lift Function - Stopping Rate This function adjusts the stopping rate, or rate of deceleration, of the hydraulic valve for the hydraulic lift function.

Increasing the stopping rate value increases the time it takes for the hydraulic lift function to stop (decelerates more slowly). Decreasing the stopping rate value decreases the time it takes for the hydraulic lift function to stop (decelerates more quickly).

Function 60 - Hydraulic Lower Function - Starting Rate This function adjusts the starting rate, or rate of acceleration, of the hydraulic valve for the hydraulic lower function.

Increasing the starting rate value increases the time it takes for the hydraulic lower function to accelerate to the selected speed (accelerates more slowly). Decreasing the starting rate value decreases the time it takes for the hydraulic lower function to accelerate (accelerates more quickly).

Function 61 - Hydraulic Lower Function - Stopping Rate This function adjusts the stopping rate, or rate of deceleration, of the hydraulic valve for the hydraulic lower function.

Increasing the stopping rate value increases the time it takes for the hydraulic lower function to stop (decelerates more slowly). Decreasing the stopping rate value decreases the time it takes for the hydraulic lower function to stop (decelerates more quickly).

MIB PLUG PIN IDENTIFICATION CAUTION: Never attempt to probe through the back of the J1 or J2 MIB plugs. These plugs are specially sealed plugs. Probing through the back of the J1 or J2 MIB plugs will destroy the seal and can cause a short circuit. If a circuit must be tested for voltage, check for voltage at an "amp" type plug, a switch or a component. If the circuit to the MIB is suspect, check the circuit by removing the MIB and disconnecting the J1 and J2 plugs. Refer to MIB REMOVAL. Test continuity from the front (pin end) of the plugs.

Figure 3-19- MIB Plug - Pin Identification

Sheet 5: Electrical System MIB STATUS, WARNING AND FAULT CODES GENERAL During normal operation the left two digits show the "STATUS" code of the truck and the right two digits show "00".

Whenever a truck function is selected the left two digits are updated to display the selected function.

The two digits on the right side of the display are used to display either a "WARNING" code or a "FAULT" code. If neither a "WARNING" code nor a "FAULT" code is present the right two digits continue to display "00". If multiple faults are present the highest priority "FAULT" code is displayed. After the highest priority fault is repaired the next highest priority "FAULT" code will be displayed.

If a "WARNING" code and a "FAULT" code are received at the same time the left two digits will display the "WARNING" code the right two digits will display the "FAULT" code and the "STATUS" code will not be displayed.

Always troubleshoot the code shown on the right side of the display first.

Codes are displayed as follows: "STATUS" codes → "WARNING" codes → "FAULT" codes →

numbers 01 to 16. numbers 34 to 38. numbers 40 to 85.

For example if an operator tries to use the sideshift and there is an open sideshift solenoid on the mast the red fault icon on the dash will light and CHECK FAULT CODE, NO SIDESHIFT will be displayed.

To repair the problem remove the cover for access to the MIB and perform the function (sideshift) which caused the fault to occur. Fault code "43" would be displayed on the right two digits of the MIB when the sideshift function was attempted. The serviceperson would refer to MIB Code "43" on the following pages to diagnose and repair the cause of the problem.

NOTE: The fault code fault message and fault icon for most faults are displayed only when the operator attempts to perform the affected function.

TROUBLESHOOTING CHARTS The sample chart below explains the format for the information provided on the following pages. Note that an "X" in the MIB CODE section represents a placeholder character and can be any number. The priority level is provided to show the relative order codes would be displayed in the event of more than one simultaneous status warning or fault condition.

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BLANK OR UNDEFINED CODE CONDITIONS

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STATUS CODES

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WARNING CODES NOTE: When WARNING codes and FAULT codes occur simultaneously, the left two digits display the WARNING code and the right two digits display the FAULT code (e.g. XX34 becomes 3458, when 34 is the WARNING code and 58 is the concurrent FAULT code).

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Sheet 6: Electrical System SEM TRACTION MOTOR CONTROLLER Description/Features The Curtis Model 1244-4405 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 armature circuit independently. The controller has many programmable features, including acceleration rate, maximum speed, braking current limit, and neutral braking current limit. The operator can also select from three different performance modes to customize the operation of the truck to the application, as required. The SEM controller includes a full range of built-in safety features and diagnostic and set-up capability for safe reliable operation.

Figure 3-20 - Traction Motor Controller The Curtis Model 1307 Programmer Handset (Yale P/N 1500359-08) is used to program and troubleshoot the traction motor controller. Refer to PROGRAMMER HANDSET. The traction motor controller communicates with the dash display for selection of performance modes and for diagnostic information. The performance-mode selection feature allows the operator to choose from three different motor controller performance levels by pushing a button on the dash display. The rate of acceleration, maximum top speed, and braking rate can be specifically assigned for each mode using the programmer hand set.

Simplified diagnostic information is communicated to the dash display to alert the operator to adverse conditions such as controller over temperature, operator sequence error or motor controller 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 multi-function 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 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 the socket head capscrews retaining the operator's compartment cover. 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 (center 2 terminals). DO NOT use a screwdriver to discharge the traction motor controller.

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

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

6. Remove the four capscrews, lockwashers and L brackets retaining the controller within the mounting brackets.

Sheet 6: Electrical System Carefully remove the traction motor controller from the lift truck.

Testing See PROGRAMMER HANDSET 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 be faulty, it must be replaced.

Installation 1. Make certain that the mounting surface for the traction motor controller is clean. There should be no dirt between the frame and the traction motor controller. Align the traction motor controller in the lift truck between the upper and lower mounting brackets. Verify that the captive nuts are in place on the mounting brackets. Install the L brackets, capscrews and lockwashers to retain the controller between the mounting brackets..

2. Connect the wires to the terminals. See WIRING SCHEMATICS AND DIAGRAMS located at the end of this section. Plug the X-3 connector into the J1 receptacle of the traction motor controller.

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

Figure 3-21 - Traction Motor Controller Pin Arrangement

PROGRAMMER HANDSET Description/Features The Programmer Handset is a hand held tool that allows the user to PROGRAM TEST, and DIAGNOSE the Traction Motor Controller. It has been designed for ease of use with eight keys to control all functions. A MORE INFO key is included to provide more detail on any display item.

The programmer is powered by the controller. When the programmer is plugged into the controller it will acquire all

Sheet 6: Electrical System the controller function values and display the model number date of manufacture and revision code. After the initial display the programmer 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 display is visible in most lighting conditions. When the programmer 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 selected item will be highlighted with a flashing arrow).

SCROLL DISPLAY Keys To scroll up and down within a menu use the two SCROLL DISPLAY 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 indication of the position of the four displayed items within the entire menu. That is when the scroll bar is at the 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 bottom the end of the menu has been reached.

CHANGE VALUE Keys The CHANGE VALUE arrow keys increase or decrease the value of the selected menu item. There is an LED on each arrow key to indicate when the key is active and a change is permissible. When the LED is off the limit setting (maximum or minimum) of the function has been reached.

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 PROGRAM 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 information 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 minimum and maximum values available for the selected item. If the minimum or maximum value has been programmed a message replaces the bar graph and any dependencies are listed.

Sheet 6: Electrical System 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 settings and stores them in its temporary memory. This allows the user to revert back to the original settings at any time. 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).

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

2. Disconnect and separate the battery connector.

3. Remove the two screws retaining the metal cover located on the right side of the operator compartment. 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 Handset should only be connected and disconnected with the key switch in the off position.

5. Connect the Programmer Handset 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 Handset from the Traction Motor Controller 1. Turn the key switch to the "OFF" position.

2. Disconnect and separate the battery connector.

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 (center 2 terminals).

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 (center 2 terminals). DO NOT use a screwdriver to discharge the traction motor controller.

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

NOTE: The Programmer Handset should only be connected and disconnected with the key switch in the off position.

5. Install the cover in the operator's compartment. Install the two screws.

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

Sheet 6: Electrical System programmer is powering up. During the SELF TEST you can toggle between the two test screens by pressing the SCROLL DISPLAY keys. The first screen turns on every LCD element and the second screen displays all the characters used in the various menus. As part of the SELF TEST you can also test the keys by pressing each one and observing whether its corner LED lights up. To exit the SELF TEST unplug the programmer or turn off the controller.

Figure 3-23- Programmer Handset Self Test

OPERATING MODES 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 display window, four at a time, with the corresponding settings. The setting of the selected item (the item at the top of the display 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 key to 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 setting, the unit of measure, and the specific minimum and maximum values for the setting. If the range is limited by the values assigned for a different function, the name of the limiting function is displayed in place of the minimum and maximum values.

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Table 3-7 - Program Menu 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 programmer has been placed in the TEST mode. The TEST menu displays 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 controller during initial installation. The MORE INFO key, when used in the TEST mode, displays additional information about the top item in the window.

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Table 3-8 - Test Menu

Table 3-9- Dash Display Drive Mode Inputs 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 DIAGNOSTIC mode. The DIAGNOSTICS menu displays all currently active faults detected by the controller. It is capable of displaying 19 different faults, four at a time.

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Table 3-10 - Diagnostic and Diagnostic History Display NOTE: The DIAGNOSTIC and DIAGNOSTIC HISTORY display shown in Table 3-10 is not a menu as such, but simply a list of the possible messages displayed when the programmer is operating in the DIAGNOSTICS or DIAGNOSTIC HISTORY modes. The messages are listed in alphabetical order for easy reference.

Diagnostic History Press the DIAGNOSTICS key and the MORE INFO key simultaneously to enter the DIAGNOSTIC HISTORY menu.

The DIAGNOSTIC HISTORY lists all of the faults observed and recorded 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 HISTORY". 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 PROGRAM key to enter the SPECIAL PROGRAM menu. The SPECIAL 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

Sheet 6: Electrical System contrast of the programmer display, select language, and display basic controller and programmer information.

Press the SCROLL DISPLAY key until the desired function is on the top line. Press the MORE INFO key for information on how to make the desired adjustment.

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 memory. The programmer can then be used to load the saved values to other similar controllers (same model number).

Table 3-11 - Special Program Menu 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 the 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 two screws retaining the metal cover located on the right side of the operator compartment. 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. 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 HANDSET 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 user to revert back to the original settings at any time. 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.

Sheet 6: Electrical System NOTE: The brake pedal must be released (up position) during Step 7.

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 HANDSET 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 of the MORE INFO button lights to indicate that the MORE INFO option has been selected.

NOTE: Some function values are limited by values set for other 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 through 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. 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 traction motor controller.

18. Install the cover in the operator's compartment. Install the two screws to retain the cover. Reconnect the battery.

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Table 3-12 - NR/NDR/NS Program Menu Range and Default Values TROUBLESHOOTING The traction motor controller provides diagnostic information to the programmer handset, the dash display and the Status LED on the controller. The following four-step process is recommended 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 handset.

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

4. Correct the problem.

Sheet 6: Electrical System 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 no faults present, the Status LED flashes steadily on and off. If the controller detects a fault, a 2-digit fault identification 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.

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.

Table 3-13 - Status LED Fault Codes 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 displayed in the TEST menu. The DIAGNOSTIC HISTORY menu provides a list of the faults that have occurred since the diagnostic 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 DIAGNOSTIC mode. The DIAGNOSTICS menu displays all currently active faults detected by the controller. It is capable of displaying 16 different faults, four at a time.

Press the DIAGNOSTICS key and the MORE INFO key simultaneously to enter the DIAGNOSTIC HISTORY menu.

The DIAGNOSTIC HISTORY lists all of the faults observed and recorded 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 programmer has been placed in the TEST mode. The TEST menu displays 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 MORE INFO key, when used in the TEST mode, displays additional information about the top item in the window.

The charts on the following pages should be used in conjunction with the wiring diagrams at the end of this section

Sheet 6: Electrical System for best results. The DIAGNOSTIC (and DIAGNOSTIC HISTORY) menu items are shown, followed by the TEST menu items.

Diagnostics Menu

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Test Menu

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DASH DISPLAY ASSEMBLY Description/Features The dash display interfaces with the MIB and the traction controller and is located on the panel adjacent to the steering tiller.

Two versions of the dash display are available: Standard Freezer

→ →

-25ºto 70ºC (-13ºto 158ºF) -40ºto 70ºC (-40ºto 158ºF)

The dash display contains the following features: Three "button-selectable" drive modes Sixteen character English LCD Message Center display for status, warning, and fault messages Three "button-selectable" hourmeters (Traction, Lift and Total Hours) Four hydraulic function selection lights Ten bar LED battery state of charge indication Low battery lift interrupt indication and permissive output

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Figure 3-24 - Dash Display Assembly Operation The Dash Display is energized when the key switch is on and the battery disconnect switch is closed. An internal back-up battery provides memory retention of the battery indicator and hourmeter readings when the battery is disconnected from the truck.

The Drive Mode Switch allows the operator to select the level of traction motor controller performance most suited to the application. Indicators on the dash display change to correspond to the level of performance selected. The three indicators are as follows: The "Turtle" indicates slowest acceleration, reduced top speed, and maximized energy efficiency. The "Rabbit" indicates maximum acceleration and maximum top speed. The middle setting is a compromise between the turtle and rabbit settings and indicates reduced acceleration, but with maximum top 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 when battery power is restored.

The Message Center is a 16-character alpha-numeric liquid crystal display (LCD), with green back-lighting.

Hourmeter readings, truck performance status messages, warning messages and fault messages are shown on the Message Center.

The Hourmeter Switch is used to display hourmeter information in the Message Center . 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 current operational status display.

After 30 seconds, the display defaults to the current operational status of the truck.

The Warning/Fault Indicator blinks to alert the operator to check the Message Center. When a warning message is displayed, the Warning/Fault Indicator blinks yellow. When a fault message is displayed, the Warning/Fault Indicator blinks red.

The Function Selection Lights are for the display of Lift, Reach, Tilt and Sideshift operations.

Battery Indicator The Battery Indicator has a 10 bar green, yellow and red light emitting diode (LED) to indicate battery charge. As battery power is used, the LEDs will turn off in sequence, starting with green. The red LED second from the bottom flashes to indicate when the battery is nearly discharged. The red LED on the bottom of the display will alternately flash with the low-battery indicator LED (a crossed battery symbol) to indicate that the battery is discharged and the hoist function is disabled.

REMOVAL The dash display is located on the panel adjacent to the steering tiller in the operator's compartment. The dash display assembly cannot be repaired and must be replaced if defective.

1. Move the lift truck to a safe level area. Turn the key switch off and remove the key. Put a "DO NOT OPERATE"

Sheet 6: Electrical System tag on the multi-function 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.

3. Remove the hydraulic tank dipstick.

Figure 3-25- Dash Display Voltage Selection Jumper Location 4. Remove the socket head capscrews retaining the battery compartment cover and the drive unit cover. Remove the covers. Open the drive unit compartment door.

5. Disconnect the two plugs from the rear of the dash display assembly.

6. Remove the two thumbscrews and the retainers securing the dash display assembly to the instrument panel.

Remove the dash display assembly.

INSTALLATION 1. Adjust the pots on the rear of the dash display assembly.

See DASH DISPLAY, ASSEMBLY, ADJUSTMENT. 2. Connect the two plugs to the rear of the dash display.

3. Position the dash display assembly in the instrument panel. Install the retainers and the thumbscrews to retain the dash display assembly to the instrument panel.

4. Install the drive unit cover and the battery cover. Close and secure the drive unit compartment door.

5. Install the hydraulic tank dipstick.

6. Connect the battery.

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

Voltage Selection Voltage selection (24 or 36 volt battery) is achieved by means of an "X-15A" jumper assembly. The "X-15A" jumper assembly is plugged into the "X-15" connector for 24 volt battery operation only. No jumper is used for 36 volt battery operation. The jumper assembly, when used, is located in the main truck wire harness beneath the dash display assembly. See Figure 3-25.

Sheet 6: Electrical System DASH DISPLAY ADJUSTMENT The dash display assembly has two potentiometers located between the connectors on the back of the assembly.

The potentiometers are set at the factory and should not require adjustment.

The RESET potentiometer sets the level to which the battery must be charged before the battery indicator resets.

The RESET potentiometer is set at the factory to B. At the factory setting, the battery must have open circuit voltage greater than 2.09 volts per cell to cause the battery indicator to reset. The battery must be disconnected for a minimum of 15 seconds (before a charged battery is connected) for the RESET function to operate.

The DISCHARGE potentiometer sets the level at which LIFT interrupt occurs. The DISCHARGE potentiometer is set at the factory to L. At the factory setting, the battery must have open circuit voltage of approximately 1.63 volts per cell to cause the lift interrupt function to occur. Adjustment of the DISCHARGE potentiometer from L toward k allows the battery to discharge more before lift interrupt occurs. Adjustment of the DISCHARGE potentiometer from L toward P allows the battery to discharge less before lift interrupt occurs.

Adjust the settings, if necessary, by inserting a small screwdriver through the access hole in the rear of the dash display and into the long slot in each adjustment screw. Rotate the screwdriver fully clockwise, then counterclockwise until the dotted end of the slot is aligned to the desired setting. See Figure 3-26.

Figure 3-26- Battery Indicator Adjustment

Table 3-14 - Battery Indicator RESET Potentiometer Adjustment

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Table 3-15 - Battery Indicator DISCHARGE Potentiometer Adjustment

TROUBLESHOOTING Inoperative Dash Display Assembly If the dash display is blank (no display, no LEDs) with the key switch on and the battery disconnect switch closed, check the following: Verify that the battery disconnect switch is closed by measuring for battery voltage on both sides of the switch. Check fuses 4, 5 and 6. Check for battery voltage at the MIB at J2-15 and J2-23 (wire #15). Check J2-7 and J2-8 (wire #13) for B-. Check for battery voltage at the dash display at X4-2 (wire #15). Wires X4-8 and X4-10 at the dash display should be B-. If all of these conditions are correct, the dash display or the MIB could be defective.

Inoperative Drive Mode Selection 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 the Dash Display with a Programmer Handset Using the Programmer Handset, enter the TEST MENU. Check the MODE SELECT INPUT 1 and the MODE SELECT INPUT 2. See Table 3-16 for the correct inputs.

Table 3-16 - Dash Display Drive Mode Inputs If the communication is occurring as shown in Table 3-16, but truck operation is still incorrect, verify the programming of the traction motor controller as follows: 1. Enter the PROGRAM MENU on the programmer. See PROGRAMMING THE TRACTION MOTOR CONTROLLER. 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 differences in top speed in each mode.

Sheet 6: Electrical System If the speeds are different for each drive mode and correspond to the selected mode, the mode selection feature is working. If speeds do not differ for each drive mode, the traction motor controller may be faulty.

6. Reprogram the traction motor controller to the correct values. See PROGRAMMING THE TRACTION MOTOR CONTROLLER. Troubleshooting Without a Programmer Handset If a Programmer Handset is not available, communication from the dash display to the traction motor controller can be checked using a digital volt ohmmeter. Check the voltage levels on wires DM1 and DM2 by testing connector pins 3 and 4 at the traction motor controller with respect to the B- terminal of the traction motor controller.

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: Use only a digital volt ohmmeter during this test procedure. Use of other test equipment can cause the internal components of the dash display and/or traction motor controller to malfunction.

The voltages should be as follows:

Table 3-17 - Dash Display Drive Mode Test Voltages If the voltages at DM1 and DM2 are correct and correspond to the appropriate drive modes, but lift truck operation is still incorrect, a programmer handset will be required for further troubleshooting.

No Warnings or Faults Displayed 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-3 connector of the traction motor controller and in the X-6 connector at the dash display. These two wires transmit digital codes corresponding to warnings or faults affecting the traction controller.

During normal operation (no faults or warnings present), the voltage between FM1 and battery negative, and the voltage between FM2 and battery negative, should be less than +5.0 volts, respectively. In a fault or warning condition, the voltage between FM1 and battery negative and/or FM2 and battery negative will change.

Sheet 6: Electrical System Table 3-18-Dash Display Status/Warning/Fault Test Voltages Lift Interrupt Wire #85 transmits the lift interrupt signal from the dash to the MIB. Normally, (when the BDI is not flashing), the signal is less than +5.0 volts. When the BDI is in the red flashing zone (lift interrupt), the signal is greater than +10.0 volts.

To check a dash display/lift interrupt circuit malfunction, by-pass the lift interrupt function by connecting a jumper wire from battery- to #85 wire of the X-6 plug at the dash display assembly. If the lift does not operate, disconnect the battery and check the continuity of wire #85 from the dash display X-6 plug to the MIB J1 plug. Check the MIB for fault or warning codes.

If lift interrupt does not occur when the BDI is in the red flashing zone, wire #85 may be shorted to battery-. Check the MIB for fault or warning codes Lost MIB Signal Displayed Wires #81, #82, and #83 also transfer status, warning and fault information to the dash display. If "LOST MIB SIGNAL' is displayed on the dash display, check the continuity of these wires. If the wires test OK, verify proper operation of the dash display and MIB.

Hourmeter Input The lift pump hourmeter input is transmitted by wire #37 from the HMR (Hourmeter Relay). The contacts of the HMR are closed when the lift pump contactor is energized. If the lift pump hourmeter is not functioning properly, check for battery voltage with the lift pump operating at wire #37, plug X-4, at the dash display. Check for battery voltage at the HMR, wires #10 and 37 (lift pump contactor energized). Check for battery voltage across wires #85 and #87 (lift pump contactor energized). If the voltages test correctly, but the hourmeter does not function correctly, replace the dash display.

The traction motor hourmeter input is transmitted by wires #6 and #8. If the drive hourmeter is not functioning properly, check for battery voltage during travel at the dash display. During forward travel, check wire #6, at dash display pin 4-6. During reverse travel, check wire #8, at dash display pin 4-7.

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 by the 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 6: Electrical System

Figure 3-27- 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 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 (center 2 terminals). DO NOT use a screwdriver to discharge the traction motor controller.

4. Remove the operator's 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 3-28 through Figure 3-36. 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 if

Sheet 6: Electrical System 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 close the 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 6: Electrical System

Figure 3-28- Normal Commutator Surfaces Commutator Problems Commutator problems and motor problems are shown in Figure 3-29 through Figure 3-36. See COMMUTATOR REPAIRS, this section.

Sheet 6: Electrical System

Figure 3-29- Commutator Problems

Figure 3-30 - Commutator Problems

Figure 3-31 - Commutator Problems

Sheet 6: Electrical System

Figure 3-32- Commutator Problems

Figure 3-33- Commutator Problems

Figure 3-34- Commutator Problems

Sheet 6: Electrical System Figure 3-35 - Commutator Problems

Figure 3-36 - 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 3-37. 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 by YALE 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 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 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. Use a screwdriver or jumper wire to make a short-circuit across the B+ and B- terminals of the traction motor controller.

4. 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.

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 sure the brush holder is fastened tightly to the mounts at the 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 lbf per each in²)

Sheet 6: Electrical System when measured with a spring scale.

NOTE: Measure the surface area on the brush which contacts the commutator (thickness x width). See Figure 3-37.

Multiply the surface area times 1.5 to 3.0 to determine the brush spring force.

1. BRUSH HOLDER (4) 2. BRUSH YOKE 3. BRUSH SPRING (4) 4. BRUSH SET 5. SPRING SURFACE OF BRUSH 6. COMMUTATOR SURFACE OF BRUSH Figure 3-37 - Traction Motor Brushes A brush for a traction motor has an area of approximately 4.27 x 0.96 cm = 4.3 cm²6 (1.75 x 0.378 in = 0.665 in²).

Brush springs for the traction motor normally have a spring force of approximately 8.5 ± 1.1 Newtons (2 lbf ±4 ozf) when measured with a spring scale as shown in Figure 3-39. (Look for a reading of approximately 2 ±.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 measures less than the minimum brush length.

Sheet 6: Electrical System

1. BRUSH 2. BRUSH SPRING Figure 3-38 - Brush Removal and Inspection A brush for a hydraulic pump motor has an area of approximately 1.74 x 0.375 in. = 0.653 in²6 (4.42 x 0.95 cm = 4.21 cm²). Brush springs for the hydraulic pump motor normally have a spring force of approximately 1 lbf and 8 ozf ±4 ozf (6.3 ±1.1 Newtons) when measured with a spring scale as shown in Figure 3-39. (Look for a reading of approximately 1.5 ± .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 measures 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 3-40.

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 6: Electrical System

1. SPRING SCALE (0-5 LB FISH SCALE) 2. BRUSH IN BRUSH HOLDER 3. COMMUTATOR 4. BRUSH SPRING Figure 3-39 - 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 of the 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

Sheet 6: Electrical System 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. 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 Figure 3-40 - 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 180º 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 (∞) 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 3-33.

Sheet 6: Electrical System 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 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 3-41 - 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 3-41. 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 greater than one ohm indicates a problem in that winding or corrosion in the terminal connection. See Figure 3-42.

1. FIELDCOILTERMINAL 2. OHMMETER

Sheet 6: Electrical System Figure 3-42 - Test for an Open Field Circuit Short-Circuit in a Field Coil A short-circuit in a motor field 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 motor with 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 (Rx 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 (∞).

Sheet 7: Electrical System

Table 3-19 - MIB Function Code Values - 24 Volt NR035AD Model Trucks

Sheet 7: Electrical System

Table 3-20 - MIB Function Tube Values -24 Volt NR040AD Model Trucks

Sheet 7: Electrical System

Table 3-21 - MIB Function Tube Values - 36 Volt NR035AD Model Trucks

Sheet 7: Electrical System

Table 3-22 - MIB Function Tube Values - 36 Volt NR040AD Model Trucks

Sheet 7: Electrical System

Table 3-23 - MIB Function Tube Values - 36 Volt NR045AD Model Trucks

Sheet 7: Electrical System

Table 3-24 - MIB Function Tube Values -24 Volt NDR030AD Model Trucks

Sheet 7: Electrical System

Table 3-25 - MIB Function Tube Values - 36 Volt NDR030AD Model Trucks

Sheet 7: Electrical System

Table 3-26 - MIB Function Tube Values - 24 Volt NS040AE Model Trucks

Sheet 7: Electrical System

Table 3-27 - MIB Function Tube Values - 36 Volt NS040AE Model Trucks

Sheet 7: Electrical System

Table 3-28 - MIB Function Tube Values - 36 Volt NS050AE Model Trucks

Sheet 8: Electrical System

Figure 3-43 - Wiring Schematic 5241353-87 - NR/NDR/NS

Sheet 8: Electrical System

Figure 3-43 - Wiring Schematic 5241353-87 - NR/NDR/NS (Continued)

Sheet 8: Electrical System

Figure 3-44 - Options Schematic 5241353-87 - NR/NDR/NS

Sheet 8: Electrical System

Figure 3-45 - Wiring Diagram 5241353-87 - NR/NDR/NS

Sheet 8: Electrical System

Figure 3-45 - Wiring Diagram 5241353-87 - NR/NDR/NS (Continued)

Sheet 8: Electrical System

Figure 3-45 -Wiring Diagram 5241353-87 - NR/NDR/NS (Continued)

Sheet 8: Electrical System

Figure 3-46 - Options Diagram 5241353-87 - NR/NDR/NS

Sheet 9: Drive Unit

DRIVE UNIT GENERAL This section has a description and the repair and adjustment procedures for the parts of the Master Drive Unit (MDU). The final drive ratio of the MDU is 14.5:1. The traction motor, steering and brake repair procedures are in separate sections. 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 that is attached to an articulating axle. 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. 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 trunnion blocks, the upper halves of which are welded to the lift truck frame. 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, providing for easy access.

NOTE: The manufacturer recommends draining and refilling the drive unit oil after the first 500 hours of use on all new trucks. See LUBRICATION INSTRUCTIONS, Section 2, this manual.

DESCRIPTION (See Figure 4-1 and Figure 4-3) 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.

ARTICULATION STOP ADJUSTMENT The stability and traction will also 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, at the following 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.

Sheet 9: Drive Unit

Figure 4-1 - Master Drive Unit with Wheel and Traction Motor

Figure 4-2 - Drive Unit Articulation Stops Nameplate

Table 4-1 - Articulation Chart

Sheet 9: Drive Unit NOTE: The articulation stop settings are also listed on the nameplate.

ARTICULATION 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 clearances 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 lbf 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.

Removal 1.

Disconnect the battery. Open the drive unit compartment door.

Sheet 9: Drive Unit

1. TRACTIONMOTOR 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. HELICALGEAR 11. HOUSING 12. BEVEL PINION SHAFT AND GEAR SET 13. COVER 14. AXLESHAFT Figure 4-3 - Traction Motor and MDU 1.

Tag the power cables of the traction motor for correct installation during installation. The motor terminals are identified on the motor as Al A2 Fl and F2. Remove the power cables from the terminals of the traction motor.

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

2.

Tag and disconnect the wires to the brake switch.

CAUTION:

Brake fluid damages paint. Immedi-ately remove any brake fluid that is on a painted surface.

4.

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 MDU upper housing.

WARNING:

The traction motor is heavy. Be sure that all lifting devices (hoists, cables, chains, slings, etc.) are

Sheet 9: Drive Unit suitable and of adequate capacity to lift the traction motor. The traction motor can weigh approximately 40 kg (85 lbs).

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 lbs).

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 lbf 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. Immedi-ately remove any brake fluid that is on a painted surface.

5.

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.

4. Install the wires to the brake switch.

5.

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.

1. HYDRAULIC STEERING MOTOR 2. MASTER DRIVE UNIT (MDU)

Sheet 9: Drive Unit 3. STEERING CHAIN Figure 4-4 - Hydraulic Steering System 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 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 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 Nm (50 lbf 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 TIREAND 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. 3.

Position a floor jack under the lower part of the axle weldment.

4.

Remove the capscrew washer and nut retaining the pivot pin.

Sheet 9: Drive Unit 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 lbs).

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 ID of the bushings and on the OD of the pivot pin.

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 lbs).

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 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 lbf 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. 7.

If removed replace the caster wheel assembly.

8.

Remove the blocks and lower the drive/steering wheel to the floor. Connect the battery.

Sheet 9: Drive Unit

1.

2.

3.

4.

5.

6.

SHIMS BUSHINGS PIVOTPIN CAPSCREW NUT ARTICULATING AXLE WELDMENT

Figure 4-5- Articulating Axle Installed MASTER DRIVE UNIT Description The master drive unit (MDU) is turned by the 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 by 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 lbf 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 lbs).

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.

Sheet 9: Drive Unit 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 3541 kg (7800 lbs) 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 1.

Slide the MDU under the lift truck frame into the correct position under the articulating axle weldment. Have another person use a bar to help lift and align the MDU. Align the marks made during removal and install the capscrews and lockwashers. Tighten the capscrews in a crisscross pattern to initially to 34.N m (25 lbf ft) torque.

After all the capscrews have been initially tightened, tighten them to 68 N m (50 lbf ft) torque.

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

2.

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

3.

Remove the fill plug and fill the MDU using the recommended oil shown in Section 2. The oil must go through the bearings, so add the oil slowly and allow time for the oil to reach the correct level. Install and tighten the fill plug.

4.

Install the traction motor. See INSTALLATION-TRACTION MOTOR.

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 damage paint. Immediately remove any brake fluid that is on a painted surface.

5.

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.

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

7.

Install the drive wheel on the hub of the MDU. Tighten the wheel nuts in a crisscross pattern to 136 Nm (100 lbf ft ) torque.

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: 1.

The capscrews and nuts used on the MDU are all metric. Do not damage them using the wrong tool.

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 9: Drive Unit

1.

2.

3.

4.

5.

UPPER HOUSING CAPSCREWS INSIDE TOP CASE HOUSING CAPSCREWS DOWEL

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

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 and axle shaft have been removed from the drive unit lower housing.

2.

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

3.

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 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 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 ® 270. It may be necessary to use a welding torch to heat the bevel gear to 100 - 120º C (212 - 2480 F) to free the bevel gear from the axle shaft.

CAUTION:

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

4.

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.

5.

Use a copper mandrel and a plastic hammer to drive the axle shaft out of the lower housing. Remove the

Sheet 9: Drive Unit bevel pinion out of the lower housing.

CAUTION:

Keep all shim sets together and for correct location and installation during assembly.

NOTE: If the bevel pinion and gear set will NOT be replaced and the shim set is not damaged the same shim set can be used during assembly. Adjustment will not be necessary.

1.

2.

3.

4.

5.

6.

TRACTIONMOTOR CAPSCREW CENTERING RING O-RING HELICAL PINION LOCKWASHER AND KEY

Sheet 9: Drive Unit 7. NUT 8. UPPER HOUSING 9. LEVEL AND FILL PLUG 10. CAPSCREW 11. NUT 12. HELICALGEAR 13. BEARING CUP AND CONE 14. SHIMS 15. SPACER 16. BEVEL PINION SHAFT AND GEAR SET 17. SPECIALWASHER 18. CAPSCREW 19. COVER 20. DRAIN PLUG 21. CAPSCREW 22. INNER SEAL 23. BEARING SHIELD 24. BEARING SEAL 25. AXLE SHAFT 26. WHEEL 27. TIRE 28. WHEEL BOLT 29. LUG NUT 30. CAPSCREW 31. HOUSING Figure 4-7 - Master Drive Unit Parts 1.

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, open the cage and remove the rollers. Use a puller to remove the cage from the axle shaft.

2.

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

3.

If necessary, remove the motor nut, lockwasher, bevel pinion and key from the motor shaft. Remove the O-ring from the motor.

Figure 4-8 - Removing Bearing Shield 4.

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

5.

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 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 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

Sheet 9: Drive Unit 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 dirt from the lower housing using a clean cloth. Spray the surface with the cleaner again and allow to air dry.

2

Check all parts for damage or cracks. Replace any damaged parts.

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 use of other special tools is recommended by the manufacturer of the drive unit.

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

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

Bevel Pinion Shaft - Installation (See Figure 4-7, Figure 4-10 and Figure 4-12) This procedure has the necessary steps needed to install the bevel pinion shaft. All of these steps are necessary if a replacement bevel pinion shaft and gear set or a replacement lower case are needed. Normally, it is not necessary to replace the lower case or helical gear set.

If the original bevel gear set will be installed in the same lower case, use the original shim sets (x) and (y). Install the shim sets, bearing, bevel pinion shaft, helical pinion and gear and special nut. Check the bearing clearance as described in Step g.

If only the bevel gear set is replaced, use the number (*) to find the correct shim set (x). If the new number is smaller than the old number, remove shims. If the old number is larger, add shims. Add or subtract shims equal to the difference between the numbers. Do NOT use damaged or distorted shims.

EXAMPLE: The old number 74.25 minus the new number 74.15, will make removing shims 0.1 mm (0.004 in) thick necessary.

If this method of finding the correct set is used, it is NOT necessary to do Steps b through d. Do Steps a and e through g.

Use all of the following Steps to assemble, adjust and install a NEW bevel pinion (if you do not have one of the above numbers) or the original bevel pinion shaft in a NEW case.

NOTE: There are two numbers on each of the two parts of the bevel gear set. One number on each part is the set number. These numbers MUST be the same. The other number on the bevel gear is the gear clearance number.

The other number on the bevel pinion is the dimension "B" value. Check that the numbers are correct.

Sheet 9: Drive Unit

1. UPPER PINION BEARING OUTER RACE 2. LOWER PINION BEARING OUTER RACE 3. INNER AXLE SHAFT BEARING OUTER RACE 4. OUTER AXLE SHAFT BEARING OUTER RACE 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 Figure 4-9 - Bearing and Shim Location Install the bevel pinion shaft as follows: a.

Make a bushing to fit the bore for the lower pinion shaft bearing. The bushing OD will be 51.5 mm (2.03 in).

Bushing (2) must be 67.5 mm (2.66 in) long. b.

Install the bushing in the bore. To find the correct thickness for shim set "x", it is necessary to know the case dimension E. To find the case dimension E, use the formula: E = L - F + D/2 L = bushing length F = the difference between the bearing bore for the axle and the end of the bushing. See Figure 4-10.

D/2 = 44.45 mm (1.75 in) c.

Measure the dimension F. See Figure 4-10. Subtract the value F from the length (L) of the bushing and add the value D/2. The result is dimension E. c.

The shim set thickness X for shim set x for the lower bearing is found as shown in Figure 4-10.

X = E -B - T E = the value found in Step c B = the number on the end of the pinion shaft T = the total thickness of the bearing

e.

Install the shim set x and press the bearing cup into the bore. Install the bearing cone and spacer on the pinion shaft. Install the pinion shaft in the case. f.

Install a piece of wood between the end of the pinion and the case to hold the pinion tightly in the bore. Do NOT install shims or bearing. Measure the distance between the top end of the spacer and the bottom of the bore for the bearing. This is distance C in Figure 4-10.

Sheet 9: Drive Unit g.

Measure the distance S between the edges of the bearing cup and cone. If the cup extends below the cone, the dimension S is negative (subtract). If the cone extends below the cup, the dimension S is positive (add). h.

Add or subtract (Step g) dimension S from dimension C. The result minus 0.02 mm (0.001 in) is the dimension X or the thickness of shim set y for the top bearing.

X (in mm) = C + or - S - 0.02 mm i.

Install the shim set y, the bearing cup, bearing cone, helical gear and special nut. Use a press to install the bearing cup. j.

Use a strap wrench or a piece of wood to keep the helical gear from turning and tighten the nut to 100 Nm (74 Ibf ft) torque. Do NOT use a punch to lock the nut at this time.

Figure 4-10 - Installing Bevel Pinion Shaft Bevel Gear - Installation (See Figure 4-12 and Figure 4-11) 1.

Use a press to install the wheel bolts.

NOTE: When installing the wheel bolts, make certain that the flat side of the bolt collars face the center of the wheel shaft.

2.

Install the seal ring on the wheel shaft. Install the cone on the axle shaft.

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.

3.

Install the cone on the bevel gear using a press.

4.

Do NOT install the inner seal ring until the bearing preload has been adjusted. Install the original shims under both the inner bearing cup and the outer bearing cup. Use a press to install both bearing cups in the case.

NOTE: Do NOT use damaged or distorted shims.

Sheet 9: Drive Unit 1. BEVEL PINION SHAFT 2. SPACER 3. SPECIAL BUSHING 4. LOWERCASE 5. LOWER BEARING 6. SHIM SET X 7. SHIM SET Y 8. UPPER BEARING 9. BEARING CUP 10. BEARING CONE 5.

Carefully install the axle assembly in the case. Install the bevel gear on the axle assembly using the M16 capscrew and special washer.

6.

Prevent the axle from turning. Tighten the M16 capscrew to 245 Nm (332 lbf ft) torque. Tighten the special nut at the large gear to 60 Nm (44 Ibf ft) torque.

7.

Check and adjust the backlash, tooth contact pattern and bearing clearances BEFORE continuing. See CHECKS AND ADJUSTMENTS. 8.

After the proper backlash and tooth contact pattern has been established, remove the bevel gear, the bearing cups and the axle assembly.

9.

Coat the seat of the thread protecting seal with Loctite No. 270. Press the shield on the lower housing as far as possible. Thinly coat the radial shaft seal with Loctite No.574. Install the inner seal into the lower housing. The inner seal, when properly installed, should be 1.8 ±0.5 mm (0.071 ±0.02 in) below the bottom edge of the outer bearing bore. See Figure 4-11. Fill the inner seal ring and the cone on the axle shaft with Shell Alvania R3 grease.

Figure 4-11 - Inner Seal Installation 10.

Install the shims, outer bearing cup and the axle shaft. Apply Loctite 270 to the internal splines of the bevel gear. Install the bevel pinion on the axle shaft. Remove any excess Loctite from the bevel gear using a clean cloth.

Install the capscrew and special washer. Tighten the M16 capscrew to 245 Nm (332 lbf ft) torque.

NOTE: If the tapped holes in the bottom of the lower housing extend through the housing, it is recommended that the capscrews be completely sealed with Loctite to prevent oil from leaking from around the threads.

11.

Use Loctite 574 on the cover. Apply one drop of Loctite 243 on each of the cover capscrew threads. Install the cover. Tighten the cover capscrews to 9.5 Nm (7 Ibf ft) torque.

12.

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. See Step 3 of the DISASSEMBLY procedure. Install the capscrews to retain the upper housing to the housing. 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.

NOTE: To replace the drive tire on the wheel, the wheel must be pressed out of the tire rim. Refer to Section 2.

Sheet 9: Drive Unit 13.

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

1. NUT 2. HELICAL GEAR 3. BEARING 4. SHIMS 5. SPACER 6. LOWER HOUSING 7. SHIMS 8. BEARING 9. BEVEL PINION GEAR 10. SPECIAL WASHER 11. CAPSCREW 12. SHIMS 13. BEARING 14. BEVEL PINION SHAFT 15. CAPSCREW 16. COVER 17. DRAIN PLUG 18. THREAD PROTECTION SEAL 19. INNER SEAL 20. SHIMS 21. BEARING 22. OUTER SEAL 23. AXLE SHAFT 24. WHEEL BOLT 25. HELICAL PINION Figure 4-12- Installing Bevel Gear Set 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 movement.

1.

Use a crane and chain or sling with a capacity rating of 450 kg (1000 lbs) to lift 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

Sheet 9: Drive Unit 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 MDU in the vertical position through the hole in the 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 lbf ft) torque.

5.

If the helical pinion on the motor shaft was 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 and adding 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 lbs) 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.

CHECKS AND ADJUSTMENTS Adjust Backlash and Tooth Contact Pattern (See Figure 4-13 and Figure 4-16) CAUTION: The axle and gear assemblies are installed and removed several times during this procedure. Be careful during installation of the axle so that the bearing seal is not damaged.

This backlash is the clearance between the teeth of the bevel gear and the teeth of the pinion. Use a dial indicator to measure the clearance. See Figure 4-13. Put the dial indicator in a position so that the sensor touches a tooth 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. Move the bevel gear in the direction away from the sensor of the dial indicator. Adjust the dial indicator for a zero reading. Move the gear toward the dial indicator and read the backlash. The backlash must be 0.1 to 0.15 mm (0.004 to 0.006 in).

1.

SPIRAL BEVEL GEAR

Sheet 9: Drive Unit 2.

3.

DIAL INDICATOR WOOD WEDGE

Figure 4-13 - Checking Backlash If the backlash is too much, the bevel gear must move toward the pinion. If the backlash is not enough, the bevel gear must move away from the pinion. The bevel gear is moved in the correct direction by adding or removing shims under the bearing cup. The shims for the shim set are available in the following thicknesses: 0.1 mm, 0.15 mm, 0.3 mm and 0.5 mm.

The tooth contact pattern must also be correct. Remove the wood wedge and check the tooth contact pattern as shown in Figure 4-1.6. Adjust the position of the bevel gear for the best tooth contact pattern and the correct backlash.

Adjust Bearing Clearance (See Figure 4-14) CAUTION: The axle and bevel gear assemblies are installed and removed several times during this procedure.

Be careful during installation of the axle so that the bearing seal is not damaged.

The correct bearing clearance for the bevel pinion and bevel gear is marked on the edge of the bevel gear. The adjustment range is ±0.03 to 0.07 mm (± 0.001 to 0.003 in). Carefully install the axle assembly and bevel gear in the case. Use the original shims under the special washer. Tighten the capscrew to 100 Nm (74 Ibf ft) torque.

Remove the capscrew and special washer. Measure the thickness of the shim set. Use a soft hammer to tap the end of the axle to move it approximately 1 mm (0.04 in). Add 0.1 mm (0.004 in) of shim to the shim set. Install the special washer and capscrew again. Tighten the capscrew as before.

Use a dial indicator to measure the bearing clearance. See Figure 4-14. Put the dial indicator in a position so that the sensor touches the flat surface of the special washer on the spiral bevel gear. Make a mark on the gear as a measurement point. Move the bevel gear in one direction (approximately 180º) while pushing on the gear. Adjust the dial indicator for a zero reading at the measurement mark. Move the gear in the opposite direction while pulling on the gear. Read the clearance on the dial indicator at the measurement mark. If the clearance is not as shown on the edge of the gear, adjust the clearance. Add or remove shims between the special washer and the gear for the value marked on the edge of the gear. There will be no noticeable clearance when the adjustment is correct, but it will be possible to rotate the axle by hand.

1. SPIRAL BEVEL GEAR 2. DIAL INDICATOR 3. SPECIAL WASHER Figure 4-14 - Checking Bearing Clearance Check Trunnion Bearing The transmission upper housing must be replaced if: 1. The sealed cover plate on the trunnion bearing has separated; or 2. The trunnion bearing is difficult to tumor binds. It is not possible to replace the outer race and/or balls; or

Sheet 9: Drive Unit 3. The maximum bearing clearance is exceeded.

To check the bearing clearance, clamp the upper housing onto a level assembly table. Install three eye bolts into the outer race of the trunnion bearing. Rotate the bearing several times. Install a cable in each eye bolt.

Position three dial gauges on the trunnion bearing and set the gauge dials to zero. Mark the position of one dial gauge on the trunnion bearing with a marking pen. See Figure 4-15.

Using a lifting device and a spring balance, raise the upper housing with approximately 50 kg (110 lbs) of force.

Rotate the trunnion bearing several times and position at the mark again. The recommended 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.

Figure 4-15 - Checking Trunnion Bearing

Sheet 9: Drive Unit

Figure 4-16 - Tooth Contact Pattern TROUBLESHOOTING

Sheet 9: Drive Unit

Sheet 10: Brake System

BRAKE SYSTEM GENERAL This section has the description and the repair procedures for the brake assembly.

NOTE: Many of the procedures need the compartment door open. To open the door, turn the capscrew that fastens the door one quarter turn 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 NOTE: Turn the screw that fastens the door one-half turn 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 10: Brake System

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BRAKERESERVOIR BRAKEASSEMBLY BRAKE PEDAL AND MASTER CYLINDER TRACTION MOTOR

Figure 5-1 - Brake Arrangement

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.

1. 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.

2. 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 diameterof 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 10: Brake System

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

Figure 5-2- Brake Assembly

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

1. 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. Immedi-ately remove any brake fluid that is on a painted surface.

2. 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.

3. 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.

4. 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.

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

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

7. 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.

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

Assembly and Installation (See Figure 5-3 and Figure 5-4)

Sheet 10: Brake System 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 lbf ft) dry.

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 flat washer 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.

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LOCKNUT WASHER BRAKE DRUM SOCKET HEAD CAPSCREW

Sheet 10: Brake System 5. LOCKWASHER 6. SOCKET HEAD CAPSCREW 7. LOCKWASHER 8. BRAKEASSEMBLY 9. JAM NUT 10. LOCKWASHER 11. CAPSCREW 12. LOCKWASHER 13. SLAVE CYLINDER 14. HOSE ASSEMBLY 15. BRAKE MOUNTING BRACKET 16. CLAMP 17. LOCKWASHER 18. CAPSCREW 19. PUSHROD 20. ACTUATION ROD 21. BRAKE SPRING 22. SPRING GUIDE 23. BUSHING 24. CAPSCREW 25. FLATWASHER 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. NUTPLATE 38. JAM NUT 39. JAM NUT 40. SETSCREW 41. BUSHING 42. RESERVOIR 43. CLAMP 44. FEED HOSE 45. TY-WRAP Figure 5-3- Brake Assembly 1.

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.

2.

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 the jam 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.

3.

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

4.

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.

5.

Adjust the brakes as described in CHECKS AND ADJUSTMENTS.

6.

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 10: Brake System

Figure 5-4- Brake Assembly Installation

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

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. Immedi-ately 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 operator's 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. CAUTION: Brake fluid damages paint. Immediately remove any brake fluid that is on a painted surface.

Sheet 10: Brake System FLOOR PLATE ASSEMBLY Removal and Disassembly 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 4. Position the operator sensing switch on the floor plate. Pass the wire leads through the hole in the plate.

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

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

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BRAKE PEDAL PAD COTTERPIN FLATWASHER BUSHING

Sheet 10: Brake System 5. GROOVE PIN 6. BRAKE PEDAL WELDMENT 7. ROD END PIN 8. HOSE ASSEMBLY 9. BRAKE FLUID FEED HOSE 10. MASTER CYLINDER 11. FLOORPAD 12. SWITCH-OPERATOR SENSING 13. FLOOR PLATE WELDMENT Figure 5-5- Master Cylinder and Pedal Assembly MASTER CYLINDER Disassembly (See Figure 5-6) CAUTION: Brake fluid damages paint. Immedi-ately remove any brake fluid that is on a painted surface.

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.

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

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

6. 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.

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SPRING SPRING RETAINER PISTON * CUP

Sheet 10: Brake System 5. RETAINING RING * 6. RUBBERBOOT * 7. CUP 8. VALVE RETAINER 9. VALVE SPRING 10. VALVESTEM 11. VALVE SEAL 12. CONNECTION BOLT 13. GASKET 14. FITTING 15. GASKET 16. CYLINDER BODY 17. HOSE CONNECTION Figure 5-6- Master Cylinder

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 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.

Sheet 10: Brake System

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RUBBERBOOT CUP PISTON CYLINDERBODY BLEED SCREW

Figure 5-7- Slave Cylinder

BRAKE SWITCH-REPLACE (SEE FIGURE 5-3 AND FIGURE 5-8) 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 Brake Adjustment (See Figure 5-8) 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 ± 0.8 mm (2.50 ± 0.03 in).

3. Loosen the jam nut and set screw retaining the push rod between the set screw and slave cylinder so that the push rod is loose but cannot be removed.

4. Tighten the set screw until the push rod causes the slave cylinder to bottom. Back oft on the set screw 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

Sheet 10: Brake System 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.

Figure 5-8- Brake Assembly Adjustments

Sheet 11: Control Handle Assembly

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 sprocket and chain. The steering tiller is positioned for easy operation and requires only five turns to obtain full steering of 1800.

When the SCU is activated by the chain 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 second 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 hydraulicoil 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 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.

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 11: Control Handle Assembly

1. STEERING TILLER 2. STEERING CONTROL UNIT (SCU) 3. HYDRAULIC STEERING MOTOR Figure 6-1 - Steering System

Sheet 11: Control Handle Assembly

1. CAPSCREW 2. LOCKWASHER 3. NUT 4. SNAP RING 5. BACK-UP WASHER 6. THRUSTWASHER 7. KNOB 8. TILLER 9. BUSHING 10. ROLLER CHAIN 11.

CAPSCREW 12. HARDENED WASHER 13. NUTPLATE 14.

SNAP RING

Sheet 11: Control Handle Assembly 15.

SPROCKET 16. WOODRUFF KEY 17.

BACK-UP WASHER 18. BEARING 19. TILLER SHAFT 20. MOUNTING BRACKET 21. CAPSCREW 22. LOCKWASHER 23. PIN 24.

SPROCKET 25. STEERING COLUMN 26. CAPSCREW 27. LOCKWASHER 28. CHECKVALVE 29. FITTING 30. FITTING 31. FITTING 32. ORBITROL UNIT 33.

MOUNTING BRACKET 34. CAPSCREW 35. HARDENED WASHER 36. HOSE ASSEMBLY 37. HOSE ASSEMBLY 38. CAPSCREW 39. LOCKWASHER 40. LOCKNUT 41. HARDENED WASHER 42. SPROCKET 43. FITTING 44. STEERING MOTOR 45. O-RING Figure 6-2- Steering System 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

Sheet 11: Control Handle Assembly 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.

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HOSE STEERING MOTOR CAPSCREW LOCKWASHER SPROCKET NUT

Figure 6-3- Hydraulic Steering Motor 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 lbf 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 lbs).

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 lbf 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

Sheet 11: Control Handle Assembly caps on the lines and fittings.

3. Use a drift pin to remove the spring pin retaining the sprocket to the shaft of the steering column assembly.

Remove the chain and sprocket.

4. Remove the two capscrews and lockwashers retaining the steering column and steering control unit to 5. Remove the two capscrews and lockwashers retaining the steering column to the steering control unit.

Installation 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 chain and sprocket with the steering column and install the spring pin to retain the sprocket on the steering column.

4. It may be necessary to loosen the capscrews and nuts retaining the mounting bracket to the lift truck frame to adjust the steering chain. Then use a 3/8" drive ratchet placed in the mounting bracket slot and rotate clockwise to adjust the steering chain. The steering chain should have a 4.06 to 3.05 mm (0.16 to 0.12 in) deflection on the slack side at midpoint. After the proper adjustment has been made tighten the capscrews to 31 Nm (23 lbf ft) torque.

5. 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.

1. 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.

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STEERING CHAIN MOUNTING BRACKET SPRING PIN SPROCKET STEERING COLUMN AND STEERING CONTROL UNIT

Figure 6-4- Steering Tiller, Steering Column and Steering Control Unit Disassembly 1. Put the control unit in a vise with soft jaws. Make an identification mark on the length of the control unit.

Sheet 11: Control Handle Assembly

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STEERING CONTROL UNIT VISE

Figure 6-5- Steering Control Unit m Vise 2. Remove the cover on the bottom of the steering control unit.

1. CAPSCREW 2. COVER 3. O-RING Figure 6-6- Cover Removal 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 11: Control Handle Assembly

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STATOR ROTOR PORTPLATE O-RING CENTERSHAFT

Figure 6-7 - Stator and Rotor Removal 3. 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.

1. SCREW 2. CHECK VALVE ASSEMBLY 3. CHECKBALL Figure 6-8 - Check Valve Removal 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.

Sheet 11: Control Handle Assembly

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SPOOL AND SLEEVE ASSEMBLY THRUSTWASHER THRUST BEARING CENTER PIN SLEEVE SPOOL RING NEUTRAL POSITION SPRINGS

Figure 6-9- Spool and Sleeve Assembly Removal 6. When installed remove the snap ring bushing O-ring and seal ring. Remove the oil seal from the bushing or housing.

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SNAPRING SEAL BUSHING O-RING

Sheet 11: Control Handle Assembly 5. OILSEAL Figure 6-10 - Oil Seal and Bushing Removal Cleaning WARNING: Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents always follow the solvent manufacturers 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.

1. HOUSING 2. DUSTSEAL Figure 6-11 - Seal Installation 1. 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.

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O-RING GUIDE RING SPOOL WASHER TUBE

Sheet 11: Control Handle Assembly 6. HOUSING Figure 6-12 - O-ring Installation 3. Carefully assemble the spool and sleeve. Make sure the spool rotates freely in the sleeve.

1. SPOOL 2. SLEEVE Figure 6-13 - Spool and Sleeve Assembly 3. 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). Install the ring (5) on the sleeve (over the neutral position springs). The ring must turn freely on the sleeve.

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NEUTRAL POSITION SPRINGS (FLAT) NEUTRAL POSITION SPRINGS (CURVED) CENTER PIN SPOOL RING

Figure 6-14 - Spring Installation 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 11: Control Handle Assembly

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HOUSING SPOOL AND SLEEVE ASSEMBLY O-RING THRUSTWASHER THRUST BEARING BUSHING SNAP RING SEAL DUSTSEAL

Figure 6-15 - Spool and Housing Assembly 6. Install the check ball and sleeve. Make sure the sleeve is even with or below the surface of the housing (2).

Lubricate the O-ring (3) and install the O-ring and port plate (4). Align the holes in the port plate with the holes in the housing.

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CHECK BALL SLEEVE HOUSING O-RING PORTPLATE

Figure 6-16-Check Ball and Port Plate Installation 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 11: Control Handle Assembly

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CENTERSHAFT CENTERPIN ROTOR STATOR O-RING

Figure 6-17 - Stator and Rotor Assembly 8. Install the spacer plate (1). Install the O-ring (2) and the Nm (265 lbf in). Make sure the capscrew (4) with the pin fits in end cap (3). Tighten the capscrews for the end cap in the sequence shown to 1 7 Nm (150 lbf in) then tighten them to 30 the hole for the check ball (5).

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SPACERPLATE O-RING ENDCAP CAPSCREW CHECKBALL

Figure 6-18 - End Cap Installation

Sheet 11: Control Handle Assembly 8. Install the steering column on the steering control unit. Make sure the spines are aligned.

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 capscrew's hardened washers and nut plate retaining the steering tiller mounting bracket assembly to the lift truck frame.

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 4. Remove the snap ring retaining the socket to the tiller shaft. Remove the sprocket and woodruff key from the tiller shaft. Remove the second snap ring and remove the back-up washer. Remove the tiller shaft.

5. Remove the bearings from the bracket.

Assembly and Installation 1. Install the bearings in the mounting bracket.

2. Install the tiller shaft through the mounting bracket and bearings.

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 a pair of snap ring pliers and install the snap ring to retain the tiller shaft in the mounting bracket. Install the back-up washer.

4. Install the sprocket woodruff key and the second snap ring to retain the sprocket on the tiller shaft.

5. Install the mounting bracket on the lift truck frame using the two capscrews hardened washers and nut plate.

6. It may be necessary to loosen the capscrews retaining the steering column and steering control unit mounting bracket to the lift truck frame to adjust the steering chain. Then use a 3/8" drive ratchet placed in the mounting bracket slot and rotate clockwise to adjust the steering chain. The steering chain should have a 4.06 to 3.05 mm (0.16 to 0.12 in) deflection on the slack side at midpoint. Tighten the capscrews to 31 Nm (23 lbf ft) torque after the steering chain has been properly adjusted.

7. 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. Close the drive unit compartment cover.

8. 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.

STEERING PUMP AND MOTOR Steering Pump Specifications

Sheet 11: Control Handle Assembly Pump Relief Valve Setting: 8.4 ± 0.35 MPa (1200 ± 50 psi) Hydraulic Steering Pump Flow Rate: 11.7 I/mm (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 by removing the five capscrews that retain the cover to the frame.

3. Identify and tag the power cables on the terminals of the motor for correct connection during installation.

Disconnect the cables from the motor.

1. BATTERY COMPARTMENT COVER 2. CAPSCREW Figure 6-19 - Battery Compartment Cover Removal 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 has a weight of approximately 27kg (60 lbs). The steering pump motor has ceramic magnets. Do not let the motor fall as 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

Sheet 11: Control Handle Assembly 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 27kg (60 lbs). The steering pump motor has ceramic magnets. Do not let the motor fall as 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.

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PUMP AND MOTOR ASSEMBLY CAPSCREW LOCKWASHER BRACKET NUT RUBBER CHANNEL MOUNT MOUNTING PLATE FLAT WASHER

Figure 6-20- Steering Pump and Motor Mounting

Sheet 11: Control Handle Assembly

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CAPSCREW O-RING FITTING ELBOW ELBOW ELBOW PUMP MOTOR

Figure 6-21 - Steering Pump and Motor Disassembly-Steering Pump 1. Disassemble the fitting's 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.

Sheet 11: Control Handle Assembly

1.

CAPSCREW 2.

SNAP RING 3.

SHAFTSEAL 4.

FLANGE 5.

BACK-UP RING 6.

SEAL 7.

BUSHING 8.

O-RING 9.

DOWEL 10. PUMPBODY 11. IDLERGEAR 12. DRIVE GEAR SHAFT 13. LOAD SENSING VALVE ASSEMBLY 14. PRESSURE RELIEF VALVE Figure 6-22 - Steering Pump Assembly-Steering Pump 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 lbf 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.

Sheet 11: Control Handle Assembly 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 for air 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 ± 0.35 MPa (1200 ± 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.

Sheet 11: Control Handle Assembly

Sheet 12: Lift Linkage And Load Wheels

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 Power Steering

NOTE: The hydraulic system on the NS series of lift trucks differs because there is no reach mechanism used.

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®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 and the location of the functions may vary between lift truck models. 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

Sheet 12: Lift Linkage And Load Wheels

Table 7-1 - 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 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 180ºof 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/auxiliary function 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 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 12: Lift Linkage And Load Wheels

Figure 7-2- Hydraulic Schematic

Sheet 12: Lift Linkage And Load Wheels

1. HOSECLAMP 2. HOSE 3. HOSE 4. HOSE 5. CAPSCREW 6. LOCKWASHER 7. SPACER BLOCK 8. 90ºHOSE FITTING 9. 45 HOSE FITTING 10. FILTER HEAD 11. FILTER ELEMENT 12. HOSE ASSEMBLY 13. HOSECLAMP 14. HOSE 15. TUBE-SUCTION 16. HOSE-MOLDED ELBOW 17. HOSE CLAMP

Sheet 12: Lift Linkage And Load Wheels 18. HOSE 19. TUBE 20. HOSE 21. ISOLATOR-MOUNT 22. CAPSCREW 23. LOCKWASHER 24. FLATWASHER 25. HOIST PUMP AND MOTOR 26. FITTING W/O-RING 27. 45ºFITTING W/O-RING 28. HOSE ASSEMBLY 29. HOSE ASSEMBLY 30. HOSE ASSEMBLY 31. CAPSCREW 32. LOCKWASHER 33. FLATWASHER 34. NUT 35. BRACKET 36. RUBBER CHANNEL MOUNT 37. MOUNTING PLATE 38. STEERING PUMP AND MOTOR 39. 45ºFITTING W/O-RING 40. FITTING W/O-RING 41. FITTING W/O-RING 42. FITTING W/O-RING 43. BULKHEAD FITTING 44. TUBE AND NUT ASSEMBLY 45. TUBE AND NUT ASSEMBLY 46.

CAPSCREW 47. FLAT WASHER 48. CONTROL VALVE 49. 90ºFITTING W/O-RING 50. FITTING W/O-RING 51. FITTING W/O-RING 52. 90ºFITTING W/O-RING 53. HOSE FITTING 54. BULKHEAD FITTING 55. HYDRAULIC TANK ASSEMBLY Figure 7-3 - Hydraulic System 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

Sheet 12: Lift Linkage And Load Wheels

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AUXILIARYUP AUXILIARY DOWN LIFT LOWER

Figure 7-4 - Electro-Hydraulic Control Valve

Electro-Hydraulic Control Valve Manual Lowering 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" allen 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 to the 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/mm (7.1 gpm) at 2000 rpm.

The rated flow for the hoist pump for the 36 volt lift trucks is 42.4 I/mm (11.2 gpm) at 2000 rpm.

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 12: Lift Linkage And Load Wheels

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MOTOR PUMP O-RING 90ºELBOW CAPSCREW LOCKWASHER 45ºELBOW

Figure 7-5- Hoist Pump and Motor 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 253.6kg (115 lbs).

Sheet 12: Lift Linkage And Load Wheels

1. SNAPRING 2. SHAFTSEAL 3. MOUNTING FLANGE 4. BACK-UP RING 5. SEAL 6. BUSHING 7. O-RING 8. PUMPBODY 9. IDLER GEAR 10. DRIVE GEAR 11. END COVER 12. CAPSCREW

Figure 7-6- Hoist Pump Disassembled 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 253.6kg (115 lbs).

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.

1. Remove the blocks from under the drive/steer wheel, caster wheels and load wheels. Check the hydraulic level.

Connect the battery.

2. Remove the plugs from the hydraulic lines. Install the hydraulic lines on the hoist pump.

HOIST PUMP

Sheet 12: Lift Linkage And Load Wheels Disassembly 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.

Sheet 12: Lift Linkage And Load Wheels 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 lbs).

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.

Installation 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 lbs).

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

Sheet 12: Lift Linkage And Load Wheels

1. PLUG 2. O-RING 3. AUX. RELIEF VALVE 4. BACK-UP RING 5. O-RING 6. O-RING 7. PLUG 8. O-RING 9. PLUG 10. ORIFICE

Sheet 12: Lift Linkage And Load Wheels 11. PLUG, SPRING 12. O-RING 13. SPRING 14. RELIEFVALVE 15. PLUG,STOP 16. O-RING 17. PLUG 18. MUFFLER 19. LIFTVALVISTOR 20. O-RING 21. O-RING 22. BACK-UP RING 23. LOWER VALVISTOR 24. BACK-UP RING 25. O-RING 26. PROPORTIONAL VALVE 27. COIL 28. CAPSCREW 29. O-RING 30. O-RING 31. O-RING 32. O-RING 33. PLUG 34. O-RING 35. CHECKVALVE 36. O-RING 37. O-RING 38. BACK-UP RING 39. MANIFOLD BLOCK Figure 7-7 - Electro-Hydraulic Control 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" open-end wrench to remove the Valvistor.

4. Remove the Lift Valvistor. Use a 1-1/2" 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" 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 Valve subassembly. The subassembly cannot be disassembled any further.

6. Remove the Auxiliary Relief Valve. Use a 1" 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" 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 Valvistor for damage, erosion or worn 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.

Sheet 12: Lift Linkage And Load Wheels 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 lbf 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 lbf 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 1 OS lbf 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 lbf 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 lbf 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 lbf 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 the breather/filler assembly and the breather from the top of the tank. Remove the strainer from the fill tube.

5. Remove the three capscrews, lockwashers nuts, flat washers and O-rings retaining the tank cover to the hydraulic tank. Remove the tank cover and gasket.

6. Remove the baffle plate from the tank.

7. Remove the hydraulic tank from the lift truck.

Sheet 12: Lift Linkage And Load Wheels

1. DIPSTICK 2. BREATHER 3. BREATHER/FILLER ASSEMBLY 4. STRAINER 5. TANKC0VER 6. NUT 7. L0CKWASHER 8. FLATWASHER 9. GASKET 10. O-RING 11. CAPSCREW 12. BAFFLE ASSEMBLY 13. HYDRAULICTANK Figure 7-8 - Hydraulic Tank

8.

Inspect all components for damage and replace any defective item.

Installation 1. Locate the hydraulic tank in the lift truck.

Sheet 12: Lift Linkage And Load Wheels 2. Install the baffle plate in the hydraulic tank.

3. 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 three capscrews, lockwashers and O-rings and six flat washers nuts to retain the tank, gasket and top cover.

4. Install the strainer in the tank cover.

5. Remove the plugs from the hydraulic lines. Connect all the hydraulic lines to the hydraulic tank.

6. Fill the hydraulic tank to the recommended level with the recommended hydraulic oil. See Section 2 for the recommended hydraulic oil.

7. Install the breather on the hydraulic tank. Fill the hydraulic tank with the recommended hydraulic oil. Refer to Section 2. Install the dipstick and the breather/filler assembly.

8. Remove the drain pan, close the drive unit compartment cover. Connect the battery.

9. Operate the lift truck through all functions. Check for oil leaks. Check the hydraulic tank for the correct oil level.

10. Install the battery compartment cover on the lift truck. Remove the blocks from both sides of the wheels.

TROUBLESHOOTING

Sheet 13: Hydraulic System

MAST AND REACH ASSEMBLY MASTS This section contains the removal installation and adjustment procedures for the simplex (limited free lift) and triplex (full free lift) 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 set screw and jam nut 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. Both the simplex and triplex mast assembly can also be removed with the carriage or reach assembly installed. Do only those procedures necessary for repair.

CARRIAGE ASSEMBLY A carriage assembly is standard on the NS series of lift trucks. 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-to-side. 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.

Sheet 13: Hydraulic System Figure 8-1 - Carriage Assembly 1. FORK 2. CARRIAGE 3. LOAD BACKREST EXTENSION

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.

Sheet 13: Hydraulic System Figure 8-2- Reach Assemblies 1. INNER FRAME 2. SCISSOR ARM 3. OUTER FRAME 4. FORKS 5. TILT CYLINDER 6. SCISSOR ARM WELDMENT 7. LOAD BEARING 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)

Sheet 13: Hydraulic System

REACH ASSEMBLY TUBE FOR SIMPLEX AND TRIPLEX ARE DIFFERENT. Figure 8-4 - Hydraulic Parts for 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 oft 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.

Sheet 13: Hydraulic System • •

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: a. Raise the mast to align the bottom crossmember of the weld-ment that moves within the outer weldment with a crossmember on the outer weldment (1). On the simplex mast the moving part is the inner weldment (2). 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) (triplex mast only) 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 compart-ment. 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).

NOTE: MAST GUARD MUST BE REMOVED TO INSTALL SAFETY CHAIN. REMOVE SAFETY CHAIN AND INSTALL THE GUARD AFTER REPAIRS ARE COMPLETE.

6 SIMPLEX MAST

Sheet 13: Hydraulic System

TRIPLEX MAST

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 lbf ft) torque.

FORK REPLACEMENT WARNING: Forks are heavy and can cause an injury. Do not try to remove forks without using a lifting device.

Hook Fork - NS 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 8-7. 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.

Pin Forks-NR or NDR 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 oft 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

Sheet 13: Hydraulic System 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 Figure 8-6. 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.

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.

LATCH ASSEMBLY LEVER ROLL PIN WASHER SPRING LATCH 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.

Sheet 13: Hydraulic System

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

CARRIAGE ASSEMBLY-REMOVAL AND INSTALLATION (SEE FIGURE 8-7 AND FIGURE 8-8) 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 LIFT/LOWER control handle to raise the carriage assembly until the thrust rollers of the carriage are above the top of the outer weldment.

2. Move the key to the OFF position and disconnect the battery. Remove the mast guard from the mast assembly.

3. 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 eye and face protection during removal or installation.

4. Remove the snap rings washers thrust rollers and spacers.

Sheet 13: Hydraulic System 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 removed. Use wire to temporarily connect the ends of the lift chains hoses or cable to the masts 5. On triplex masts remove the safety chains installed in Step 3. Lower the carriage 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.

6. Fasten the chains or slings to the carriage frame. Use the crane to raise the carriage assembly so that the lift chains become loose.

7. Disconnect the sideshift hydraulic lines at the carriage. 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.

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.

8. Hold the lift chains to keep them from falling. Remove the pins in the chain anchors at the back of the outer weldment of simplex masts. 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 carriage.

Figure 8-7 - NS Carriage Assembly 1. CARRIAGE FRAME 2. SCREW 3. NUT 4. STUD 5. THRUST ROLLER 6. WASHER 7. SNAP RING 8. GREASE FITTING 9. LOAD ROLLER 10. SNAP RING 11. WEAR PLUG 12. SHIM 13. SIDE ROLLER

Sheet 13: Hydraulic System 14. LOCKWASHER 15. SCREW 16. GREASE FITTING 17. SNAP RING 18. CHAIN ANCHOR 19. COTTER PIN 20. FORK REMOVAL NOTCH

WARNING: The carriage assembly is heavy and can cause an injury if it tips or falls. Make sure the carriage assembly is stable during and after removal. If the forks are removed put the carriage assembly on the floor so that the load rollers are up.

CAUTION: Do not damage lift chains hoses or electrical cables as the carriage assembly is lifted out of the mast weldment.

1. Carefully lift the carriage assembly out of the channels of the inner weldment. Carefully lower the carriage assembly to the floor.

NOTE: The carriage side rollers must be adjusted while the carriage is out of the mast. Adjust the side rollers as described in CHECKS AND ADJUSTMENTS before installing the carriage assembly.

10. To install the carriage 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.

11. Adjust the carriage assembly. See ADJUSTMENTS in CHECKS AND ADJUSTMENTS. Test the carriage assembly for correct operation.

REACH ASSEMBLY-REMOVAL AND INSTALLATION 1. Operate the LIFT/LOWER control handle to raise the reach assembly until the thrust rollers of the inner frame (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 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 outer weldment of simplex masts. 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.

Sheet 13: Hydraulic System 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.

Figure 8-8 - Reach Assembly 1. LOAD ROLLER (4 OR 6) 2. CHAIN ANCHORS 3. INNERFRAME 4. SHIMS 5. SNAP RING 6. SIDE ROLLER 7. THRUST ROLLER 8. SPACER 9. WASHER 10. GREASE FITTING 11. WEAR PLUG

CARRIAGE LOAD ROLLER REMOVAL AND INSTALLATION (SEE FIGURE 8-9 AND FIGURE 8-10) 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.

Sheet 13: Hydraulic System 3. If necessary replace the wear plugs by pushing at the back of the wear plug.

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 removed. Use wire to temporarily connect the ends of the lift chains hoses or cable to the masts.

Figure 8-9 - 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 MAST, REACH OR CARRIAGE COMPONENT

Figure 8-10 - Removing Load Roller 1.

2.

3.

4.

LOAD ROLLER WITH SNAP RING REMOVED PRYBAR MAST REACH OR CARRIAGE COMPONENT SIDE ROLLER

4. On triplex masts remove the safety chains installed in Step 4. 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.

Sheet 13: Hydraulic System 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 pry bar to remove the load roller from the stub shaft for the load roller. See Figure 8-10.

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. ADJUSTMENTS in CHECKS AND ADJUSTMENTS.

SIDE ROLLER - DlSASSEMBLY AND ASSEMBLY (SEE FIGURE 8-10) 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.

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 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.

Sheet 13: Hydraulic System 1. If necessary remove the forks as described in FORK REPLACEMENT. 2. Remove the sideshift cylinder as described in SIDESHIFT CYLINDER-REMOVAL. 3. Install labels for correct connections during installation and disconnect the hydraulic lines at the top of the TILT/SIDESHIFT 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.

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 8-12) 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 8-11

Figure 8-11 - Install Blocks and Clamps 1.

2.

3.

4.

INNER FRAME OF REACH ASSEMBLY LOAD BEARING WOOD BLOCK CLAMP

Sheet 13: Hydraulic System 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 8-12) 1. Remove the tilt cylinder and tilt pivot assemblies as described in TILT CYLINDER AND TILT PIVOT ASSEMBLIES. 2

If 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 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 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 8-12) 1. If necessary assemble the selector valve as described in ASSEMBLY OF TILT/SIDESHIFT SELECTOR 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 0-rings on the 0-ring fittings.

4. Install the tilt cylinder and tilt pivot assemblies as described in INSTALLATION OF TILT CYLINDER. Installation (See Figure 8-12) 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 0-rings on the 0-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.

Sheet 13: Hydraulic System 1. 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. 2. 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 8-13) 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.

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 8-11.

CAUTION: Do NOT operate the tilt or sideshift functions if the outer frame has been removed. Hydraulic oil can come out of the hoses.

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 remove the forks as described in FORK REPLACEMENT. NOTE: If necessary remove the outer frame as described in OUTER FRAME-REMOVAL. If 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 8-13. For units with sideshift see Figure 8-12. 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 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 8-12) (Item 7 Figure 8-13) 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 CYLINDER AND TILT PIVOT

Sheet 13: Hydraulic System ASSEMBLIES. 2. Remove the solenoid valve body and hose guide. Disassemble the selector valve as described in TILT/SIDESH IFT SELECTOR VALVE-DISASSEMBLY.

Figure 8-12 - Outer Frame with Sideshifter 1.

2.

3.

4.

5.

6.

7.

HOSE ASSEMBLY HOSE ASSEMBLY ELBOW CONNECTOR HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY

Sheet 13: Hydraulic System 8. HOSE ASSEMBLY 9. ROLL PIN 10. PIVOT PIN 11. CAPSCREW 12. LOCKWASHER 13. HOSE AND WIRE GUIDE 14. CAPSCREW 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 REQ'D) 26. FLATWASHER 27. ROD END PIN 28. ROD END 29. SIDESHIFT CYLINDER 30. CAPSCREW 31. FLATWASHER 32. BEARING BLOCK 33. SPACER 34. HAIR PIN 35. PIN 36. FORK BRACKET 37. SPREADER BAR 38. TILT CYLINDER PIN 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. 0-RING

Sheet 13: Hydraulic System

Figure 8-13 - Outer 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 LOCKWASHER 10. HOSE AND WIRE GUIDE

Sheet 13: Hydraulic System 11. CAPSCREW 12. LOCKWASHER 13. CAPSCREW 14. SELECTOR VALVE 15. FORK RETAINING PIN 16. CAPSCREW 17. LOCKWASHER 18. FORK SHAFT 19. PIN 20. ROD END 21. CAPSCREW 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 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 8-13) 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 8-13) 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 13: Hydraulic System NOTE: The outer frame can be installed with the forks installed.

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.

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 8-11.

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 8-12) (Item 7, Figure 8-13) 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 8-13. For units with sideshift, see Figure 8-12.

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 8-14) NOTE: Make sure that the reach assembly is in the fully extended position.

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 8-11.

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 13: Hydraulic System 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 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 8-30). 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.

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.

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.

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 13: Hydraulic System

Figure 8-14 - Single Reach Scissor Arms 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

Sheet 13: Hydraulic System 12. TWO THRUST WASHERS 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 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.

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 the pins at the reach cylinders or scissor arm.

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 weldment to 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 8-30.

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 8-14. 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 lbf 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 oft 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 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.

4. 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.

CAUTION: Do not let the load bearings or shims fall off the scissor arms.

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. 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 SCISSOR ARMS

Sheet 13: Hydraulic System Removal and Disassembly (See Figure 8-15) NOTE: Make sure that the reach assembly is in the fully extended position.

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.

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 8-11.

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 13: Hydraulic System

Figure 8-15 - Double Reach Scissor Arms 1.

2.

3.

4.

5.

6.

7.

8.

9.

SCISSOR ARM REACH CYLINDER SCISSOR ARM WELDMENT LOAD BEARING PIN ROLL PIN BUSHING SHIM HOSE SHEAVE

Sheet 13: Hydraulic System 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 8-15) 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 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. 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 8-30). 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 "1B" and "2B" 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 8-15. 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 "1B" and "2B". Install the labels 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.

Sheet 13: Hydraulic System 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 "1B" and "2B".

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.

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 "1B" 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 "1B" 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 scissor arm "2B" following this same procedure. 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 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 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 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.

Assembly and Installation (See Figure 8-15) 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.

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 scissor arm weldment. Use a brass drift to remove the pins.

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 8-1 5. 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 "2B" on scissor arm weldment "B" as shown in Figure 8-15. 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 lbf ft) torque.

3. Install two of the thrust washers and the bushing on the stub shaft at the end pivot of scissor arm "2B".

Sheet 13: Hydraulic System 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 lbf 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 person help you support the scissor arm during removal and installation.

5. Install scissor arm "1B" on scissor arm weldments "B" and "A" as shown in Figure 8-15. 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 lbf ft) torque. Tighten the two capscrews at the end pivots to 39 Nm (29 lbf ft) torque. Bend the corners of the special lockwashers against the flat of each capscrew.

CAUTION: Do not let the load bearings or shims fall off the scissor arms.

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.

6. Slowly raise the weldment so you can install the shim sets and load bearings on scissor arms "1B" 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 8-15. 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 lbf 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 lbf ft) torque. Bend the corners of the special lockwashers against the flat of each capscrew.

Install scissor arm "1A" using the same procedure.

CAUTION: Do not let the load bearings or shims fall oft the scissor arms.

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.

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 8-16) 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

Sheet 13: Hydraulic System reach assembly from the mast as one assembly. The inner frame assembly can also be removed after the scissor assembly has been removed.

CAUTION: Do NOT operate the tilt or sideshift functions if the outer frame has been removed. Hydraulic oil can come out of the hoses.

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.

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.

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 removed. Use wire to temporarily connect the ends of the lift chains, hoses or cable to the masts.

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 13: Hydraulic System

Figure 8-16 - Inner Frame Parts 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.

Sheet 13: Hydraulic System 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.

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 8-16) 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.

If necessary, remove the reach cylinders. See REACH CYLINDERS. 1. Remove the jam nuts and set screws for the load rollers.

2. If necessary, replace the wear plugs by pushing at the back of the wear plug. See Figure 8-17.

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.

3. Remove the snap rings from the stub shaft for the load roller.

4. Use a pry bar to remove the load roller from the stub shaft for the load roller. See Figure 8-18.

5. 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.

6. If necessary, remove the cover for the REACH/TILT selector valve.

7. If necessary, remove the hydraulic lines and hoses.

8. If necessary, remove the REACH/TILT selector valve. See REACH/TILT SELECTOR VALVE to repair the valve.

Figure 8-17-Load Roller and Wear Plug Assembly 1.

2.

3.

4.

5.

6.

LOAD ROLLER WEAR PLUG SNAP RING SET SCREW JAM NUT STUB SHAFT

Sheet 13: Hydraulic System 7. 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 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 8-16) WARNING: The inner frame assembly is heavy and can cause an injury if it tips or falls. Make sure the inner frame assembly is stable before installing any parts 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. 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.

Figure 8-18-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 8-16) NOTE: If the scissor arm assembly will be installed in the inner frame, it is easier to install after the inner frame is installed in the mast. See SINGLE REACH SCISSOR ARMS or DOUBLE REACH SCISSOR ARMS to install the scissor arm assembly.

Sheet 13: Hydraulic System 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. 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) OD) 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.

SIMPLEX MAST ASSEMBLY Removal (See Figure 8-20 and Figure 8-22) NOTE: If the mast assembly will be disassembled after it is removed from the truck, first remove the NS carriage assembly or on the NR or NDR models remove the outer frame as a complete assembly. See CARRIAGE ASSEMBLY-REMOVAL AND INSTALLATION OUTER FRAME-REMOVAL AND INSTALLATION. If the outer frame 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 the inner frame of the reach assembly. 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 capscrews and nuts that fasten the mast guard and remove the guard. See Figure 8-19.

2. Remove the capscrews that fasten the rear legs to the overhead guard. See Figure 8-19. The overhead guard will be removed with the mast assembly.

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 for access to the four capscrews, the shims and the nut plates that fasten the bottom of the outer weldment to the truck frame. See Figure 8-20. Install safety chains to keep the mast components from moving.

Sheet 13: Hydraulic System

Figure 8-19 - Overhead Guard and Mast Guard 1.

2.

3.

4.

5.

6.

OVERHEAD GUARD LEG, LEFT HAND LEG, RIGHT HAND MAST LEG CAPSCREW MAST GUARD

4. Remove the capscrews, shims and nut plates.

5. Remove the safety chains installed in Step 2. 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 by holding the lever in the LOWER position for approximately five seconds.

6. Mark the trunnion caps so they can be assembled 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. 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 lbs). 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.

7. 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. Mark the trunnion caps for proper installation at assembly. Remove the four capscrews that fasten the trunnion caps. Raise the mast assembly high enough to clear the trunnions. Move the mast assembly approximately 30cm (1ft) away from the truck for access to the hoses.

8. 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.

9. Move the mast assembly away from the truck.

10. 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.

11. If the mast will NOT be disassembled, put the mast on a level floor with the overhead guard on top.

Cleaning and Inspection 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.

Sheet 13: Hydraulic System 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. Get authorization and instructions from your Yale lift truck dealer before doing any welding on the mast reach or carriage assembly.

2. Inspect the sliding and rolling surfaces of the channels for damage (dents) and wear (grooves). Inspect all welds for cracks.

Lift Cylinders-Removal and Installation (See Figure 8-21) NOTE: It is necessary to remove the mast assembly from the truck to remove the lift cylinders.

1. Remove the mast assembly as described in SIMPLEX MAST ASSEMBLY-REMOVAL. 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.

2. Remove the safety chains that fasten the mast weldments together and use a pry bar to carefully and slowly move the inner 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 the lift 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 one cylinder rod to the inner weldment. See Figure 8-21. 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 lift cylinder and the flow regulator. See Figure 8-22. Install a cap on the regulator fitting to prevent leakage.

6. Remove the lift cylinder retainer, capscrews and washers.

Sheet 13: Hydraulic System

Figure 8-20- Simplex Mast Assembly 1. INNER WELDMENT 2. CHAIN SHEAVE 3. CYLINDER RETAINER 4. LOAD ROLLER 5. LIFT CYLINDER 6. OUTER WELDMENT 7. LIFT TRUCK FRAME 8. HYDRAULIC HOSE (LIFT) 9. FLOW REGULATOR HOUSING 10. HYDRAULIC TUBE (LIFT) 11. LOCK PLATE 12. NUT PLATE 13. SHIM PLATE 14. CAPSCREWS FOR MOUNTING MAST ASSEMBLY 15. REGULATOR MOUNTING BRACKET 16. DOWEL PIN 17. TRUNNION STUB SHAFT

Sheet 13: Hydraulic System 18. ELECT. CABLE FOR REACH ASSEMBLY 19. HOSES FOR REACH OR SIDESHIFT 20. WEAR STRIP 21. WEAR STRIP SHIM 7. Push the cylinder toward the top of the mast assembly to move the lift cylinder off the locating dowel pin.

Continue to push the cylinder so that the rod moves into the cylinder to allow removal from the inner weldment.

8. Repeat the Steps 2 through 7 to remove the other lift cylinder.

NOTE: See the HYDRAULIC SYSTEM, Section 7, for disassembly and repair the lift cylinders.

9. Reverse the procedure to install the lift cylinders.

Inner Mast Assembly-Removal And Installation (See Figure 8-21 and Figure 8-22) To remove the inner weldment from the mast assembly, the mast assembly must be removed from the lift truck. The lift cylinders and chain sheaves must also be removed.

1. Remove the mast assembly as described in SIMPLEX MAST ASSEMBLY-REMOVAL. Remove the lift cylinders.

See LIFT CYLINDERS-REMOVAL AND INSTALLATION. Remove the chain sheaves. See SIMPLEX CHAIN SHEAVE-RE-MOVAL AND INSTALLATION. 2. If it is necessary to repair the inner mast assembly, the load rollers and wear plugs must be removed. See LOAD ROLLERS AND WEAR PLUGS-REMOVAL AND INSTALLATION. 3. Use a crane or lifting device to support the inner weldment while sliding the inner weldment far enough out to clear the outer weldment.

4. Reverse the removal procedure to install the inner mast assembly into the outer weldment.

Hoses-Replace (See Figure 8-22) 1. To replace any hydraulic hoses, fully lower the reach or carriage 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 position. Disconnect the battery and put a tag or lock on the battery connector.

2. Disconnect hose and install caps to prevent dirt from entering the hydraulic system.

Sheet 13: Hydraulic System

Figure 8-21 - Lift Cylinder Removal 1.

2.

3.

4.

5.

6.

7.

8.

9.

INNER WELDMENT LIFT CYLINDER OUTER WELDMENT SNAP RING WASHER RUBBER BUSHING SHIMS (IF REQUIRED) RETAINER W/CUSH ION LOCK PLATE

3. Replace the hose. Operate the system to remove all the air from the oil and to check for leaks.

NOTE: The following procedure describes how to replace the hose and cable sheaves without removing the reach assembly, carriage assembly or mast assembly from the lift truck. If the mast assembly has been removed, carefully move the carriage assembly or inner weldment using a pry bar.

Hose and Cable Sheaves-Replace (See Figure 8-22)

Sheet 13: Hydraulic System 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.

1. To replace any hydraulic hoses, fully lower the reach or carriage 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 position. Disconnect the battery and put a tag or lock on the battery connector.

2. Fasten the hoses to the top of the inner mast at the sheaves. Disconnect or remove the hoses at the reach or carriage assembly. Install caps to prevent dirt from entering the hydraulic system.

3. Disconnect the spring of the tension device for the electrical cable. Fasten the cable to the top of the inner mast at the sheave. Install tags on the wires of the electrical cable at the reach assembly for correct connection later.

Disconnect the electrical cable.

4. Remove the capscrew, washers and cotter pin in the shaft at the sheave assembly. Use a drift to carefully remove the shaft at the sheaves. Do not let the sheaves or shims fall.

5. Follow the reverse procedure to install the hose and cable sheaves. Make sure to operate the reach or carriage hydraulic function(s) and check for leaks after the hoses are connected.

Simplex Lift Chains-Removal and Installation (See Figure 8-23) 1. Operate the LIFT/LOWER control lever to raise the reach or carriage assembly so that the forks are approximately 150 mm (6 in) off the floor. Use safety chains to fasten the carriage or reach assembly to the outer weldment so that it cannot move.

2. 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.

WARNING: keep control of the lift chains when disconnecting them from the chain anchor. This procedure will prevent the lift chains from falling and causing injury or damage.

3. Remove the cotter pins that fasten the chain anchor pins. Remove the chain anchor pins. Remove the lift chains.

WARNING: Never replace just the worn section of a lift chain. Replace the complete chain. Never replace just one chain of a chain pair. Replace both chains 4. Clean and inspect the lift chains. See CHECK LIFT CHAINS-Cleaning and Inspection in CHECKS AND ADJUSTMENTS. Replace the lift chains if necessary.

5. To install the lift chains reverse the removal procedure.

6. Adjust and test the lift chains for correct operation as described in CHECKS AND ADJUSTMENTS. Cleaning and Inspection Clean and inspect the lift chains as described in CHECKS AND ADJUSTMENTS. Simplex Chain Sheave- Removal and Installation (See Figure 8-23) 1. Operate the LIFT/LOWER control lever to raise the carriage or reach assembly so that the forks are approximately 150 mm (6 in) off the floor. Use safety chains to fasten the carriage or reach assembly to the outer weldment so that it cannot move.

WARNING: Keep control of the lift chains when disconnecting them from the chain anchor. This procedure will prevent the lift chains from falling and causing injury or damage.

2. Remove the cotter pin from the pin that fastens the lift chain to the chain anchor near the top of the outer weldment. Remove the anchor pins.

3. Put the lift chains over the carriage or reach assembly.

Sheet 13: Hydraulic System 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 from the sheave mounting stud.

5. Use a pry bar to remove the sheave from the stud.

Figure 8-22- Hose and Cable Assemblies - Simplex Mast 1. TO SHEAVE AND REACH OR CARRIAGE (1 OF 2) 2. OUTER MAST 3. TO TRUCK (1 OF 2) 4. ELECTRICAL CABLE & TENSION DEVICE (REACH ONLY) 5. CAPSCREW 6. SHEAVE SUPPORT 7. SHAFT 8. COTTER PIN 9. HOSE AND CABLE SHEAVE 10. SHIM (AS REQUIRED) 11. HOSE SHEAVE 12. LIFT TRUCK FRAME 13. HYDRAULIC HOSE-LIFT 14. HYDRAULIC TUBE-LIFT 15. FLOW REGULATOR HOUSING 16. REGULATOR MOUNT PLATE 17. INNER WELDMENT NOTE: Reach assembly shown. Chain anchor on NS carriage assembly similar.

Sheet 13: Hydraulic System

Figure 8-23 - Removing the Chain Sheave 1. INNER WELDMENT 2. CHAIN SHEAVE 3. BEARING 4. SNAP RING 5. LIFT CHAIN 6. COTTER PIN 7. PIN 8. CHAIN ANCHOR 9. ADJUSTMENT NUTS 10. OUTER WELDMENT 6. Remove the internal snap ring from the chain sheave.

7. Inspect all parts for wear or damage. Replace any worn or damaged parts.

8. If necessary, use a press to remove and install new ball bearings in the sheaves for the lift chains.

9. Reverse the procedure to install the chain sheaves.

10. Operate the truck and test for correct operation of the chain sheave. Check and adjust lift chains. Refer to CHECKS AND ADJUSTMENTS. Load Rollers and Wear Plugs-Removal and Installation (See Figure 8-24) 1. Remove the mast assembly as described in SIMPLEX MAST ASSEMBLY-REMOVAL. Remove the lift cylinders as described in LIFT CYLINDERS-REMOVAL AND INSTALLA-TION. Remove the chain sheaves as described in SIMPLEX CHAIN SHEAVE-REMOVAL AND INSTALLATION. The mast assembly must be horizontal with the carriage or reach assembly side on top.

WARNING: The mast weldments can move and cause an injury. Make sure the mast assembly is level to prevent unexpected movement of the mast weldments.

2. Remove the safety chains that fasten the mast weldments together and use a pry bar to carefully and slowly

Sheet 13: Hydraulic System move the inner weldment out of the bottom of the outer weldment for access to the load rollers. The inner mast load rollers are at the bottom. The outer mast load rollers are at the top. Use safety chains to fasten the inner weldment to the outer weldment so that they do not separate completely.

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.

3. Always install the safety chains to prevent the weldments from moving BEFORE starting to replace any load roller. Remove the snap rings that fasten the load rollers.

NOTE: Replace wear plugs at this time to save the cost of removal and disassembly of the mast assembly for wear plug replacement.

4. Use a pry bar to remove the load roller from the mast weldment. See Figure 8-10.

5. 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.

6. Reverse the procedure to install the load rollers.

7. Adjust the wear plugs. See MAST ADJUSTMENTS under CHECKS AND ADJUSTMENTS. The wear plugs are adjusted after the mast assembly is installed on the lift truck.

NOTE: The inner mast assembly must be in a position to allow access to the mount capscrews at the bottom of the outer weldment. Use safety chains to fasten the mast weldments together so that they cannot move.

1. Use the crane or lifting device to lift the mast assembly and move it close enough to the truck to make the necessary connections. Make sure the truck and mast assembly cannot move.

2. Install and tighten the mast and carriage or reach hoses on their correct bulkhead fittings according to the labels installed during removal.

3. Move the mast assembly into position. Lower the mast assembly so that the outer weldment is aligned with the trunnion blocks on the lift truck frame.

NOTE: Make sure all hoses and the electrical cable are not between a mast crossmember and the truck.

4. Align the trunnion caps according to the marks made during removal. Install the capscrews, but leave them loose.

5. Connect all the wires of the electrical cable according to the labels made during removal. Connect the hydraulic hoses.

Sheet 13: Hydraulic System

Figure 8-24- Mast Load Rollers 1.

2.

3.

4.

5.

6.

7.

INNER WELDMENT OUTER WELDMENT LOAD ROLLER SNAP RING WEAR PLUG SET SCREW JAM NUT

Installation (See Figure 8-20 and Figure 8-22) NOTE: If the carriage or reach assembly is installed on the mast, it must have a safety chain installed as described in SAFETY PROCEDURES. WARNING: Do not install the simplex mast assembly unless it is completely assembled. Mast parts can move and cause an injury if not fastened together during assembly.

CAUTION: Install tape on all electrical wires for the reach assembly if the wires are not connected. If the wires are not connected, they can make a short circuit and cause damage.

6. Operate the LIFT/LOWER control handle to raise the inner weldment for access to the bottom of the outer weldment.

7. Install safety chains between the outer and inner weldments to keep the inner weldment from moving.

8. Use a pry bar to align and install the four mount capscrews and the nut plates that fasten the bottom of the mast to the truck frame. Move the bottom of the weldment in or out and add shims until the mast is adjusted between vertical to 1/2 degree of back tilt.

9. Tighten the four mount capscrews to 203 Nm (150 lbf ft) torque.

10. Install the hose clamps and hose bracket. Operate the LIFT/LOWER control handle to raise the inner weldment high enough to carefully remove the safety chains. Remove the safety chains.

Sheet 13: Hydraulic System 11. Tighten the four trunnion cap capscrews to 203 Nm (150 lbf ft) torque. Use the crane to lower the inner weldment until the chain and crane are no longer the support. Remove the chain and crane.

12. Install the mast guard and capscrews that fasten the rear legs to the overhead guard.

13. Make all adjustments and test the operation of the mast assembly before returning the truck to service. See CHECKS AND ADJUSTMENTS.

TRIPLEX MAST ASSEMBLY (SEE FIGURE 8-25 AND FIGURE 8-27) Removal NOTE: If the mast assembly will be disassembled after it is removed from the truck, first remove the NS 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 mast guard and remove the guard. See Figure 8-19.

2. Remove the capscrews that fasten the rear legs to the overhead guard. See Figure 8-19. The overhead guard will be removed with the mast assembly.

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 lbs). 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.

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.

Sheet 13: Hydraulic System 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 instructions from your Yale lift truck dealer before welding on the mast, reach or carriage assembly.

Sheet 13: Hydraulic System

Figure 8-25 - Triplex Mast Assembly 1.

2.

3.

4.

5.

INNER WELDMENT INTERMEDIATE WELDMENT OUTER FREE LIFT CYLINDER MAIN LIFT CYLINDER A. LOCK PLATE B. RETAINER 1. SHEAVE SUPPORT ASSEMBLY A. SPACER B. SNAP RING C. BALL BEARING

Sheet 13: Hydraulic System D. CHAIN SHEAVE E. SPACER (NS ONLY) F. SHAFT 1. FREE LIFT CHAIN 2. CHAIN ANCHOR 3. CLAMP 4. 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 1. 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 8-25, Figure 8-28 and Figure 8-28) 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 through 12 to remove and install the cylinder.

1. On NR or NDR units, 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 8-27.

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 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.

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 weldment will 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, see the HYDRAULIC SECTION.

Sheet 13: Hydraulic System 11. Reverse the procedure to install the cylinder. Make sure the locating screw for the base of the free lift cylinder is 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 8-25) 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 pry bar 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 pry bar 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: See the 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 13: Hydraulic System

Figure 8-26-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 8-25, Figure 8-27, and Figure 8-28) 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-RE-PLACE, 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 8-27 and Figure 8-28)

Sheet 13: Hydraulic System 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 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 8-27 and Figure 8-28) 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 pry bar as necessary.

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.

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.

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.

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.

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 of the 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.

Sheet 13: 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.

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 8-27- 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

Sheet 13: Hydraulic System 15. MANIFOLD BLOCK 16. TO TRUCK 17. FREE LIFT CYLINDER 18. HYDRAULIC HOSE FROM SHEAVE SUPPORT 19. HYDRAULIC HOSE TO CARRIAGE

Figure 8-28- Hose and Cable Assemblies-Outer Weldment 1. HOSE BRACKET (NR OR NDR) 2. HOSE BRACKET (NS) 3. TO FLOW REGULATOR

Sheet 13: Hydraulic System 4. TO FREE LIFT CYLINDER 5. TENSION DEVICE 6. HOSE TO MANIFOLD BLOCK (EACH SIDE OF WELDMENT) 7. HOSE BRACKET (EACH SIDE OF WELDMENT) 8. TO REACH OR CARRIAGE ASSEMBLY 9. ELECTRICAL CABLE FOR REACH ASSEMBLY 10. TO LIFT TRUCK 11. HYDRAULIC HOSE (LIFT) 12. LIFT TRUCK FRAME 13. HOSE TO RIGHT MAIN CYLINDER 14. TUBE TO LEFT MAIN CYLINDER 15. FLOW REGULATOR HOUSING 16. REGULATOR MOUNT PLATE 17. MAIN LIFT CYLINDERS 18. OUTER WELDMENT

6. Remove the two capscrews and nuts that fasten the two halves of the hose and cable sheave together. See Figure 8-27. Do not let the sheave halves fall.

7. Carefully remove the capscrews that fasten the hose and cable sheaves at the top of the intermediate weldment.

Do not let any of the parts fall. These capscrews fasten to the stub shafts of the chain sheaves.

8. Follow the reverse procedure to install the hose and cable sheave for the carriage. Make sure to operate the carriage hydraulic function(s) and check for leaks after the hoses are connected.

Triplex Lift Chain Removal and Installation (See Figure 8-25) WARNING: Keep control of the lift chains when disconnecting them from the chain anchor. This procedure will prevent the lift chains from falling and causing injury or damage.

WARNING: Never replace just the worn section of a lift chain. Replace the complete chain. Never replace just one chain of a chain pair. Replace both chain.

Free Lift Chains 1. Operate the LIFT/LOWER control lever to raise the carriage. Use safety chains to fasten the carriage so that it cannot move and the forks are approximately 60cm (2 ft) off the floor.

2. Lower the carriage so that the safety chains are the support for the carriage and the lift chains do not have tension.

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.

3. Fasten both free lift chains so that they cannot move over the sheaves of the sheave support. Remove the chain anchor pins at each end of both free lift chains. Hold each chain to keep it from moving too fast and carefully remove them.

4. Inspect the free lift chains as described in CHECKS AND ADJUSTMENTS. Replace the free lift chains if necessary.

5. Reverse the procedure to install the free lift chains.

6. Adjust the free lift chains as described in CHECKS AND ADJUSTMENTS. Main Lift Chains 1. Raise the mast until the lower chain anchors are visible on the inner weldment.

2. Use safety chains to fasten the inner weldment so that it cannot move. Operate the LOWER control lever to lower the masts until the safety chains are a support for the inner weldment and lift chains do not have tension.

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.

Sheet 13: Hydraulic System 3. Fasten both main lift chains so that they cannot move over the sheaves. Remove the chain anchor pins at each end of both main lift chains. Hold each chain to keep it from moving too fast and carefully remove them.

4. Inspect the main lift chains as described in CHECKS AND ADJUSTMENTS. Replace the main lift chains if necessary.

5. Reverse the procedure to install the main lift chains.

6. Adjust the main lift chains as described in CHECKS AND ADJUSTMENTS. Triplex Chain Sheaves-Disassembly and Assembly (See Figure 8-25) Free Lift Chain Sheaves 1

If necessary, remove the free lift chains as described in TRIPLEX LIFT CHAINS-REMOVAL AND INSTALLATION.

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.

2. Remove the snap ring from the shaft in the sheave support.

3. Use a drift to tap the shaft out of the sheave support.

4. Remove the sheaves and spacers as a group. Inspect all components for wear or damage. Replace any part that is worn or damaged.

5. Reverse the procedure to install the chain sheaves.

Main Lift Chain Sheaves 1. If necessary, remove the main lift chains as described in TRIPLEX LIFT CHAINS-REMOVAL AND INSTALLATION. 2. Remove both pins from the chain anchors at the rear of the free lift cylinder. Remove each lift chain from the sheaves.

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.

3. Remove the snap ring from the chain sheave bracket.

4. Use a pry bar to remove the chain sheave from the bracket. Inspect all components for wear or damage.

Replace any item that is worn or damaged.

5. Reverse the procedure to install the chain sheaves.

Load Rollers and Wear Plugs-Removal and Installation (See Figure 8-29) 1. Remove the mast assembly as described in TRIPLEX MAST ASSEMBLY REMOVAL. Remove the free lift cylinder as described in FREE LIFT CYLINDER-REMOVAL AND INSTALLATION. Remove the main lift cylinders as described in MAIN CYLINDERS-REMOVAL AND INSTALLATION. The mast assembly must be horizontal with the carriage or reach assembly side on top.

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.

2. Remove the safety chains that fasten the mast weldments together and use a pry bar to carefully and slowly move the correct mast weldment for access to the load rollers. The inner weldment load rollers are at the bottom. The load rollers for the outer weldment are at the top. The load rollers for the intermediate weldment are at the top and the bottom of the weldment. Use safety chains to fasten the inner weldment to the outer weldment

Sheet 13: Hydraulic System so that they do not separate completely.

NOTE: If the inner weldment and the intermediate weldment will be disassembled from the outer weldment, do not install the load rollers at this time.

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.

3. Always install safety chains to prevent the weldments from moving BEFORE starting to replace any load roller.

Remove the snap rings that fasten the load rollers.

Figure 8-29 - Triplex Load Rollers 1.

2.

3.

4.

5.

6.

7.

8.

OUTER WELDMENT INTERMEDIATE WELDMENT INNER LOAD ROLLER SNAP RING WEAR PLUG SET SCREW JAM NUT

Sheet 13: Hydraulic System NOTE: Replace wear plugs at this time to save the cost of removal and disassembly of the mast assembly for wear plug replacement.

3. Use a pry bar to remove the load roller from the mast weldment.

4. 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.

5. Reverse the procedure to install the load rollers.

6. Adjust the wear plugs after all load rollers and wear plugs are replaced. See Checks AND ADJUSTMENTS. The wear plugs are adjusted after the mast assembly is installed on the lift truck.

Triplex Mast Assembly-Installation NOTE: If the carriage or reach assembly is installed on the mast, it must have a safety chain installed as described in SAFETY PROCEDURES. WARNING: Do not install the triplex mast assembly unless it is completely assembled. Mast parts can move and cause an injury if not fastened together during assembly.

NOTE: The inner and intermediate mast assemblies must be in a position to allow access to the mount capscrews at the bottom of the outer weldment. Use safety chains to keep the mast assembly from moving as described in SAFETY PROCEDURES. 1. Use the crane or lifting device to lift the mast assembly and move it close enough to the truck to make the necessary connections. Make sure the truck and mast assembly cannot move.

2. Install and tighten the mast and carriage or reach assembly hoses on their correct bulkhead fittings according to the labels installed during removal.

3. Move the mast assembly into position. Lower the mast assembly so that the outer weldment is aligned with the trunnion blocks on the lift truck frame.

NOTE: Make sure all hoses and the electrical cable are not between a mast crossmember and the truck.

4. Align the trunnion caps according to the marks made during removal. Install the capscrews, but leave them loose.

5. Connect all the wires of the electrical cable according to the labels made during removal.

CAUTION: Install tape on all electrical wires for the reach assembly if the wires are not connected to the reach assembly. If the wires are not connected, they can make a short-circuit and cause damage.

6. Operate the LIFT/LOWER control handle to raise the inner and intermediate weldments high enough for access to the bottom of the outer weldment.

7. Install safety chains between the outer, intermediate and inner weldments to keep the intermediate and inner weldments from moving.

8. Use a pry bar to align and install the four mount capscrews and the nut plates that fasten the bottom of the mast to the truck frame. Move the bottom of the weldment in or out and add shims until the mast is adjusted between vertical to 1/2 degree of back tilt.

9. Tighten the four mount capscrews to 203 Nm (150 lbf ft) torque.

10. Install the hose clamps and hose bracket. Operate the LIFT/LOWER control handle to raise the inner weldment high enough to carefully remove the safety chains. Remove the safety chains.

11. Tighten the four trunnion cap capscrews to 203 Nm (150 lbf ft) torque. Use the crane to lower the inner and intermediate weldments until the chain and crane are no longer the support. Remove the chain and crane.

12. Install the mast guard and capscrews that fasten the rear legs to the overhead guard.

Sheet 13: Hydraulic System 13. Make all adjustments and test the operation of the mast assembly before returning the truck to service. See CHECKS AND ADJUSTMENTS.

REACH CYLINDERS Removal (See Figure 8-30) NOTE: Fully extend the reach mechanism. If the scissor arms and outer frame are installed, use clamps and blocks to prevent the scissor arms from retracting. Install the clamps and blocks on the channels of the inner frame and the outer frame or apron. Install the blocks under the load bearings. See Figure 8-30. Tighten the clamps so that the blocks cannot move.

1. If necessary, remove the cable bracket and manifold block.

2. If necessary, remove the stops, shims and stop supports. Install labels for correct installation of the shims sets in the same positions. When the new stops are installed, the shim arrangement will normally be the same or similar.

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 operate the tilt or sideshift functions if the outer frame has been removed. Hydraulic oil can come out of the hoses.

1. Operate the LIFT/LOWER control handle to raise the reach assembly for access to the reach cylinders from the operator compartment of the lift truck.

2. Move the key to the OFF position and disconnect the battery. Remove the mast guard from the mast assembly.

3. Install safety chains to fasten the carriage and mast weldments so that they cannot move. Install the safety chains as described in SAFETY PROCEDURES.

Figure 8-30- Reach Cylinder Mounts 1. INNER FRAME MOUNT 2. BUSHING

Sheet 13: Hydraulic System 3.

4.

5.

6.

7.

PIN ROLL PIN REACH CYLINDER ROD END SCISSOR ARM MOUNT

NOTE: It is normally not necessary to remove the hydraulic tube from the reach cylinder.

1. Install labels on the hydraulic lines for correct connection during installation. Disconnect the hydraulic lines at the reach cylinders. Install caps on the hydraulic lines and cylinder ports to prevent dirt from entering the system.

NOTE: If disassembly of a reach cylinder is necessary, loosen the retainer in the cylinder shell while the cylinder is installed in the reach assembly. It is possible that reach adjustments will not be necessary. If disassembly is NOT necessary and the rod ends will NOT be replaced, mark the reach cylinders for installation in the same position.

5. Use a punch or small drift to remove the roll pin from the mount at each end of each reach cylinder. Make a mark on each rod end of the reach cylinders for correct installation. There is a right hand and a left hand rod end.

6. Have a helper hold the reach cylinder to keep it from falling. Use a drift to remove the pins that fasten each end of cylinder to the frame. Remove the other reach cylinder using the same procedure.

7. Remove the bushings from each mount of the inner frame and each scissor arm.

Disassembly (See Figure 8-31) 1. Loosen the capscrew at the rod end. Hold the rod to keep it from turning and remove the rod end from the cylinder rod.

2. Carefully remove the retainer and rod assembly from the cylinder shell.

3. Carefully remove the parts of the rod assembly as shown in Figure 8-31.

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 Clean all of the parts of the reach cylinder with solvent. Dry the parts with compressed air. Inspect the parts of the reach cylinder for damage and wear. Replace all parts that are worn or damaged. Replace all parts included in the cylinder repair kit.

Assembly (See Figure 8-31) 1.

Install the parts of the rod assembly as shown in Figure 8-31. Make sure to replace all seals and other parts included in the cylinder repair kit. Use Loctite No.242 on the rod and nut for the piston. Install the piston seal and piston rings. If removed, tighten the piston nut to 95 Nm (70 lbf ft) torque.

CAUTION: Do not cut or damage seals during installation. Be especially careful when moving seals across threads or edges of parts. Install tape over the rod threads to protect the seals.

2.

Install the rod seal, back-up ring, 0-ring and wiper on the retainer. Put a thin coat of hydraulic fluid on the inside of the shell and all parts of the piston and rod. Use 0-ring lubricant and install the rod assembly in the shell.

Carefully install the retainer on the rod and in the shell. Use a spanner wrench to tighten the retainer to 129 to 142 Nm (95 to 1 OS lbf ft) torque.

Sheet 13: Hydraulic System

Figure 8-31 - Reach Cylinder Parts 1. LOCKNUT 2. PISTON RINGS 3. PISTON PACKING 4. PISTON 5. CYLINDER TUBE 6. PISTON ROD 7. 0-RING 8. BACK-UP RING 9. ROAD SEAL 10. WIPER RING 11. PACKING GLAND Installation NOTE: It can be necessary to loosen the hydraulic fittings to allow movement of the rods. The rods need to move for correct alignment at the mounts for the scissor arms.

1. If removed, install the correct rod end on the rod as marked during removal. Install new bushings in all four mounts for the reach cylinders. Lubricate the bushings with multi-purpose grease. If necessary, install the hydraulic tube on each reach cylinder.

2. Align the anchor end of the cylinders on the cylinder mount of the inner frame of the reach assembly. See Figure 8-30. Install the mount pins and roll pins to fasten the cylinders to the inner frame. Use a hammer with a "soft" metal (brass or copper) or a plastic face to install the pins.

3. Connect the hydraulic lines to the reach cylinders as marked during removal. Always use new 0-rings on the 0-ring fittings.

4. Install labels for correct connection during installation and disconnect the hydraulic lines at the tilt cylinder. Install caps on the hydraulic lines and cylinder ports to prevent dirt from entering the system.

5. Hold each reach cylinder to align the rod end to the scissor arm mounts. Use a hammer with a "soft" metal (brass or copper) or a plastic face to install the mount pins to fasten the rod end of each reach cylinder. Align the holes for the roll pins. Install the roll pins.

NOTE: If the rod ends were not removed and the cylinders are installed in the same positions, reach adjustment is normally not necessary.

6. If the rod ends were NOT removed, install the roll pins at each mount pin. If the rod ends were removed, reach adjustment IS necessary. Make sure the adjustment is complete before installing the roll pins.

7. Make sure the hydraulic fittings are tightened and remove the clamps and blocks under the load bearings.

Sheet 13: Hydraulic System CAUTION: Do NOT operate the tilt or sideshift functions if the outer frame has been removed. Hydraulic oil can come out of the hoses.

8. Operate the REACH control lever to operate the function to check for leaks and correct operation.

9. Remove the air from the system and adjust the stroke of each reach cylinder as described in CHECKS AND ADJUSTMENTS.

TILT CYLINDER AND TILT PIVOT MECHANISM Removal-with Sideshifter NOTE: If the outer frame is installed on the scissor arms, fully extend the reach mechanism. Use clamps and blocks to prevent the scissor arms from retracting. Install the clamps and blocks on the channels of the inner frame and the outer frame. Install the clamps and blocks under the load bearings. See Figure 8-32. Tighten the clamps so that the blocks cannot move.

NOTE: If the outer frame is not installed on the scissor arms make sure of the following: a. There is access to the reach assembly side of the frame. b. The outer frame is stable so that it cannot tip.

WARNING: The outer frame is heavy and can cause an injury if it tips or falls. If the frame is not installed, make sure the frame is stable. If the frame is NOT on the floor with the fork side down for stability, use a crane and chains to raise the frame. Install a solid 100 mm (4 in) block under each fork heel and near each fork tip. Lower the frame so that the forks are on the blocks and install a capacity load on the forks. You can also use safety chains to fasten the frame to an object that cannot tip or fall.

Figure 8-32- Install Blocks and Clamps 1.

2.

3.

4.

INNER FRAME OF REACH ASSEMBLY LOAD BEARING WOOD BLOCK CLAMP

Sheet 13: Hydraulic System NOTE: Make sure the tilt cylinder rod is fully extended.

1. If this unit has the sideshift function, remove the outer frame as described in OUTER FRAME-REMOVAL. Read the WARNING and make sure the frame cannot tip or fall.

NOTE: If disassembly of the tilt cylinder is necessary, loosen the retainer while the cylinder is installed in the frame.

If disassembly is NOT necessary and the rod end will NOT be removed, it is possible that tilt adjustments will not be necessary.

2. Remove the two capscrews, lockwashers and cotter pins that fasten the top two tilt roller shafts for the left and right hand tilt pivots. Remove the two tilt roller shafts. Hold the tilt cylinder so that the cylinder and tilt pivots cannot fall.

3. Carefully remove the capscrew, lockwasher and cotter pin that fastens the tilt cylinder pin. Remove the tilt cylinder pin that fastens the tilt cylinder to the outer frame. Do not let the cylinder and tilt pivots fall. See Figure 8-33.

4. Carefully remove the tilt cylinder and the tilt pivot assemblies. Remove the four bushings for the two pivot shafts.

5. Remove the locknuts that fasten the two tilt pivots and the rod end of the tilt cylinder together. Separate the two tilt pivots and remove the bushings from the rod end.

6. Remove the two capscrews, lockwashers and cotter pins that fasten the tilt roller shafts in each tilt pivot.

Remove the shafts and the tilt slider assemblies. Remove the bushings from the tilt slider shafts.

7. Disassemble the tilt slider assemblies by removing the six capscrews, end caps and poly bearing blocks.

Removal-without Sideshifter NOTE: If the outer frame is installed on the scissor arms, fully extend the reach mechanism. Use clamps and blocks to prevent the scissor arms from retracting. Install the clamps and blocks on the channels of the inner frame and the outer frame. Install the clamps and blocks under the load bearings. See Figure 8-32. Tighten the clamps so that the blocks cannot move.

Sheet 13: Hydraulic System

Figure 8-33 - Tilt Pivot Mechanism With Sideshifter 1. CAPSCREW 2. LOCKWASHER 3. COTTER PIN 4. PIN 5. TILT PIVOT SHAFT 6. HOSE ASSEMBLY 7. FITTING 8. O-RING 9. TILT CYLINDER 10. LOCKNUT 11. LOCKWASHER 12. BUSHING 13. TILT PIVOT R.H. 14. LOCKNUT 15. TILT CYLINDER PIN 16. ROD END 17. TILT PIVOT L.H. 18. TILT SLIDER 19. POLY BEARING BLOCK 20. END CAP 21. CAPSCREW 22. TILT SLIDER SHAFT

NOTE: If the outer frame is not installed on the scissor arms make sure of the following:

Sheet 13: Hydraulic System a.

There is access to the reach assembly side of the frame.

b.

The outer frame is stable so that it cannot tip.

WARNING: The outer frame is heavy and can cause an injury if it tips or falls. If the frame is not installed, make sure the frame is stable. If the frame is NOT on the floor with the fork side down for stability, use a crane and chains to raise the frame. Install a solid 100 mm (4 in) block under each fork heel and near each fork tip. Lower the frame so that the forks are on the blocks and install a capacity load on the forks. You can also use safety chains to fasten the frame to an object that cannot tip or fall.

NOTE: Make sure the tilt cylinder rod is fully extended.

1. If this unit has the sideshift function, remove the outer frame as described in OUTER FRAME-REMOVAL. Read the WARNING and make sure the frame cannot tip or fall.

2. Install labels for correct connection during installation and disconnect the hydraulic lines at the tilt cylinder. Install caps on the hydraulic lines and cylinder ports to prevent dirt from entering the system.

NOTE: If disassembly of the tilt cylinder is necessary, loosen the retainer while the cylinder is installed in the frame.

If disassembly is NOT necessary and the rod end will NOT be removed, it is possible that tilt adjustments will not be necessary.

3. Remove the two capscrews, lockwashers and cotter pins that fasten the top two tilt roller shafts for the left and right hand tilt pivots. Remove the two tilt roller shafts. Hold the tilt cylinder so that the cylinder and tilt pivots cannot fall.

4. Carefully remove the capscrew, lockwasher and cotter pin that fastens the tilt cylinder pin. Remove the tilt cylinder pin that fastens the tilt cylinder to the outer frame. Do not let the cylinder and tilt pivots fall. See Figure 8-34.

5. Carefully remove the tilt cylinder and the tilt pivot assemblies. Remove the four bushings for the two pivot shafts.

6. Remove the locknuts that fasten the two tilt pivots and the rod end of the tilt cylinder together. Separate the two tilt pivots and remove the bushings from the rod end.

7. Remove the capscrew and lockwashers retaining the cotter pin and tilt roller assemblies to the left and right hand tilt pivots. Remove the bushings from the tilt rollers.

Disassembly 1.

Loosen the locknut at the rod end. Remove the rod end, special lockwashers and nut from the cylinder rod.

2.

Carefully remove the retainer and rod assembly from the cylinder shell.

3.

Carefully remove the parts of the rod assembly as shown in Figure 8-35.

Sheet 13: Hydraulic System

Figure 8-34 - Tilt Pivot Mechanism Without Sideshifter 1. CAPSCREW 2. LOCKWASHER 3. COTTER PIN 4. PIN 5. TILT PIVOT SHAFT 6. HOSE ASSEMBLY 7. FITTING 8. 0-RING 9. TILT CYLINDER 10. LOCKNUT 7. FITTING 8. 0-RING 9. TILT CYLINDER 10. LOCKNUT 11. LOCKWASHER 12. BUSHING 13. TILT PIVOT R.H. 14. LOCKNUT 15. TILT CYLINDER PIN 16. ROD END 17. TILT PIVOT L.H. 18. TILT ROLLER 19. TILT ROLLER SHAFT Cleaning And Inspection

Sheet 13: Hydraulic System 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.

Clean all of the parts of the tilt cylinder with solvent. Dry the parts with compressed air. Inspect the parts of the tilt cylinder for damage and wear. Replace all parts that are worn or damaged. Replace all parts included in the cylinder repair kit.

Assembly 1. Install the parts of the rod assembly as shown in Figure 8-35. Make sure to replace all seals and other parts included in the cylinder repair kit. Use Loctite No.242 on the rod and nut for the piston. Install the piston seal and tighten the piston nut to 149 N m (110 lbf ft) torque.

CAUTION: Do not cut or damage seals during installation. Be especially careful when moving seals across threads or edges of parts. Install tape over the rod threads to protect the seals.

2. Install the rod seal, back-up ring, 0-ring and wiper on the retainer. Put a thin coat of hydraulic fluid on the inside of the shell and all parts of the piston and rod. Use 0-ring lubricant and install the rod assembly in the shell.

Carefully install the retainer on the rod and in the shell. Use a spanner wrench to tighten the retainer to 167 to 76 N m (123 to 130 lbf ft) torque.

3. Install a new bushing in the mount hole at the shell end of the tilt cylinder.

Figure 8-35 - Tilt Cylinder Parts 1. LOCKNUT 2. PISTON 3. PISTON PACKING 4. PISTON ROD 5. CYLINDER TUBE 6. ROD PACKING 7. 0-RING 8. BACK-UP RING 9. GLAND 10. WIPER RING 11. BUSHING

Installation-with Sideshifter NOTE: If the outer frame is not installed on the scissor arms make sure of the following:

Sheet 13: Hydraulic System a.

There is access to the reach assembly side of the frame.

b.

The outer frame is stable so that it cannot tip.

WARNING: The outer frame is heavy and can cause an injury if it tips or falls. If the frame is not installed, make sure the frame is stable. If the frame is NOT on the floor with the fork side down for stability, use a crane and chains to raise the frame. Install a solid 100 mm (4 in) block under each fork heel and near each fork tip. Lower the frame so that the forks are on the blocks and install a capacity load on the forks. You can also use safety chains to fasten the frame to an object that cannot tip or fall.

1. Install the nut, special lockwashers and rod end on the rod. Make sure the flat sides of the special lockwashers are both facing out. Install new bushings in the anchor end of the tilt cylinder and in the rod end. Lubricate the bushings with multi-purpose grease.

2. Align the anchor end of the cylinder on the cylinder mount (ports to the rear). Install the pin, cotter pin, lockwasher and capscrew to fasten the cylinder to the outer frame.

3. Install new bushings for all pivot points of the tilt assembly. Lubricate all bushings with multi-purpose grease.

4. Install the poly-bearing block in the tilt slider assemblies. Align the end cap and install the capscrews. Install the shafts for the tilt slider assemblies in the tilt pivots. Install the cotter pins and secure with the capscrews and lockwashers.

5. Align and install the right hand and left hand tilt pivots and spacer pins in the rod end of the tilt cylinder. Install four new locknuts. See Figure 8-34. Tighten all four locknuts to 136 N m (100 lbf ft) torque.

6. Install the tilt pivot assemblies in the outer frame using the shafts, cotter pins, lockwashers and capscrews.

CAUTION: The outer frame assembly must be installed on the apron as described in OUTER FRAME. The reach assembly must also be installed on the mast before doing Step 8.

7. Connect the hydraulic lines to the tilt cylinder as marked during removal and disassembly. Always use new 0-rings on the 0-ring fittings.

8. After all hydraulic lines are connected, operate the functions to check for leaks and correct operation.

Installation-without Sideshifter NOTE: If the outer frame is not installed on the scissor arms make sure of the following: a.

There is access to the reach assembly side of the frame.

b.

The outer frame is stable so that it cannot tip.

WARNING: The outer frame is heavy and can cause an injury if it tips or falls. If the frame is not installed, make sure the frame is stable. If the frame is NOT on the floor with the fork side down for stability, use a crane and chains to raise the frame. Install a solid 100 mm (4 in) block under each fork heel and near each fork tip. Lower the frame so that the forks are on the blocks and install a capacity load on the forks. You can also use safety chains to fasten the frame to an object that cannot tip or fall.

1. Install the nut, special lockwashers and rod end on the rod. Make sure the flat sides of the special lockwashers are both facing out. Install new bushings in the anchor end of the tilt cylinder and in the rod end. Lubricate the bushings with multi-purpose grease.

2. Align the anchor end of the cylinder on the cylinder mount (ports to the rear). Install the pin, cotter pin, lockwasher and capscrew to fasten the cylinder to the outer frame.

3. Install new bushings for all pivot points of the tilt assembly. Lubricate all bushings with multi-purpose grease.

4. Install the tilt roller shafts for the tilt roller assemblies in the tilt pivots. Install the cotter pins and secure with the capscrews and lockwashers.

5. Align and install the right hand and left hand tilt pivots and spacer pins in the rod end of the tilt cylinder. Install four new locknuts. See Figure 8-34. Tighten all four locknuts to 136 N m (100 lbf ft) torque.

Sheet 13: Hydraulic System 6. Install the tilt pivot assemblies in the outer frame using the shafts, cotter pins, lockwashers and capscrews.

7. Connect the hydraulic lines to the tilt cylinder as marked during removal and disassembly. Always use new 0-rings on the 0-ring fittings.

CAUTION: The outer frame assembly must be installed on the apron as described in OUTER FRAME. The reach assembly must also be installed on the mast before doing Step 8.

8. After all hydraulic lines are connected, operate the functions to check for leaks and correct operation.

SIDESHIFT CYLINDER Removal NOTE: If the outer frame is not installed on the scissor arms, make sure the frame is stable so that it cannot tip.

WARNING: The outer frame is heavy and can cause an injury if it tips or falls. If the frame is not installed, make sure the frame is stable. If the frame is NOT on the floor with the fork side down for stability, use a crane and chains to raise the frame. Install a solid 100 mm (4 in) block under each fork heel and near each fork tip. Lower the frame so that the forks are on the blocks and install a capacity load on the forks. You can also use safety chains to fasten the frame to an object that cannot tip or fall.

1. Install labels for correct connection during installation and disconnect the hydraulic lines from the sideshift cylinder. Install caps on the hydraulic lines and cylinder ports to prevent dirt from entering the system.

NOTE: If disassembly of a sideshift cylinder is necessary, loosen the retainer while the cylinder is installed.

Figure 8-36- Sideshift Cylinder Mounting 1. HOSE ASSEMBLY 2. FITTING 3. 0-RING 4. ROLL PIN 5. CLEVIS PIN 6. COTTER PIN 7. WASHER 8. CLEVIS PIN 9. FLATWASHER 10. ROD END 11. LOCKNUT

Sheet 13: Hydraulic System 12. SIDESHIFT CYLINDER 2. Remove the roll pin from the stationary end of the sideshift cylinder. Remove the cotter pin from the clevis pin at the opposite end.

3. Support the cylinder and remove the clevis pins. Remove the cylinder.

Disassembly 1. Loosen the locknut at the rod end. Remove the rod end and locknut from the cylinder rod.

2. Carefully remove the retainer and rod assembly from the cylinder shell.

3. Carefully remove the parts of the rod assembly as shown in Figure 8-37.

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.

Clean all of the parts of the sideshift cylinder with solvent. Dry the parts with compressed air. Inspect the parts of the sideshift cylinder for damage and wear. Replace all parts that are worn or damaged. Replace all parts included in the cylinder repair kit.

Assembly 1. Install the parts of the rod assembly as shown in Figure 8-37. Make sure to replace all seals and other parts included in the cylinder repair kit. Use Loctite No.242 on the rod and nut for the piston. Install the piston seal and tighten the piston nut to 149 N m (110 lbf ft) torque.

CAUTION: Do not cut or damage seals during installation. Be especially careful when moving seals across threads or edges of parts. Install tape over the rod threads to protect the seals.

1. Install the rod seal, back-up ring, 0-ring and wiper on the retainer. Put a thin coat of hydraulic fluid on the inside of the shell and all parts of the piston and rod. Use 0-ring lubricant and install the rod assembly in the shell.

Carefully install the retainer on the rod and in the shell. Use a spanner wrench to tighten the retainer to 129 to 142 N m (95 to 105 lbf ft) torque.

Installation NOTE: If the outer frame is not installed on the apron, make sure the frame is stable so that it cannot tip.

WARNING: The outer frame is heavy and can cause an injury if it tips or falls. If the frame is not installed, make sure the frame is stable. If the frame is NOT on the floor with the fork side down for stability, use a crane and chains to raise the frame. Install a solid 100 mm (4 in) block under each fork heel and near each fork tip. Lower the frame so that the forks are on the blocks and install a capacity load on the forks. You can also use safety chains to fasten the frame to an object that cannot tip or fall.

1. Hold the sideshift cylinder in the correct position on the outer frame. Align the cylinder for installation on the outer frame and the apron.

2. Install the clevis pins at both cylinder mounts. Install the washers and a new cotter pin in the moveable end of the sideshift cylinder. Install a roll pin in the stationary end of the sideshift cylinder.

3. Connect the hydraulic lines to the sideshift cylinder as marked during removal. Always use new 0-rings on the 0-ring fittings. If necessary to connect the hydraulic lines, see Figure 8-36. Operate the sideshift function to check for leaks and correct operation.

4. Remove the air from the system as described in CHECKS AND ADJUSTMENTS.

Sheet 13: Hydraulic System

Figure 8-37 - Sideshift Cylinder Parts

1. LOCKNUT 2. PISTON 3. PISTON PACKING 4. PISTON ROD 5. CYLINDER TUBE 6. ROD PACKING 7. O-RING 8. BACK-UP RING 9. PACKING GLAND 10. WIPER RING

REACH/TILT SELECTOR VALVE Removal NOTE: The selector valve can be removed with the inner frame installed or removed from the mast. It is easier to remove the selector valve with the inner frame or reach assembly removed from the mast. If the inner frame must be removed for other repairs, remove the selector valve after the inner frame is removed. Do all the steps of the procedure if the inner frame is installed in the mast. If the inner frame is removed from the mast, do Steps 4 through 8.

1. Operate the LIFT/LOWER control handle to raise the reach or inner frame assembly for access to the selector valve from the operator's compartment.

WARNING: There are pinch points on the mast and reach assembly that can cause an injury. 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. 2. If the scissor arm assembly is installed, operate the REACH/RETRACT control handle to fully retract the forks.

3. Move the key to the OFF position and disconnect the battery. Use safety chains to fasten the parts of the reach assembly so that the forks cannot extend.

WARNING: The outer frame is heavy and can cause an injury if it tips or falls. If the frame is not installed, make sure the frame is stable. If the frame is NOT on the floor with the fork side down for stability, use a crane and chains to raise the frame. Install a solid 100 mm (4 in) block under each fork heel and near each fork tip. Lower the frame so that the forks are on the blocks and install a capacity load on the forks. You can also use safety chains to fasten the frame to an object that cannot tip or fall.

4. Remove the cover for the REACH/TILT selector valve.

Sheet 13: Hydraulic System 5. Install labels on all hoses, hydraulic lines and electrical wires connected to the selector valve for correct connections during installation. Make a note of the location of all cable ties for correct installation of new cable ties during installation.

WARNING: 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 hoses and cables as they are removed. Use wire to temporarily fasten the ends of the hoses or cables.

6. Remove the hydraulic lines, electrical cables and hoses. See Figure 8-38. Install caps on all hydraulic lines and valve ports to prevent dirt from entering the system.

7. Remove the hose and cable sheave assembly from the bottom of the selector valve.

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.

8. If necessary, remove the snap rings that fasten the sheaves to the shafts.

9. Hold the selector valve and remove the two capscrews and lockwashers that fasten the selector valve to the inner frame.

Disassembly 1. Remove all fittings from the selector valve. See Figure 8-38.

2. If necessary carefully remove the solenoids check valves relief valve and spools.

3. Remove and discard all 0-rings from the valve and fitting parts.

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.

Clean all of the parts of the selector valve with solvent. Dry the parts with compressed air. Inspect the parts of the selector valve for damage and wear. Replace all parts that are worn or damaged. Replace all 0-rings.

Assembly 1. Use 0-ring lubricant and install new 0-rings on the parts of the selector valve.

2. Install the parts in the valve block as shown in Figure 8-38.

Installation 1. Hold the selector valve in the correct position on the frame and install the two capscrews and lockwashers.

2. Connect the hydraulic lines as marked during disassembly. Always use new 0-rings on the 0-ring fittings. If necessary to connect the hydraulic lines see Figure 8-38. Connect the electrical wires to the solenoids. Install new cable ties at the original locations for clearance of hoses and electrical cables during operation.

CAUTION: Do NOT operate the tilt or sideshift functions if the outer frame has been removed. Hydraulic oil can come out of the hoses.

3. Remove the safety chains from the scissor arms of the reach assembly. Operate the REACH TILT and SIDESHIFT functions to check for leaks and correct operation.

4. Remove the air from the system as described in CHECKS AND ADJUSTMENTS.

Sheet 13: Hydraulic System

Figure 8-38 - Reach/Tilt Selector Valve 1.

2.

3.

4.

5.

6.

7.

8.

HYDRAULIC FITTING SOLENOID VALVE BODY HOSE INNER FRAME PORT TUBES CHECK VALVE ASSEMBLY

TILT/SIDESHIFT SELECTOR VALVE Removal NOTE: The tilt/sideshift selector valve is installed even if there is no sideshift function. If there is no sideshift function there is no electrical cable or solenoids. Plugs are installed at the solenoid and cylinder ports.

NOTE: The selector valve can be removed with the outer frame installed or removed from the scissor arms. Do Steps 1 through 4 only if the outer frame is installed. The outer frame must be removed to remove the selector valve from the outer frame. Remove the outer frame as described in OUTER FRAME-REMOVAL. WARNING: There are pinch points on the mast that can cause an injury. 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. 1. If the outer frame is installed operate the REACH/RETRACT control handle to fully extend the forks.

2. Move the key to the OFF position and disconnect the battery.

WARNING: There are pinch points on the outer frame 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 8-32.

Sheet 13: Hydraulic System 3. If necessary install labels for correct connection during installation and remove the hoses at the top of the outer frame. See Figure 8-39. Install caps on the hydraulic lines of the solenoid valve to prevent dirt from entering the system.

WARNING: The outer frame is heavy and can cause an injury if it tips or falls. Make sure the frame is stable. If the frame is NOT on the floor with the fork side down for stability use a crane and chains to raise the frame. Install a solid 100 mm (4 in) block under each fork heel and near each fork tip. Lower the frame so that the forks are on the blocks and install a capacity load on the forks. You can also use safety chains to fasten the frame to an object that cannot tip or fall.

4. Install labels on all hoses connected to the selector valve for correct connections during installation.

5. Remove the hose and cable guide and the solenoid valve body.

Disassembly 1. Remove all fittings from the selector valve.

2. If necessary carefully remove the solenoids check valves relief valve and spools.

3. Remove and discard all 0-rings from the valve and fitting parts.

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.

Clean all of the parts of the selector valve with solvent. Dry the parts with compressed air. Inspect the parts of the selector valve for damage and wear. Replace all parts that are worn or damaged. Replace all 0-rings.

Assembly 1. Use 0-ring lubricant and install new 0-rings on the parts of the selector valve.

2. Install the parts in the valve block as shown in Figure 8-39.

Sheet 13: Hydraulic System

Figure 8-39 - Tilt/Sideshift Selector Valve 1.

2.

3.

4.

5.

6.

HOSE AND CABLE GUIDE VALVE BODY SOLENOID (1 OF 2) (SIDESHIFT ONLY) PLUG OUTER FRAME TILT CYLINDER

Installation WARNING: There are pinch points on the mast that can cause an injury. 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. 1. If the outer frame or outer frame is installed operate the REACH/RETRACT control handle to fully extend the forks.

WARNING: There are pinch points on the outer frame 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 8-32.

2. Move the key to the OFF position and disconnect the battery.

3. Hold the hose and cable guide and the selector valve in the correct position on the frame and install the two

Sheet 13: Hydraulic System capscrews and lockwashers.

4. Connect the hydraulic lines as marked during disassembly. Always use new 0-rings on the 0-ring fittings. If necessary to connect the hydraulic lines see Figure 8-39.

5. Operate the TILT and SIDESHIFT functions to check for leaks and correct operation.

6. Remove the clamps and blocks from all channels for the load bearings. Remove the air from the system as described in CHECKS AND ADJUSTMENTS.

CHECKS AND ADJUSTMENTS Check Mast Operation

WARNING: Do not try to locate hydraulic leaks by putting hands on pressurized hydraulic components. Hydraulic oil can be injected into the body by pressure 1. Check for leaks in the hydraulic system. Check the condition of the hydraulic hoses and tubes.

2. Slowly raise and lower the mast several times without a load. The mast components must raise and lower smoothly in the correct sequence.

NOTE: Some parts of the mast move at different speeds during raising and lowering.

3. The weldments and the carriage or reach assembly must lower completely.

4. Check that the controls for the carriage and reach assembly operate the functions installed on the lift truck. See the symbols by each of the controls and refer to the OPERATING MANUAL for your lift truck. Make sure all of the hydraulic lines are connected correctly and do not leak.

Remove Air from Hydraulic System NOTE: When you are removing the air from the hydraulic system, make sure that all of the hydraulic fittings are tight and do not leak. Also make sure that the level of the oil in the hydraulic tank is correct.

CAUTION: procedure.

The reach assembly must be completely assembled and installed on the lift truck before doing this

Operate the reach the tilt and the sideshift functions to remove the air from the hydraulic system. Fully extend and retract each cylinder rod. When the cylinder rod reaches the end of its stroke hold the control handle for approximately two seconds. Repeat the procedure as many times as necessary for each cylinder until the operation of all cylinders is smooth.

Check for Leaks in Hydraulic System 1. Slowly raise and lower the mast several times without a load. On NR or NDR trucks operate the reach assembly functions several times. Put a capacity (see the Nameplate) load on the forks and raise and lower the load several times. On NR or NDR trucks operate the reach assembly functions several times. Lower the load. Check for leaks and repair as necessary.

2. On all models raise the reach or carriage assembly and the capacity load one meter (3 ft). If the reach or carriage assembly lowers slowly with the control handle in a NEUTRAL position there are leaks inside the hydraulic system. The maximum speed that the reach or carriage assembly is allowed to lower is 50 mm (2 in) in 10 minutes when the hydraulic oil is 300°C (900°F). If the oil temperature is 700°C (1600°F) the maximum speed that the reach or carriage assembly can lower is 150 mm (6 in) per 10 minutes.

3. Check the lift cylinders for internal leaks. Remove the load from the forks. Install a gate valve in each of the supply lines between the electro-mechanical control valve and the mast. Put a capacity load on the forks again.

Raise the carriage one meter (3 ft). Close both gate valves. If the reach or carriage assembly or inner mast lowers slowly the seals in the lift cylinders have leaks.

Sheet 13: Hydraulic System 4. If the reach or carriage assembly does not move open both gate valves and check the movement again. If the reach or carriage assembly lowers when the gate valves are open check for leaks in the hydraulic lines and fittings. If no leaks are found the electro-mechanical control valve can have a defect. Remove the load from the forks.

5. On NR or NDR trucks slowly tilt the forks forward. If the forks continue to slowly tilt forward when the control handle is in a neutral position there are leaks inside the hydraulic system. The maximum speed that the forks are allowed to tilt forward is 13 mm (0.50 in) per 10 minutes (measured at the tilt cylinder). This maximum speed is measured when the hydraulic oil is 30°C (90°F). If the oil temperature is 70°C (160°F) the maximum speed is 39 mm (1.5 in) per 10 minutes.

6. If the leak rate for the tilt function is greater than specifications remove the load from the forks. Install a gate valve between the port at the rod end of the tilt cylinder and the hydraulic line. Put the load on the forks again.

Close the valve. Tilt the forks approximately halfway back. If the forks tilt slowly forward the piston seals are leaking.

7. If the forks do not move open the gate valve and check for movement again. If the forks move forward when the gate valve is open check for leaks in the hydraulic lines or fittings. If no leaks are found the electro-mechanical control valve or Valvistors can be damaged. Remove the load from the forks.

Check Lift Chains NOTE: These procedures are for both the simplex and triplex mast assemblies.

Cleaning and Inspection CAUTION: Do NOT use steam to clean the lift chains sheaves or load rollers. The sheaves and bearings are sealed and permanently lubricated. Do not use compressed air on the bearings. The air can force the lubricant out of the bearings.

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 lift chains using solvent. Inspect the lift chains for wear or damage. A lift chain becomes longer when it is worn. If a lift chain is 3% longer than a new lift chain the lift chain must be replaced. Use a chain scale to measure the chains. If a chain scale is not available check the lift chains with the measurements given in Figure 8-40.

WARNING: Never replace just the worn section of a lift chain. Replace the complete chain. Never replace just one chain of a chain pair. Replace both chains 2. Inspect the chain anchors and pins. Replace any parts that are worn or damaged.

3.

Inspect the chain sheaves. Replace any parts that are worn or damaged.

Sheet 13: Hydraulic System

1. CHAIN WEAR SCALE 5180968-69 NOTE: The instructions for measuring chain wear are shown on the chain wear scale.

Figure 8-40- Inspect the Lift Chains 1.

2.

3.

4.

5.

6.

7.

WORN PIN CRACKS EDGE WEAR HOLE WEAR LOOSE LEAVES DAMAGED PIN CORROSION

Lubrication Clean and inspect the chains before lubrication. Use SAE 30 engine oil as a lubricant for the chains. The recommendation for adding lubricant is to remove the chains from the lift truck and soak them in oil. See SIMPLEX or TRIPLEX LIFT CHAINS-REMOVAL AND INSTALLATION to remove the lift chains for lubrication.

MAST ADJUSTMENTS NOTE: These procedures are for both the simplex and triplex mast assemblies. Move the lift truck to an area with a

Sheet 13: Hydraulic System smooth level floor to make sure the adjustments are accurate.

The mast weldments must be aligned so that they are parallel to each other during operation. Keeping the weldments parallel will have the result of smoother operation and wear.

The only adjustment for the load rollers is the adjustment of the wear plugs. These adjustments are made for minimum side clearance and to keep the weldments parallel with equal clearance on each side between all weldments.

Wear plugs and wear strips allow adjustment for alignment and wear. Always adjust the wear plugs and wear strips for one weldment before making adjustments on other weldments.

Chains are adjusted for the following reasons: •

So each lift chain of a pair has an equal load to prevent too much load and wear on one chain of a pair.

•

So mast weldments move in the correct sequence.

•

So chains move over chain sheaves correctly.

Adjustments must be made to both the free lift (triplex only) and main lift chain sets. Each lift chain is adjusted at the chain anchor.

Adjust Wear Plugs Adjust the wear plugs as follows: 1. Loosen the jam nut on the wear plug using the special tool 5062050-00 available from your Yale lift truck dealer. See Figure 8-41. Also see Figure 8-42. Raise and lower the mast weldments several times to find the point of minimum clearance of the weldment.

2. Adjust the wear plugs to attain zero clearance between the wear plug and the weldment channel at the tightest point. Adjust wear plugs on opposite sides to keep the weldment in the center.

3. Adjust the clearance to approximately 0.5 mm (0.02 in) by turning the adjustment handle 1/8 turn counter clockwise. Keep the clearance between the weldments equal on both sides. Keep the weldments parallel to each other.

4. Tighten each jam nut without moving the setscrew.

5. Raise and lower the weldments without a load. Check that there is minimum clearance as described in Step 3 with free movement. If the weldments do not move smoothly during lowering follow the WARNING and adjust the wear plugs equally for more clearance.

WARNING: NEVER loosen the wear plugs if a mast weldment does not move freely during checks after an adjustment. The weldments or carriage or reach assembly can suddenly move and cause an injury. Raise the weldment move the key to the OFF position and install safety chains as described in SAFETY PROCEDURES. Loosen the wear plugs to allow movement.

1. If necessary operate the system so that the lift chains are taut. Carefully remove the safety chains. Raise and lower the weldments with a load. Check that there is minimum clearance as described in Step 3 with free movement. If the weldments do not move smoothly during lowering follow the WARNING and adjust the wear plugs equally for more clearance.

2. Repeat Steps 1 through 6 for each weldment.

Sheet 13: Hydraulic System

Figure 8-41 - Load Roller and Wear Plug Assembly 1.

2.

3.

4.

5.

6.

7.

8.

LOAD ROLLER WEAR PLUG SNAP RING SET SCREW JAM NUT STUB SHAFT MAST OR CARRIAGE WELDMENT WELDMENT CHANNEL

Figure 8-42- Wear Plugs-Adjustment 1. SPECIAL TOOL 5062050-00 2. ADJUSTMENT HANDLE 3. WELDMENT

Adjust Wear Strips (See Figure 8-43) NOTE: The wear plugs and lift chains must be adjusted before the wear strips are checked for wear replaced and adjusted.

The wear strips and shims are fastened to the lower guide blocks of weldments that move. The wear strips and shims are adjusted for the following reasons:

Sheet 13: Hydraulic System •

For minimum clearance to prevent too much side movement of the weldments.

•

To keep the weldments parallel.

NOTE: Wear strips and shims on the triplex inner weldment can be used on either side. There are right and left wear strips and shims on simplex inner and the triplex intermediate weldments. See Figure 8-43.

Check and adjust the wear strips as follows: 1. Remove the mast guard. Raise the carriage or reach assembly for access to the wear strips. Install safety chains as described in SAFETY PROCEDURES. 2. Remove the capscrews washers wear strips and shims. Replace all worn or damaged parts. One wear strip and one shim on each side are usually the correct adjustment. There must be the same number of shims under the wear strip on both sides of the weldment. Equal shims will keep the weldment parallel with equal clearance.

3. Use a prybar to move the weldment to install shims for minimum clearance. Install the shims and new wear strips as shown in Figure 8-43. Remove the safety chains.

4. Check that the mast operates correctly as described in CHECK THE OPERATION OF THE MAST at the beginning of this CHECKS AND ADJUSTMENTS section.

Adjust Free Lift Chain (Triplex Only) (See Figure 8-44) NOTE: Make sure the forks of the reach assembly are parallel to the floor (no forward or backward tilt).

1. Fully lower the carriage or reach assembly. Measure the distance from the floor to the top of the forks at the heel. The correct distance is 57 mm (2.25 in).

2. If the distance is correct the free lift chains are adjusted for the correct height. Do Step S next. If the distance is NOT correct do all of the steps.

3. Raise the carriage or reach assembly for access to the chain anchors near the top of the free lift cylinder. Install safety chains as described in SAFETY PROCEDURES on Page 2. Remove the mast guard. See Figure 8-19.

Loosen both locknuts at the chain anchors to make any adjustments.

4. Adjust the nuts of the chain anchors equal amounts for the correct distance (Step 1).

Figure 8-43-Typical Wear Strip Assembly 1.

2.

3.

4.

5.

CAPSCREW WASHER WEAR STRIP SHIM WELDMENT CHANNEL

Sheet 13: Hydraulic System NOTE: WEAR STRIPS AND SHIMS ON THE TRIPLEX INNER WELDMENT CAN BE USED ON EITHER SIDE. THERE ARE RIGHT AND LEFT WEAR STRIPS AND SHIMS ON SIMPLEX INNER AND THE TRIPLEX INTERMEDIATE WELDMENTS. 5. Check chain tension by pushing on both chains at the same time. If the tension is not the same, adjust the nuts on the chain anchors until the tension is the same and the distance (Step 1) is also correct. When the tension is equal on both chains, the chain sheave assembly will be level. Tighten the locknuts.

NOTE: When the chain adjustments are complete, make sure that the cotter pin at the bottom of the chain anchor can be installed under the adjustment nut. If there is no room to install the cotter pin, the chains are too short. Install the correct chains. Make sure that the locknuts on the chain anchors are tight against the mount plate. If there are not enough threads on the chain anchor for correct adjustment, new chains are too long or old chains are too worn.

Links can be removed from old chains if the chains are less than 3% longer than the correct new chain. Replace old chains that are too long or new chains that are not the correct length.

6. Check the mast operation described at the beginning of this CHECKS AND ADJUSTMENTS section.

7. Install the mast guard if removed.

Adjust Main Lift Chains NOTE: On triplex masts, the free lift chains must be adjusted before adjusting the main lift chains.

NOTE: The adjustment nuts, to adjust the main lift chains, are at the chain anchors near the top of the outer weldment.

Read and follow the instructions in MAST ADJUSTMENTS in this CHECKS AND ADJUSTMENTS section.

Simplex: 1. Fully lower the carriage or reach assembly. Measure the distance from the floor to the top of the forks at the heel. The correct distance is 57 mm (2.25 in).

2. If the distance is correct, the chains are adjusted for the correct height. Do Step 5 next. If the distance is NOT correct, do all of the steps.

3. Remove the mast guard. See Figure 8-19. Loosen both locknuts at the chain anchors to make any adjustments.

4. Adjust the nuts of the chain anchors equal amounts for the correct distance (Step 1).

5. Check chain tension by pushing on both chains at the same time. If the tension is not the same, adjust the nuts on the chain anchors until the tension is the same and the distance (Step 1) is also correct. Tighten the locknuts.

NOTE: When the chain adjustments are complete, make sure that the cotter pin at the bottom of the chain anchor can be installed under the adjustment nut. If there is no room to install the cotter pin, the chains are too short. Install the correct chains. Make sure that the locknuts on the chain anchors are tight against the mount plate. If there are not enough threads on the chain anchor for correct adjustment, new chains are too long or old chains are too worn.

Links can be removed from old chains if the chains are less than 3% longer than the correct new chain. Replace old chains that are too long or new chains that are not the correct length.

6. Tighten the chain anchor jam nuts.

7. Check the mast operation as described at the beginning of this CHECKS AND ADJUSTMENTS section.

8. Install the mast guard if removed.

Triplex: 1. Adjust the main lift chains for equal tension.

2. Check chain tension by pushing on both main lift chains at the same time. If the tension is not the same, remove the mast guard. See Figure 8-19. Loosen both locknuts at the chain anchors to make any adjustments.

Sheet 13: Hydraulic System 3. Adjust the nuts on the chain anchors until the tension is the same. Tighten the locknuts.

4. Check the mast operation as described at the beginning of this CHECKS AND ADJUSTMENTS section.

5. Install the mast guard.

CARRIAGE OR REACH ASSEMBLY ADJUSTMENTS Adjust Wear Plug (See Figure 8-41 and Figure 8-42) Adjust the wear plugs as follows: 1. Fully lower the carriage or reach assembly and make sure the lift chains are the support for the carriage or reach assembly. If the lift chains are loose, operate the system to raise the carriage or reach assembly until the lift chains are the support.

WARNING: NEVER loosen the wear plugs if the carriage or reach assembly does not move freely during checks after an adjustment. The carriage or reach assembly can suddenly move and cause an injury. Raise the carriage or reach assembly, move the key to the OFF position and install safety chains as described in SAFETY PROCEDURES.

SIMPLEX

TRIPLEX MAIN LIFT

Sheet 13: Hydraulic System

TRIPLEX FREE LIFT Figure 8-44- Lift Chains - Adjustment 1. INNER WELDMENT 2. CHAIN SHEAVE 3. LIFT CHAIN 4. COTTER PIN 5. ANCHOR PIN 6. CHAIN ANCHOR 7. LOCKNUT 8. OUTER WELDMENT 9. ADJUSTMENT NUT 10. REACH ASSEMBLY 11. TYPICAL FIXED ANCHOR 12. INTERMEDIATE WELDMENT 13. FREE LIFT CYLINDER 1. Loosen the jam nut on the wear plug using the special tool available from your Yale lift truck dealer. See Figure 8-41 and Figure 8-42.

2. Adjust the wear plugs to attain zero clearance between the wear plug and the weldment channel.

3. Adjust the clearance to approximately 0.5 mm (0.02 in) by turning the adjustment handle 1 '8 turn counter clockwise. Keep the clearance between the carriage or reach assembly and mast weldments equal on both sides. Keep the carriage or reach assembly parallel to the mast weldment.

Sheet 13: Hydraulic System 4. Tighten each jam nut without moving the setscrew.

5. If necessary carefully remove the safety chains. Raise and lower the carriage without a load. Check that there is minimum clearance with free movement. If the carriage does not move smoothly during lowering follow the WARNING and adjust the wear plugs equally for more clearance.

6. Raise and lower the carriage with a load. Check that there is minimum clearance with free movement. If the carriage does not move smoothly, during lowering, follow the WARNING and adjust the wear plugs equally for more clearance.

Adjust Side Rollers 1. If necessary, remove the carriage or reach assembly from the mast. See CARRIAGE or REACH ASSEMBLY-REMOVAL AND INSTALLATION. 2. Measure the width of the inside face of the inner weldment in several places. See Figure 8-45. Make a note of the location and the value of the minimum measurement.

3. Measure and record the distance across the side rollers of the carriage assembly. See "A" of Figure 8-46.

4. Add or remove shims under the side rollers so that the distance across the rollers is 1/2 mm (0.02 in) less than the measurement of Step 2.

NOTE: Make sure the total shim thickness for each side is the same for each set of side rollers. Equal shim thickness will keep the clearance equal between the carriage or reach assembly and mast weldment on both sides.

5. Install the carriage or reach assembly. See CARRIAGE or REACH ASSEMBLY-REMOVAL AND INSTALLATION or INSTALLATION OF THE INNER FRAME ASSEMBLY Adjust Thrust Rollers 1. Measure the width between the outside edges of the inner weldment in several places. See Figure 8-45. Make a note of the location and the value of the maximum measurement.

2. Measure and record the distance between the inside faces of the thrust rollers of the carriage or reach assembly. See "B" of Figure 8-46.

3. If the distance "B" is more than 4 mm (0.16 in) less than the maximum measurement of Step A, install smaller size thrust rollers. If the distance "B" is more than 4mm (0.16 in) greater than the maximum measurement of Step A, install larger size thrust rollers. Install the same size rollers on each side for a minimum clearance at the maximum measurement point (Step 1). Thrust rollers have outside diameters of 74, 76 or 78 mm (2.88, 2.96 or 3.04 in).

Sheet 13: Hydraulic System Figure 8-46- Carriage and Reach Assembly Side and Thrust Roller Widths Adjustment for the Reach Cylinders NOTE: The reach cylinders must be adjusted if either reach cylinder has been replaced or the rod ends have been removed. Adjustment is also necessary if major parts of the reach mechanism have been replaced.

The reach mechanism must be adjusted so that the outer frame or sideshift apron just touches the stops on the inner frame with the cylinders fully retracted. The mechanism must also extend the correct distance.

WARNING: The points between the scissor arms and the inner frame outer frame or apron are pinch points and can cause an injury. Do NOT put any part of your body between these assemblies if they can move. Always move the key to the OFF position and disconnect the battery 1. Remove the air from the reach system as described in REMOVE AIR FROM THE HYDRAULIC SYSTEM. Operate the reach mechanism to fully extend and retract the forks for several cycles.

2. Fully extend the forks move the key to the OFF position and disconnect the battery. Measure the distance between the contact surface of the outer frame or apron and the stops on the inner frame. Measure the distance on both sides. The correct distance for a single reach unit is 610+3-6 mm (24+0.12-0.25 in). The correct distance for a double reach unit is 1067+3-6 mm (42+0.12-0.25 in).

3. If the distance is not within specifications on both sides loosen the capscrews at the rod ends of the reach cylinders. Use a wrench to rotate the cylinder rods for the correct distance. Temporarily tighten the capscrews without moving the rods.

4. Operate the reach mechanism through several cycles and fully extend the forks. Move the key to the OFF position and disconnect the battery. Measure the distance on each side again. Both measurements must be within specifications AND the measurements must be within 3 mm (0.12 in) of each other. If the measurements are not within specifications do Steps 3 and 4 until all measurements are correct. Temporarily tighten the capscrews without moving the rods after all measurements are correct.

5. Fully retract the forks check each stop on the inner frame. The outer frame or sideshift apron must be just touching the stop pads.

6. Extend the reach mechanism move the key to the OFF position and disconnect the battery. Add or remove shims under each stop pad as necessary. Do NOT use more than two shims. Do Steps 5 and 6 until the outer frame just touches on both sides.

7. Fully extend the forks move the key to the OFF position and disconnect the battery. Loosen the capscrews at the rod ends of the reach cylinders. Use a wrench to rotate the cylinder rods 1/4 turn clockwise into the cylinder. This adjustment allows the stop pads to absorb the shock instead of the reach cylinders as the mechanism retracts.

Tighten the rod end capscrews to 48 to 54 N m (35 to 40 lbf ft) torque.

Adjustment for the Tilt Cylinder WARNING: The points between the scissor arms and the inner frame outer frame or apron are pinch points and can cause an injury. Do NOT put any part of your body between these assemblies if they can move. Always move the key to the OFF position and disconnect the battery.

Remove the air from the tilt system as described in REMOVE AIR FROM THE HYDRAULIC SYSTEM. Operate the tilt mechanism to move the fork tips to the full up and full down positions for several cycles.

CAUTION: Make sure the tilt pivots do not go over the center point. The fork tips will start to move down instead of continuing to move up during adjustment if the pivots are past center. Higher stress increased wear and poor operation will also occur during operation Fully extend the forks and operate the tilt function for a full UP tilt of the forks (tilt cylinder fully extended). Move the key to the OFF position and disconnect the battery. Loosen the locknut at the rod end of the tilt cylinder. Rotate the cylinder rod for maximum height of the fork tips. Tighten the locknut to 81 to 156 N m (60 to 115 lbf ft) torque without rotating the rod.

Adjustment for the Sideshift Cylinder

Sheet 13: Hydraulic System WARNING: The points between the scissor arms and the inner frame outer frame apron or outer frame are pinch points and can cause an injury. Do NOT put any part of your body between these assemblies if they can move Always move the key to the OFF position and disconnect the battery.

Remove the air from the sideshift system as described in REMOVE AIR FROM THE HYDRAULIC SYSTEM. Operate the sideshift mechanism to move the forks to the full right and full left for several cycles.

Operate the sideshift function for full movement of the outer frame. Move the key to the OFF position and disconnect the battery. Make a measurement of the total movement of the outer frame (total stroke of the cylinder). Operate the sideshift function to move the outer frame to one end of the stroke then halfway back. The cylinder rod will now be at the center of the stroke. Move the key to the OFF position and disconnect the battery. Loosen the locknut at the rod end of the sideshift cylinder and use a wrench to rotate the cylinder rod. Rotate the rod to move the center of the outer frame to the center of the apron. Tighten the lock nut without rotating the rod.

TROUBLESHOOTING-MAST

TROUBLESHOOTING-REACH AND CARRIAGE

Sheet 13: Hydraulic System

SPECIFICATIONS

Sheet 14: 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 14: 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 power tracks 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.

Sheet 14: Battery And Charging System 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.

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

Sheet 14: Battery And Charging System

Sheet 14: Battery And Charging System

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

Sheet 14: Battery And Charging System 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 (PbO3) 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 mix with sulfuric acid to make lead sulfate (PbSO4) 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 14: 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 14: 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: 24volts 12 cell battery 36volts 18 cell battery 48 volts 24 cell battery

Sheet 14: Battery And Charging System

Figure 9-6- Cell Voltage Battery Ratings The ratings of batteries are measured in ampere-hours (AH) and kilowatt-hours (kWH) 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

Sheet 14: Battery And Charging System 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 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.

Keep batteries clean and free of acid spills.

Do not over-discharge. Excessive discharge shortens battery life.

Do not overcharge. Overcharging produces corrosion of positive grids and excessive gassing, which loosens the active material of the plates.

Charge batteries in a well ventilated area to remove the explosive gases and acid fumes.

Maintain electrolyte at the proper level. If low, add water. Before charging, make sure tops of plates are covered;

Sheet 14: Battery And Charging System after charge, fill to recommended level. Do not add acid.

Keep batteries from freezing.

Keep batteries in a charged state.

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.

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.

Sheet 14: Battery And Charging System 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 plates, the cell can be damaged. 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.

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 electrolyte.

Table 9-1 - Electrolyte Level

Figure 9-10 - Electrolyte Level Hydrometer 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 14: 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 60° C (100° F), the specific gravity will decrease by 0.003 points. Refer to Figure 9-12 for making specific gravity corrections.

Table 9-2- Specific Gravity Corrections

Sheet 14: Battery And Charging System Figure 9-12 - Battery Thermometer Never charge or discharge a battery at a rate that will raise the temperature of the electrolyte above 500° C (1200° 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 250° C (770°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.

CHARGING THE BATTERY WARNING: Batteries produce explosive hydrogen as 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 these circumstances.

CAUTION: A battery should always be recharged immediately following a complete discharge. 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:

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The battery is too small for the job.

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The battery is not fully charged.

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The battery charger is not operating correctly.

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The battery is near the end of its service life.

Methods of Charging There are three methods of charging a battery.

Sheet 14: Battery And Charging System 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 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.

3. 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 140°C (250° 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 terminal. Any other connection will cause injury 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 WARNING: Always deenergize the charger before you connect or disconnect the charger from 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.

Sheet 14: Battery And Charging System 7. Safety regulations and instructions.

Equipment Needed

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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.

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A battery charger that will charge your batteries. e Tools for maintenance.

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An area with a drain for cleaning batteries and battery compartments.

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Distilled water.

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Air and water supplies for cleaning.

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Maintenance records.

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A work bench.

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Spare parts and repair equipment.

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Protective clothing and safety equipment for handling batteries.

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Water sources for washing eyes and preventing acid burns.

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Install a NO SMOKING sign in the service area.

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Keep the charger in a clean, dry area with good ventilation.