Download PDF: Service Manual for Yale MP30UX (A7T1) Motorized Hand Truck

Maintenance

SERVICE MANUAL MOTORIZED HAND TRUCK MP30UX (A7T1)

PART NO. 550234297

8000 YRM 2405

SAFETY PRECAUTIONS •

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The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Yale® dealer.

Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

Do not lift heavy parts by hand, use a lifting mechanism.

Wear safety glasses.

DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.

Disconnect the battery ground cable on internal combustion lift trucks.

Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Maintenance section.

Keep the unit clean and the working area clean and orderly.

Use the correct tools for the job.

Keep the tools clean and in good condition.

Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

Be sure to follow the WARNING and CAUTION notes in the instructions.

Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.

Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.

Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual: WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

WARNING California Proposition 65 - Operating, servicing and maintaining a powered industrial truck can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information, go to www.P65Warnings.ca.gov.

Table of Contents

TABLE OF CONTENTS General ...................................................................................................................................................................1 Serial Number.......................................................................................................................................................1 Periodic Maintenance..............................................................................................................................................2 Maintenance Schedule......................................................................................................................................... 2 Maintenance Procedures......................................................................................................................................4 How to Put the Lift Truck on Blocks................................................................................................................... 4 How to Move a Disabled Lift Truck.................................................................................................................... 4 Charge the Battery with an External Charger.................................................................................................... 4 Repair......................................................................................................................................................................5 Frames and Covers Repair...................................................................................................................................5 Remove and Install the Fork Frames.................................................................................................................5 Remove and Install the Upper Cover.................................................................................................................5 Remove and Install the Rear Cover and Rear Panel.........................................................................................6 Remove and Install the Box Cover.....................................................................................................................6 Driving System Repair..........................................................................................................................................7 Operation Principles...........................................................................................................................................7 Driving System Structure................................................................................................................................... 7 Driving System Repair....................................................................................................................................... 8 Brake Repair....................................................................................................................................................8 Hold on Grade Test.......................................................................................................................................8 Remove and Install the Electromagnetic Brake............................................................................................ 8 Remove and Install the Traction Motor............................................................................................................9 Remove and Install the Drive Wheel ............................................................................................................ 10 Remove and Install the Tiller Handle.............................................................................................................10 Gearbox Repair............................................................................................................................................. 12 Drain Oil from the Gearbox......................................................................................................................... 12 Remove and Install the Gearbox................................................................................................................ 12 Remove the Gearbox End Cover................................................................................................................12 Refill the Gearbox....................................................................................................................................... 13 Lifting System Repair..........................................................................................................................................14 Operation Principles.........................................................................................................................................14 Hydraulic Schematic Diagram..........................................................................................................................14 Hydraulic System Components........................................................................................................................14 Lifting System Structure...................................................................................................................................15 Adjust Relief Valve Rated Pressure................................................................................................................. 16 Add Hydraulic Oil............................................................................................................................................. 16 Adjust Pull Rods...............................................................................................................................................17 Remove and Install the Lift Cylinder................................................................................................................ 17 Disassemble Lift Cylinder.................................................................................................................................18 Remove and Install the Load Wheel................................................................................................................ 19 Casters Repair................................................................................................................................................. 19 Adjust the Casters......................................................................................................................................... 19 Disassemble the Casters...............................................................................................................................20 Remove and Install the Rocker Arm, Linkage, and Wheel Carrier...................................................................20 Adjust the Fork Height......................................................................................................................................21 Electrical System Repair.....................................................................................................................................21 Operation Principles.........................................................................................................................................21 Start-up..........................................................................................................................................................21 Traveling........................................................................................................................................................21 Lift and Lower................................................................................................................................................21 Alarm............................................................................................................................................................. 21 Controller.......................................................................................................................................................21

©2021 Yale Materials Handling Corp.

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Table of Contents

TABLE OF CONTENTS (Continued) Controller Connectors.................................................................................................................................22 Tiller Handle Connectors............................................................................................................................... 24 BDI Display Connectors................................................................................................................................ 25 Electrical Schematic Diagram.......................................................................................................................... 25 Electrical Components Identification................................................................................................................26 Main Electrical Components............................................................................................................................ 28 Discharge the Capacitor...................................................................................................................................28 Electrical Components Repair..........................................................................................................................29 Remove and Install Emergency Stop Switch.................................................................................................29 Remove and Install Gauge............................................................................................................................29 Remove and Install Fuse...............................................................................................................................29 Remove and Install Key Switch.....................................................................................................................30 Remove and Install Horn...............................................................................................................................30 Remove and Install Charger..........................................................................................................................31 Remove and Install Built-in Charger Plug......................................................................................................31 Remove and Install Drive Controller..............................................................................................................31 Remove and Install Fan.................................................................................................................................31 Remove and Install Batteries........................................................................................................................... 32 Troubleshooting.....................................................................................................................................................33 Mechanical Breakdowns and Resolution............................................................................................................33 The Lift Truck Cannot Lift.................................................................................................................................33 Check Lift Switch...........................................................................................................................................33 Check Power Meter.......................................................................................................................................33 Check Height Limit Switch.............................................................................................................................33 Check the Lift Contactor................................................................................................................................33 The Lift Truck Cannot Lower............................................................................................................................33 Check the Lower Switch................................................................................................................................33 The Lift Truck Cannot Travel............................................................................................................................34 Check the Status LED................................................................................................................................... 34 Check Travel with the Handheld Programmer................................................................................................. 34 Other Mechanical Faults and Resolution......................................................................................................... 35 Faults Codes.......................................................................................................................................................36 Check Controller ............................................................................................................................................. 36 Fault Codes and Troubleshooting Procedure for the Controller.......................................................................36 Diagnostics....................................................................................................................................................36 Fault Code Identification with LED................................................................................................................ 37 Fault Codes................................................................................................................................................... 37 Troubleshooting Procedure........................................................................................................................... 39 1.1 THERMAL FAULT.................................................................................................................................39 1,4 UNDERVOLTAGE FAULT, 1,5 OVERVOLTAGE FAULT, and 4,5 BATTERY DISCONNECT FAULT... 39 1,2 THROTTLE FAULT, 3,1 WIRING FAULT, and 3,5 HPD FAULT............................................................ 40 3,2 BRAKE ON FAULT and 3,4 BRAKE OFF FAULT ................................................................................ 41 3,3 PRECHARGE FAULT .......................................................................................................................... 42 4,2 HARDWARE FAIL SAFE...................................................................................................................... 42 4,4 MOTOR OPEN..................................................................................................................................... 42 Handheld Programmer....................................................................................................................................... 43 Programmer Connectors..................................................................................................................................43 Pushbuttons Functions.....................................................................................................................................43 Power up the Programmer...............................................................................................................................45 Display Programmer Information..................................................................................................................... 45 System Info Menu..........................................................................................................................................46 Parameter Menu............................................................................................................................................46

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Table of Contents

TABLE OF CONTENTS (Continued) Monitor Menu.................................................................................................................................................47 Diagnostics Menu..........................................................................................................................................48 Programmer Access Level...............................................................................................................................49 Specifications........................................................................................................................................................ 50 Electrical Components Specifications.................................................................................................................50 Charger Specifications........................................................................................................................................50 Charger LED Display..........................................................................................................................................51 Motor Specifications........................................................................................................................................... 51 Oil and Grease Specifications............................................................................................................................ 53 Performance Specifications................................................................................................................................53 Wheels Specifications.........................................................................................................................................53 Torque Specification........................................................................................................................................... 54 Storage and Transportation...................................................................................................................................56 Loading and Unloading.......................................................................................................................................56 Transportation.....................................................................................................................................................56 Storage............................................................................................................................................................... 56

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8000 YRM 2405

General

General SERIAL NUMBER The serial number identifies the truck and is printed on the nameplate. It is also stamped on the lift truck

frame. For serial number location on the lift truck, see Figure 1.

Figure 1. Serial Number Location

1

Periodic Maintenance

8000 YRM 2405

Periodic Maintenance MAINTENANCE SCHEDULE

maintenance will help your lift truck provide more efficient performance and operate for a longer period of time. If the parts must be adjusted and replaced, contact maintenance personnel.

CAUTION For safety purpose, maintenance shall be carried out according to maintenance procedure. A regular program of inspection, lubrication, and

Figure 1. Maintenance Items

2

8000 YRM 2405

Periodic Maintenance

Item No.

Item

Maintenance Cycle

Comments

1

Wheel Bearings

1200 hours

Replace if damaged. See Remove and Install the Drive Wheel .

2

Wheels

1200 hours

Replace if damaged. See Remove and Install the Drive Wheel and Remove and Install the Load Wheel.

3

Seals

1200 hours

Replace if damaged. See Lifting System Repair.

4

Gearbox

1000 hours

Replace grease. See Refill the Gearbox.

5

Hydraulic Oil

1000 hours

Replace hydraulic oil. See Add Hydraulic Oil.

6

High Pressure Oil Tube

2000 hours

Replace if damaged. See Lifting System Repair.

7

Hydraulic Tank Strainer Mesh

1000 hours

Cleaning.

8

Drive Motor

1000 hours

Check carbon brush and bearings; replace if damaged. See Remove and Install the Traction Motor.

9

Electric Motor of Oil Pump 1000 hours

Contact the factory.

10

Brake

Hold on grade test. See Hold on Grade Test.

2000 hours

3

Periodic Maintenance

8000 YRM 2405

MAINTENANCE PROCEDURES

For how to remove the brake, see Remove and Install the Electromagnetic Brake.

HOW TO PUT THE LIFT TRUCK ON BLOCKS WARNING The lift truck must be put on blocks for some types of maintenance and repair. The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any blocks used to support the lift truck are solid, onepiece units.

1.

Find out the four lifting points marked on the lift truck. See Figure 2.

2.

Use lifting equipment to lift up the truck. Make sure that the lifting equipment has sufficient lifting capacity.

Figure 3. Move a Disabled Lift Truck

3.

Insert blocks under the truck after lifting.

Figure 2. Lift up Lift Truck

HOW TO MOVE A DISABLED LIFT TRUCK 1.

Turn off the emergency stop switch.

2.

Remove the brake (Figure 3, item 1) from the drive wheel (Figure 3, item 2), and manually drag the disabled lift truck to the maintenance or charging area.

4

CHARGE THE BATTERY WITH AN EXTERNAL CHARGER When the battery state of charge indicator of the truck indicates that the battery is insufficient, conduct charging at once to avoid battery damage.

1.

Move the lift truck to the designated area for battery charging.

2.

Turn off the key switch.

3.

Push in the emergency power disconnection.

4.

Disconnect the power cable from the battery to the truck.

5.

Connect the battery cable connector to the charger to start charging.

When the green pilot light of the charger turns on, it indicates that the battery is fully charged. The connecting cable can be removed and inserted into the truck battery connector.

If the battery is completely discharged, a full charge can take up to 12 hours. It is strictly prohibited to open the storage battery air vent valve. Poor sealing will affect the service life of the battery.

8000 YRM 2405

Repair

Repair FRAMES AND COVERS REPAIR

REMOVE AND INSTALL THE UPPER COVER

REMOVE AND INSTALL THE FORK FRAMES

1.

Loosen the screw (Figure 3, item 1).

2.

Remove the coil (Figure 3, item 2) from the upper cover hole.

3.

Push charging plug (Figure 3, item 3) into cover through the hole.

4.

Lift off the upper cover (Figure 3, item 4).

5.

To install the upper cover, perform the steps in reverse order.

1.

2.

3.

Remove the electrical wires before removing the mechanical structures. See Electrical System Repair.

Remove the snap ring (Figure 1, item 1) and pin (Figure 1, item 2) from the upper pivot point of the lift cylinder.

Remove pin (Figure 1, item 4) and nut (Figure 1, item 3) on both left and right side.

Figure 1. Remove Snap Ring, Pin, and Nut 4.

After removal, rear frame (Figure 2, item 5) and front frame (Figure 2, item 6) are separated.

5.

To install the fork frames, perform the steps in reverse order.

Figure 3. Remove Upper Cover

Figure 4. View after Removing Upper Cover

Figure 2. Front Frame and Rear Frame

5

Repair

8000 YRM 2405

REMOVE AND INSTALL THE REAR COVER AND REAR PANEL 1.

Loosen the screws (Figure 5, item 1) on both left and right side.

2.

Lift off the rear cover (Figure 5, item 2).

Figure 7. View after Removing Rear Cover and Rear Panel

REMOVE AND INSTALL THE BOX COVER 1.

Loosen the screws (Figure 8, item 1) on both left and right side.

Figure 5. Remove Rear Cover 3.

Loosen two screws (Figure 6, item 3) on both left and right side.

4.

Remove the rear panel (Figure 6, item 4) forwards.

5.

To install the rear cover and rear panel, perform the steps in reverse order.

Figure 8. Remove Screws

Figure 6. Remove Rear Panel

6

2.

Lift off the box cover (Figure 9, item 2).

3.

To install the box cover, perform the steps in reverse order.

8000 YRM 2405

Repair

DRIVING SYSTEM REPAIR OPERATION PRINCIPLES

Figure 9. Remove Box Cover

The truck uses one electric traction motor. When the accelerator knob is turned, the motor is energized, the motor turns and applies power to the gear box, which then turns the combined steering and traction tire.

Steering is manual. When the tiller handle is moved, the drive unit assembly turns and the truck moves in the desired direction. Braking is supplied through regen braking when the accelerator control is released. An electromagnetic brake mounted to the drive motor engages when the truck is stopped or when the tiller handle is in the fully horizontal or fully vertical position.

DRIVING SYSTEM STRUCTURE

Figure 10. View after Removing Box Cover 1. TRACTION MOTOR 2. BRAKE 3. GEARBOX Figure 11. Driving System Structure

7

Repair

8000 YRM 2405

DRIVING SYSTEM REPAIR

3.

Brake Repair

Loosen three screws (Figure 13, item 1) from the brake.

Hold on Grade Test

Figure 13. Remove Brake Screws 1. 10% GRADE 2. TEST LOAD 3. LIFT TRUCK

4.

Unplug the electrical connector (Figure 14, item 2) and then take off the brake.

Figure 12. Hold on Grade Test

WARNING DO NOT stand below or ride on the lift truck when performing the hold on grade test.

The brake should be checked for hold capacity every 2000 hours or yearly or any time substandard brake performance is suspected. Load a stable, full-capacity load on the forks and position the lift truck at the base of a 10-percent grade [1.0 m rise in 10.0 m (3 ft rise in 30 ft)] grade with the forks facing uphill. Standing to the side of the lift truck, slowly drive the lift truck up the grade and bring the lift truck to a stop using the directional controls (plugging). Move the control handle to the BRAKE ON position to apply the parking brake.

See Figure 12. If the brake fails to hold the lift truck on the grade, the brake assembly must be replaced. For how to replace the brake, see Remove and Install the Electromagnetic Brake.

Figure 14. Unplug Brake Electrical Connector 5.

Remove the snap ring (Figure 15, item 3) with tools.

Remove and Install the Electromagnetic Brake 1.

Remove the rear cover and rear panel. See Remove and Install the Rear Cover and Rear Panel.

2.

Turn the tiller handle so that the brake face outwards.

8

Figure 15. Remove Snap Ring

8000 YRM 2405 6.

Repair

Remove the spline gear (Figure 16, item 4).

Figure 18. Remove Motor Wiring Figure 16. Remove Spline Gear 7.

5.

Remove the flat key (Figure 17, item 5).

Figure 19. Remove Setscrews

Figure 17. Remove Flat Key 8.

To install the brake, perform the steps in reverse order.

Loosen four setscrews (Figure 19, item 2) from the motor.

6.

Turn the tiller handle so the motor assembly faces outwards.

Remove and Install the Traction Motor 1.

Remove the rear cover and rear panel. See Remove and Install the Rear Cover and Rear Panel.

2.

Remove the electromagnetic brake. See Remove and Install the Electromagnetic Brake.

3.

Turn the tiller handle so that the motor wiring faces outwards.

4.

Disconnect the motor wiring (Figure 18, item 1).

Figure 20. Motor 7.

Carefully remove the motor from the truck.

(Figure 20, item 3).

9

Repair 8.

8000 YRM 2405

Remove the snap ring (Figure 21, item 4) on the motor shaft, and remove gear (Figure 21, item 5), oil retainer (Figure 21, item 6), and O-ring (Figure 21, item 7).

Figure 23. Remove Wheel Bolts

Figure 21. Remove Snap Ring, Gear, Oil Retainers, and O-ring 9.

Remove the flat key (Figure 22, item 8) from the shaft.

4.

Remove the drive wheel.

5.

To install the drive wheel, perform the steps in reverse order.

Remove and Install the Tiller Handle 1.

Figure 22. Remove Flat Key 10. To install the motor, perform steps in reverse order.

Remove and Install the Drive Wheel 1.

Remove the rear cover and rear panel. Remove and Install the Rear Cover and Rear Panel.

2.

Turn the tiller handle so that the wheel bolts face outwards.

3.

Remove five wheel bolts (Figure 23, item 1) from the drive wheel.

10

Loosen the lock nut (Figure 24, item 1) on the tiller handle wiring harness connector.

Figure 24. Remove Lock Nut 2.

Disconnect the tiller handle wiring harness (Figure 25, item 2).

8000 YRM 2405

Repair

Figure 27. Tiller Handle

Figure 25. Disconnect Tiller Handle Wiring Harness 3.

Turn the tiller handle so that the two screws are accessible.

7.

4.

Remove two screws (Figure 26, item 3) from the tiller handle.

NOTE: During installation, align the lift cylinder gap plane (Figure 28, item 6) with tiller handle plane (Figure 29, item 7).

To install the tiller handle, perform the steps in reverse order.

Figure 26. Remove Tiller Handle Screws 5.

Lower the tiller handle (Figure 27, item 4).

6.

Remove the clamp (Figure 27, item 5) and the tiller handle from the frame.

Figure 28. Lift Cylinder Gap Plane

Figure 29. Tiller Handle Plane

11

Repair

8000 YRM 2405

Gearbox Repair

Remove and Install the Gearbox

Drain Oil from the Gearbox

1.

Remove the lift cylinder. See Remove and Install the Lift Cylinder.

2.

After removing the lift cylinder, the gearbox is separated from the truck.

WARNING Dispose the waste oil according to the local laws and regulations.

Remove the Gearbox End Cover

1.

Remove the gearbox filling plug (Figure 30, item 1) and O-ring (Figure 30, item 2).

1.

Remove the screw (Figure 31, item 2), dowel pin (Figure 31, item 1).

2.

Remove the oil drain plug screw (Figure 30, item 3) and the compound gasket (Figure 30, item 4).

2.

Remove the end cover (Figure 31, item 3) from the box (Figure 31, item 4).

3.

Drain the oil from the gearbox.

Figure 31. Remove Gearbox End Cover Figure 30. Drain Oil from Gearbox

12

For gearbox internal structure, see Figure 32 .

8000 YRM 2405

Repair

1. RIGHT GEARBOX BODY 2. LEFT GEARBOX BODY 3. O-RING 4. SLINGER 5. FLAT KEY 6. SEALING RING 7. RETAINING RING 8. GEARS 9. FLAT KEY 10. RETAINING RING 11. O-RING 12. PLUG SCREW 13. FLAT KEY 14. BEARING 15. GEAR SHAFT 16. GEAR 17. FLAT KEY

18. ROUND NUT 19. GEAR 20. O-RING 21. STEP SHAFT 22. BEARING 23. SEALING RING 24. BOLT 25. WASHER 26. WHEEL 27. PLUG SCREW 28. MAGNETIC STEEL 29. COMPOUND GASKET 30. PLUG SCREW 31. SCREW 32. PIN 33. SCREW 34. WASHER Figure 32. Gearbox Internal Structure

Refill the Gearbox 1.

Remove the filling plug (Figure 33, item 1) and Oring (Figure 33, item 2).

2.

Remove the oil level observer plug screw (Figure 33, item 3) and the compound gasket (Figure 33, item 4).

3.

Add slowly about 320 ml (0.39 qt) gear oil GL-5 (85 W / 90) through the oil filling port. When the gearbox is in the upright position and the oil overflows from the observer port, the oil is sufficient for service.

Figure 33. Refill Gearbox

13

Repair

8000 YRM 2405

LIFTING SYSTEM REPAIR OPERATION PRINCIPLES The truck uses one electric hydraulic pump. When the lift button is pressed, the pump is energized, and provides hydraulic pressure to the lift cylinder. The lift

cylinder extends, lifting the fork frame. This action operates moves the pull rod forward, which pivots the load wheels down and lifts the forks. When the lower button is pressed, the solenoid valve is energized and pressure is released at a constant rate, which allows the forks to lower.

HYDRAULIC SCHEMATIC DIAGRAM

Figure 34. Hydraulic Schematic Diagram

14

8000 YRM 2405

Repair

HYDRAULIC SYSTEM COMPONENTS

1. LIFT CYLINDER 2. CONNECTOR 3. HIGH PRESSURE OIL TUBE

4. CONNECTOR 5. HYDRAULIC POWER UNIT Figure 35. Hydraulic System Components

LIFTING SYSTEM STRUCTURE

1. LOAD WHEEL 2. FORK 1. HYDRAULIC POWER UNIT

Figure 37. Load Wheel and Fork

Figure 36. Hydraulic Power Unit

1. ROCKER ARM 2. PULL ROD Figure 38. Rocker Arm and Pull Rod

15

Repair

8000 YRM 2405

ADJUST RELIEF VALVE RATED PRESSURE CAUTION The rated pressure of the relief valve has been adjusted at factory. Only trained and authorized service technicians shall adjust the relief valve rated pressure.

If the oil pressure is not in accordance with the specified value, it shall be adjusted by professionals using the method as below: 1.

2.

Remove the upper cover. See Remove and Install the Upper Cover.

Figure 40. Adjust Screw 6.

Remove the relief valve cover (Figure 39, item 1) on the hydraulic power unit.

Turn the screw clockwise to increase pressure.

Turn the screw counterclockwise to reduce pressure. Adjust the screw to make the lift truck just be able to lift the rated load, and the maximum lifting weight shall not exceed 115% of the rated load.

Rated Load

1500 kg (3307 lb) 7.

Set System Pressure 12 MPa (1740.5 psi)

After adjustment, re-install the relief valve cover and tighten it.

ADD HYDRAULIC OIL

Figure 39. Relief Valve Cover 3.

Prepare a heavy load or a pallet of goods that matches the rated load.

4.

Insert fork into the pallet or heavy load with the center of gravity roughly at the center of the truck.

5.

Use a hex wrench to adjust the screw to adjust the pressure to the specified value. (Figure 40, item 2).

1.

Remove the upper cover. See Remove and Install the Upper Cover.

2.

Remove the hydraulic tank cover (Figure 41, item 1).

Figure 41. Remove Hydraulic Tank Cover 3.

16

Check the fluid level on the dipstick.

8000 YRM 2405 4.

Repair

Add hydraulic fluid up to the Max. Fluid level marked on the dipstick (Figure 42, item 2).

Figure 44. Remove Roll Pin Figure 42. Max. Fluid Mark on Dipstick

3.

NOTE: Do not fill the tank above the Max. Fluid mark.

5.

Re-install the hydraulic tank cover.

Rotate the pull rod end (Figure 45, item 3) to adjust the length of the pull rod. To reduce the length of the pull rod, turn the pull rod end clockwise. To increase the length of the pull rod, turn the pull rod end counterclockwise.

ADJUST PULL RODS 1.

Remove the snap ring (Figure 43, item 1) from the pull rod and rocker arm.

Figure 45. Rotate Pull Rod End

Figure 43. Remove Snap Ring 2.

Remove the roll pin (Figure 44, item 2) from the mounting hole.

REMOVE AND INSTALL THE LIFT CYLINDER 1.

Separate front frame and rear frame. See Remove and Install the Fork Frames.

2.

Remove the connector (Figure 46, item 1), screw (Figure 46, item 2), gasket (Figure 46, item 3), press plate (Figure 46, item 4), and handle assembly (Figure 46, item 5).

17

Repair

8000 YRM 2405 4.

On the subassembly (Figure 48, item 13), remove the screw (Figure 48, item 14), the disc (Figure 48, item 15), the screw (Figure 48, item 17), and the cylinder subassembly (Figure 48, item 16) from the drive wheel subassembly (Figure 48, item 18).

Figure 46. Remove Connector, Screw, Gasket, Press Plate, Handle Assembly 3.

Remove the retaining ring (Figure 47, item 6), the support, the retaining ring (Figure 47, item 8), the bearings (Figure 47, item 9), (Figure 47, item 10), (Figure 47, item 11), and the retaining ring (Figure 47, item 12).

Figure 48. Screws, Disc, and Cylinder Subassembly Removal 5.

To install the lift cylinder, perform the steps in reverse order.

DISASSEMBLE LIFT CYLINDER CAUTION Do not damage the seals when reassembling the cylinder to avoid damage to the hydraulic system.

Figure 47. Remove Retaining Rings and Bearings

18

1.

Remove the self-lubricating bearing (Figure 49, item 1).

2.

Pull the piston rod (Figure 49, item 2) from the cylinder subassembly.

8000 YRM 2405

Repair

Figure 51. Remove Pin Roll 3.

1.

2.

3.

4.

5.

6.

Remove the load wheel (Figure 52, item 3).

SELF-LUBRICATING BEARING PISTON ROD DUST RING SEALING RING GUIDE BELT CYLINDER BLOCK Figure 49. Lift Cylinder Components

REMOVE AND INSTALL THE LOAD WHEEL 1.

Remove two spring pins (Figure 50, item 1).

Figure 52. Remove Load Wheel 4.

To install the load wheel, perform the steps in reverse order.

CASTERS REPAIR Adjust the Casters

Figure 50. Remove Spring Pins 2.

1.

When properly adjusted, both left and right casters will be 2 mm (0.08 in.) above the ground.

2.

Rotate the nut (Figure 53, item 1) to adjust the height of the casters. Rotate the nut clockwise to raise the casters. Rotate the nut counterclockwise to lower the casters.

Remove the pin roll (Figure 51, item 2) from the load wheel.

19

Repair

8000 YRM 2405 Legend for Figure 54.

1. NUT 2. SNAP RING 3. BEARING 4. SELF-LUBRICATING BEARING 5. SPRING 6. BEARING 7. FRAME OF OMNI-DIRECTIONAL WHEEL 8. WHEEL 9. PIN ROLL 10. SNAP RING

Figure 53. Adjust Casters

REMOVE AND INSTALL THE ROCKER ARM, LINKAGE, AND WHEEL CARRIER 1.

Remove the screw (Figure 55, item 3) and then remove the spacer (Figure 55, item 2) and the pin roll (Figure 55, item 1).

2.

Remove the spring pin (Figure 55, item 5) and then the pin roll (Figure 55, item 4).

3.

Remove the snap ring (Figure 54, item 10) to remove the wheel (Figure 54, item 8) and the pin roll (Figure 54, item 9).

The wheel carrier subassembly with the linkage (Figure 56, item 2) is separated from the carriage (Figure 56, item 1).

4.

Remove the snap ring (Figure 57, item 2) and then the pin roll (Figure 57, item 1).

3.

Remove two bearings (Figure 54, item 3) from the wheel (Figure 54, item 8).

5.

Remove the spring pin (Figure 57, item 3) and then remove the pin roll (Figure 57, item 4).

4.

Remove the snap ring (Figure 54, item 2) to remove the bearing (Figure 54, item 3) in the wheel seat.

6.

The rocker arm, linkage, and wheel carrier are disassembled from the wheel carrier subassembly.

7.

To install the rocker arm, linkage, and wheel carrier, perform the steps in reverse order.

Disassemble the Casters 1.

2.

Remove the nut (Figure 54, item 1) to remove the subassemblies (Figure 54, item 5), (Figure 54, item 6), (Figure 54, item 7), (Figure 54, item 8), (Figure 54, item 9), (Figure 54, item 10) and the bearing (Figure 54, item 3) in the wheel (Figure 54, item 8).

Figure 54. Disassemble Casters Figure 55. Remove Rocker Arm

20

8000 YRM 2405

Repair

ELECTRICAL SYSTEM REPAIR OPERATION PRINCIPLES Start-up The truck is energized when both the emergency power disconnect (EME STOP SW) and the key switch (KEY SW) are turned on.

Figure 56. Carriage Separation

Traveling When the tiller handle is pulled down, the tiller switch (TILLER SW) closes providing energy to pin A6 on the controller (CURTIS 1212P).

Figure 57. Wheel Carrier subassembly

ADJUST THE FORK HEIGHT 1.

Remove the roll pin (Figure 58, item 2) and snap ring (Figure 58, item 1).

2.

Rotate the connector (Figure 58, item 3) to adjust the length of the linkage.

3.

Lengthen the linkage to raise the fork height or shorten the linkage to lower the fork height.

4.

When properly adjusted, the difference in height between the left fork and the right fork is 3 mm (0.12 in.) or less.

When the accelerator knob is rotated in the forward direction, it provides 0-5 V of power on pin A1 of the controller. Rotating the accelerator knob further increases the voltage to the controller. Power from the controller rotates the traction motor in the clockwise direction. The speed of the truck increases proportionally to the voltage to the controller.

When the accelerator knob is rotated in the reverse direction, it provides 0-5 V of power on pin A12 of the controller. Rotating the accelerator knob further increases the voltage to the controller. Power from the controller rotates the traction motor in the counterclockwise direction. The speed of the truck increases proportionally to the voltage to the controller.

Lift and Lower When the lift button is pressed, the lift switch (Lifting SW) closes and wired 28 is energized. This provides power to pin 4 on the indicator (INDICATOR). The indicator detects the state of charge (SoC) of the battery. If the SoC is greater than 20%, the contactor (KM1) energizes the pump motor (M2), which provides hydraulic pressure to lift the forks. If the SoC is lower than 20%, the contactor (KM1) refuses the lift command. When the maximum lift height is reached, the height limit switch (Height Limit SW) opens to prevent moving the forks.

When the lower button is pressed, the lowering switch (Lowering SW) allows the solenoid valve to close, which allows the forks to lower.

Alarm Figure 58. Adjust Fork Height

When the horn button is pressed, the horn switch (Horn SW) closes, which energizes the alarm.

21

Repair

8000 YRM 2405

Controller

Figure 59. Controller Schematic Diagram

Controller Connectors Low current logic control connections are provided by a 14-pin connector. The mating connector is a Molex Mini-Fit-Jr. receptacle p/n 39-01-2140 with 45750series crimp terminals. See Figure 60, item 1 and Figure 61.

A 4-pin low power connector is provided for the programmer and the battery charger. The mating connector is a Molex Mini-Fit-Jr. receptacle p/n 39-01-2040 with 45750-series crimp terminals. See Figure 60, item 1 and Figure 62.

22

A 2-pin low power connector is provided for the electromagnetic brake. The mating connector is a Molex Mini-Fit-Jr. receptacle p/n 39-01-2020 with 45750-series crimp terminals. See Figure 60, item 1 and Figure 63.

Four 6.35 mm (1/4 in.) Faston terminals are provided for high current connections. Each motor connection has one terminal (M1 and M2). Each battery connection has one terminal (B+ and B-). See Figure 60, item 2 and Figure 64.

8000 YRM 2405

Repair

1. LOW CURRENT CONNECTIONS 2. HIGH CURRENT CONNECTIONS Figure 60. Controller Connectors

Pin

Description

Pin

Description

1

Pot Wiper

1

Rx

2

Pot High

2

Battery -

3

Horn

3

Tx/charge Inhibit

4

Mode Switch

4

Battery +

5

Key Switch Input (KSI)

6

Speed Inhibit

7

Battery +

8

Pot Low

9

Speed Pot

10

Status LED

11

BDI

12

Reverse Switch

Pin

13

Battery -

1

Brake +

14

Push Switch

2

Brake -

Figure 61. 14-pin Connector

Figure 62. 4-pin Connector

Description

Figure 63. 2-pin Connector

23

Repair

8000 YRM 2405

Figure 64. High Current Connections

Tiller Handle Connectors

1.

2.

3.

4.

5.

6.

7.

8.

EMERGENCY REVERSE BUTTON ACCELERATOR KNOB ACCELERATOR CONNECTOR EMERGENCY REVERSE BUTTON CONNECTOR LIFT/LOWER BUTTON CONNECTOR MAIN HARNESS CONNECTOR HORN BUTTON CONNECTOR SLOW BUTTON CONNECTOR Figure 65. Tiller Handle Connector

24

Pin

Wire Color

Description

1

Black

Negative Pole

2

Blue

Forward

3

Green

Backward

4

Purple

Lower

5

Pink

Horn

6

Red

Positive Pole 24 V

7

Brown

Emergency Reverse

8

White

Accelerator 0-5 V

9

Yellow

Lift

10

Orange

Slow

Figure 66. Main Harness Wire Connector

8000 YRM 2405

Repair

BDI Display Connectors

Pin

Description

1

Debugging Port

2

Key Switch

3

Relay

4

Relay

5

Negative Pole

6

Timing Port

7

-

8

Positive Pole Figure 67. BDI Display

ELECTRICAL SCHEMATIC DIAGRAM

Figure 68. Electrical Schematic Diagram (Standard)

25

Repair

8000 YRM 2405

Figure 69. Electrical Schematic Diagram (North America Option)

26

8000 YRM 2405

Repair

ELECTRICAL COMPONENTS IDENTIFICATION

1. TILLER HANDLE 2. MICROSWITCH (HANDLE SWITCH) 3. DRIVING MOTOR 4. ELECTROMAGNETIC BRAKE 5. BDI DISPLAY 6. KEY SWITCH 7. LED 8. CONTROLLER 9. FUSE BRACKET 10. FUSE

11. CHARGER 12. FUSE 13. FUSE BRACKET 14. HYDRAULIC PUMP 15. ALARM 16. COOLING FAN 17. EMERGENCY STOP SWITCH 18. MICROSWITCH (HEIGHT LIMIT SWITCH) 19. STORAGE BATTERY

Figure 70. Electrical Components Identification

27

Repair

8000 YRM 2405

MAIN ELECTRICAL COMPONENTS

1. EMERGENCY STOP SWITCH 2. GAUGE 3. FUSE 4. ELECTRIC LOCK 5. BRAKE 6. DRIVING MOTOR 7. HYDRAULIC STATION 8. LIFT CONTACT 9. HORN 10. BUILT-IN CHARGER 11. BUILT-IN CHARGER PLUG 12. BUILT-IN CHARGING INDICATOR 13. DRIVE CONTROLLER 14. FAN Figure 71. Main Electrical Components

1.

2.

3.

4.

5.

DISPLAY STATUS LED KEY SWITCH CHARGING LED EMERGENCY STOP SWITCH Figure 73. Display, Status LED, Key switch, Charging LED, and Emergency Stop Switch

DISCHARGE THE CAPACITOR WARNING

1. CHARGER 2. CONTROLLER 3. BATTERIES Figure 72. Charger, Controller, and Batteries

28

The capacitor in the controller can hold an electrical charge after the battery is disconnected.

To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any components. Wear safety glasses.

Make certain that the battery has been disconnected.

8000 YRM 2405

Repair

CAUTION To avoid controller damage, always disconnect the battery. Discharge the capacitor, and never put power to the controller while any power wires are disconnected. Never short any controller terminal or motor terminal to the battery. Make sure to use proper procedure when servicing the controller.

1.

Move the truck to a safe, level area. Turn off the key switch and disconnect the battery.

2.

Connect a 30 Ω, 5 W resistor between terminals B- and B+ on the controller to discharge the capacitor. See Figure 74. DO NOT short across the motor controller terminals with a screwdriver or jumper wire.

Figure 75. Emergency Stop Switch

Remove and Install Gauge 1.

Disconnect the battery from the truck.

2.

Loosen two nuts (Figure 76, item 1).

3.

Remove the bent plate (Figure 76, item 2) to remove the gauge from the top for replacement.

4.

To install the gauge, perform the steps in reverse order.

Figure 74. Discharge Capacitor

ELECTRICAL COMPONENTS REPAIR Remove and Install Emergency Stop Switch

Figure 76. Gauge

1.

Disconnect the battery from the truck.

2.

Put the screwdriver into the hole (Figure 75, item 2) and rotate the mushroom button (Figure 75, item 1) counterclockwise for removal.

1.

Disconnect the battery from the truck.

2.

Loosen two nuts (Figure 77, item 1).

3.

Loosen two screws (Figure 75, item 3) to remove the emergency stop switch.

3.

Remove the bolt type fuse (Figure 77, item 2) for replacement.

4.

Loosen bolt (Figure 75, item 4) and then remove the connecting power line to replace the emergency stop switch.

4.

To install the fuse, perform the steps in reverse order.

5.

To install the emergency stop switch, perform the steps in reverse order.

Remove and Install Fuse

29

Repair

8000 YRM 2405 4.

Remove the black connector (Figure 80, item 4) to remove the key switch.

Figure 77. Fuse

Remove and Install Key Switch 1.

Disconnect the battery from the truck.

2.

Remove the upper cover. See Remove and Install the Upper Cover and

3.

Loosen setscrews (Figure 78, item 1) and then unplug the white connector (Figure 78, item 2) to remove the display (Figure 78, item 3).

Figure 80. Remove Black Connector 5.

To install the key switch, perform the steps in reverse order.

Remove and Install Horn 1.

Disconnect the battery from the truck.

2.

Loosen the setscrew (Figure 81, item 1) to disengage the connector.

3.

To install the horn, perform the steps in reverse order.

Figure 78. Loosen Setscrews and Unplug Connector

Figure 81. Horn

Figure 79. Remove Display

30

8000 YRM 2405

Remove and Install Charger 1.

Disconnect the battery from the truck.

2.

Remove the connecting wire of the built-in charger.

3.

Loosen four screws (Figure 82, item 1) to remove the charger.

4.

To install the charger, perform the steps in reverse order.

Repair 4.

To install the drive controller, perform the steps in reverse order.

Figure 83. Drive Controller

Remove and Install Fan

Figure 82. Remove Charger Screws

Remove and Install Built-in Charger Plug 1.

Disconnect the battery from the truck.

2.

Unplug the built-in charger plug directly from the charger.

3.

To install the built-in charger, perform the steps in reverse order.

1.

Disconnect the battery from the truck.

2.

Unplug the connector on the fan.

3.

Loosen two screws (Figure 84, item 1) to remove the fan.

4.

To install the fan, perform the steps in reverse order.

Remove and Install Drive Controller 1.

Disconnect the battery from the truck.

2.

Unplug the connector on the controller.

3.

Loosen two screws (Figure 83, item 1) to remove the controller.

Figure 84. Fan

31

Repair

8000 YRM 2405

REMOVE AND INSTALL BATTERIES 1.

Remove the upper cover. See Remove and Install the Upper Cover.

2.

Remove the box cover. See Remove and Install the Box Cover.

3.

Loosen, but do not remove, the screw (Figure 85, item 1) on both left and right side of the bracket in the battery compartment.

Figure 86. Remove Battery Positive and Negative Wire 6.

Remove the batteries from the frame.

Figure 85. Remove Screws

CAUTION To avoid electric shock, always remove battery negative wires before removing battery positive wires.

4.

Use a wrench to remove the battery negative wire from each battery.

5.

Use a wrench to remove the battery positive wire from each battery.

32

Figure 87. Remove Battery Removal 7.

To install the batteries, perform steps in reverse order.

8000 YRM 2405

Troubleshooting

Troubleshooting MECHANICAL BREAKDOWNS AND RESOLUTION The Lift Truck Cannot Lift If the truck has no response when lift function is commanded, follow these steps to resolve the breakdown:

Check Lift Switch 1.

Press the lift button.

2.

Use a digital multimeter to measure voltage between wire 28 and B-. See Electrical Schematic Diagram.

3.

If the voltage does not read 24 V, check the height limit switch and the height limit switch wiring and repair if necessary.

4.

If the voltage read 24 V or no fault is found with the height limit switch or height limit switch wiring, check the lift contactor. See Check the Lift Contactor.

Check the Lift Contactor 1.

Press the lift button.

2.

Use a digital multimeter to measure voltage between the two motor terminals. See Electrical Schematic Diagram.

The voltage should read 24 V. 3.

If the voltage does not read 24 V, check the lift switch and the lift switch wiring and repair if necessary.

4.

If the voltage reads 24 V or no fault is found with the lift switch or the lift switch wiring, check the power meter. See Check Power Meter.

Check Power Meter 1.

Press the lift button.

2.

Use a digital multimeter to measure voltage between wire 28# and B-. See Electrical Schematic Diagram.

The voltage should read 24 V. 3.

If the voltage does not read 24 V, check the lift contactor and repair if necessary.

4.

If the voltage does read 24V or no fault is found with the lift contactor, check the hydraulic oil line for leaks or damage and repair if necessary.

5.

If no fault is found with the hydraulic oil line, the motor may be damaged.

The Lift Truck Cannot Lower If the lift truck has no respond when lower function is commanded, follow these steps to resolve the breakdown:

The voltage should read 24 V. 3.

4.

If the voltage does not read 24 V, check the power meter and the power meter wiring and repair if necessary.

Check the Lower Switch 1.

Press the lower button.

2.

Use a digital multimeter to measure voltage between wire 29# and B-. See Electrical Schematic Diagram.

If the voltage read 24 V or no fault is found with the power meter or power meter wiring, check the height limit switch. See Check Height Limit Switch.

Check Height Limit Switch 1.

Press the lift button.

2.

Use a digital multimeter to measure voltage between wire 28#A and B-. See Electrical Schematic Diagram.

The voltage should read 24 V. 3.

If the voltage does not read 24 V, check the lower switch and the lower switch wiring and repair if necessary.

4.

If the voltage read 24 V or no fault is found with the lower switch or the lower switch wiring, press the lower switch, and watch and listen for the electromagnet to actuate.

The voltage should read 24 V.

33

Troubleshooting 5.

If the electromagnet does not actuate, replace the electromagnet.

6.

If the electromagnet actuates or no fault is found with the electromagnet, check the hydraulic oil line for leaks or damage and repair if necessary.

The Lift Truck Cannot Travel Check the Status LED 1.

Check if the status LED is flashing.

2.

If the status LED is not flashing, connect the model 1313 handheld programmer and follow the instructions in Check Travel with the Handheld Programmer.

3.

If the status LED is flashing, check to see if the status LED is flashing with a fault code. If there is a fault code, troubleshoot the fault code as described in Fault Codes and Troubleshooting Procedure for the Controller. If there is no fault code, go to step 4 of this procedure.

4.

Check to see if the battery is fully charged. If it needs charging, charge the battery. If it does not need charging, go to step 5 of this procedure.

5.

Check all motor wiring and for short circuits, corrosion, broken wires, or other damage. See Electrical Schematic Diagram. Repair any damaged wiring then retest. If there is no damaged motor wiring, go to step 6 of this procedure.

6.

If the motor wiring needs repair, use a digital multimeter or handheld programmer to check TILLER SW input, accelerator signal input, and BACKWARD input. See Electrical Schematic Diagram and If any values are out of range, repair the wiring or component for that input.

34

8000 YRM 2405 7.

Jack up the vehicle and retest to confirm diagnosis. Clean connections, inspect system wiring, and retest. If the truck still cannot travel, replace the controller.

Check Travel with the Handheld Programmer 1.

Connect the handheld programmer to the lift truck. See Power up the Programmer.

2.

If the handheld programmer connects and the Main Menu opens, go to step 3 of this procedure.

If the Main Menu does not open and the handheld programmer will not connect to the controller, check controller wiring for faults, then repair and retest.

3.

Navigate to the Monitor menu.

4.

Check the input signal for the key switch. If the value is within acceptable range, there is a controller fault. See Check Controller . If the value is outside of acceptable range, go to step 5 of this procedure.

5.

There is a fault in the key switch or the fuses.

Inspect the fuses and the key switch and repair as necessary, then retest. See Electrical Schematic Diagram.

8000 YRM 2405

Troubleshooting

Other Mechanical Faults and Resolution Faults Abnormal Noise during Lift Operation

Possible Causes Suction filter is clogged

Resolution Clean or replace the suction filter

Oil and foam is leaking from suction Tighten the connector, and check hose the oil level or add oil Hydraulic pump or motor is damaged

Contact maintenance staff

Failed seal with air entering oil pump Contact the factory Incorrect oil viscosity and low oil level

Change or add oil

Hydraulic System Does Not Operate Pump unable to suck oil and it is or the Pressure is Too Low noisy

Change or add oil

Oil pump is damaged

Contact the factory

Valve block is faulty

Contact the factory

Tube is ruptured or leaked

Replace the oil tube or tighten the connector

Oil viscosity is too low to cause leakage

Replace oil

The causes are the same as that of abnormal noises

See resolution of abnormal noises

Lift cylinder or sealing ring is worn

Replace the liner or sealing ring

Insufficient oil

Add oil

Battery depleted

Check, charge or replace the battery

Loose wire connectors

Tighten the connector screws

Burned fuse

Replace fuse

Accelerator malfunction

Replace accelerator

Foreign object stuck in the steering gear

Clean up the foreign matter

Worn steering bearing

Replace bearings

No Brake

Damaged electromagnetic brake shoe

Replace electromagnetic brake

Unreleased Brake

No power supply to the electromagnetic brake

Check the circuit

The clearance of the electromagnetic brake is too large

Replace electromagnetic brake

Unstable Oil Pressure

Lift Truck Start Failure

Poor Steering Heavy Steering

35

Troubleshooting

8000 YRM 2405

FAULTS CODES

5.

Check Controller If the controller has an internal fault, it is necessary to check controller outputs to detect the fault.

1.

Disconnect the controller from the truck.

2.

Discharge the capacitor. See Discharge the Capacitor.

3.

Set the digital multimeter to Ω (resistance value detection).

4.

Connect the black probe and red probe on the multimeter to the controller terminals and measure each value for tests 1-4 as indicated in Table 1. Record the measured values.

6.

Set the digital multimeter to detection).

(polarity value

Touch the black probe and red probe on the multimeter to the controller terminals and measure each value for tests 5-6 as indicated in Table 1. Record the measured values.

Figure 93. Multimeter Connection 7.

If any values are out of range, there is an internal controller fault and the controller must be replaced.

Figure 92. Multimeter Connection Table 1. Controller Outputs Test

Red Probe

Black Probe

Acceptable Range

1

B+

B-

Above 40 KΩ

2

B+

M

Above 80 KΩ

3

B+

M1

Above 80 KΩ

4

M1

M2

Above 60 KΩ

5

B-

M2

0.3 V-0.6 V

6

B-

M1

0.3 V-0.6 V

Fault Codes and Troubleshooting Procedure for the Controller

cleared. Faults are displayed by name in these devices.

Diagnostics

Without a handheld device, the fault codes are communicated by the status LED on the truck itself.

The patterns of this LED communicates the status of the controller (including a fault code number if there are faults present).

If a 1313 handheld programmer is available, the fault log in this device shows the current faults and the faults that have been active since the fault log was last

36

8000 YRM 2405

Troubleshooting

Fault Code Identification with LED During normal operation, the status LED is steadily on and does not flash. If there is an active fault code, the status LED will flash to indicate the two-digit number of the fault code. The status LED will flash one or more times to indicate the first digit of the fault code, then

pause. After the pause, the status LED will flash one or more times to indicate the second digit of the fault code.

For example, if fault code 4,4 MOTOR OPEN is active on the truck, the status LED will flash four times, then pause, and then flash four more times.

Fault Codes Code 1,1

Name

Description

THERMAL FAULT High/low temperature cut off

Possible Causes • • • •

1,2

1,3

THROTTLE FAULT

SPEED POT FAULT

The voltage at the sliding or low end of the potentiometer is out of range.

Speed limit potentiometer fault

1,5

Operation in an extremely harsh environment The electromagnetic brake does not release normally

•

The input end of accelerator is open or short-circuit Faulty accelerator potentiometer

•

Accelerator type selection error

•

Speed limit potentiometer wire is open or short-circuit Speed limit potentiometer is opencircuit

•

• 1,4

Temperature > 80℃ (176℉) or < -10℃ (14℉) Excessive load on vehicle

UNDERVOLTAGE Low battery voltage FAULT

•

Battery voltage < 17 V

•

Battery or malfunction

OVERVOLTAGE FAULT

•

Battery voltage > 31 V

•

Charger is still connected when the vehicle is operating Poor battery contact

Battery voltage is too high

•

main

controller

wire

2,1

MAIN OFF FAULT Main contacts coil drive "off" Incorrect start of main contacts coil fault

2,2

EMR SEQUENCING FAULT[1212P]

Incorrect operation sequence

The Emergency reverse switch is activated without turning on the key switch

MOTOR STALLED[1212]

Stalled Motor

Motor is stalled

MAIN FAULT

Main contactor fault

2,3

• •

Main contacts are sticking together or open-circuit main contacts coil drive error

2,4

MAIN ON FAULT

Main contacts coil drive "on" Wrong shutdown of main contacts coil fault

2,5

PUMP SRO FAULT[1212P]

Wrong pump operation sequence

Pump switch acts before the key switch

37

Troubleshooting

Code 3,1

3,2

8000 YRM 2405

Name WIRING FAULT

Description HPD fault is over 10 seconds

BRAKE ON FAULT Brake on fault

Possible Causes •

Incorrect operation of accelerator

•

Failure at the port or mechanical part of accelerator

•

Electromagnetic brake coil is opencircuit Electromagnetic brake drive is shortcircuit

• 3,3 3,4

PRECHARGE FAULT

Precharge fault

BRAKE OFF FAULT

Brake off fault

•

Controller fault

•

Low battery voltage

•

Electromagnetic brake coil is shortcircuit Electromagnetic brake drive open circuit

• 3,5

4,1 4,2

•

Incorrect operation sequence of accelerator, key switch, push or there is no input Incorrect adjustment of accelerator

CURRENT SENSE Current detection error FAULT

•

Motor or motor wiring is short-circuit

•

Controller failure. See NOTE

HARDWARE FAILSAFE

•

Motor voltage does not match the input from accelerator Motor or motor coil is short-circuit

HPD FAULT

HPD fault

Overvoltage of motor

•

• 4,3

EEPROM CHECKSUM FAULT

EEPROM fault

EEPROM failures or malfunctions

4,4

MOTOR OPEN[1212]

Motor open fault

Motor wiring is open

4,5

BATTERY DISCONNECT FAULT

Battery is not connected

•

Battery is not connected

•

Poor connection to battery terminals

NOTE: Jack up the truck and retest to confirm diagnosis. Clean connections, inspect system wiring, and retest.

38

8000 YRM 2405

Troubleshooting

Troubleshooting Procedure 1.1 THERMAL FAULT 1.

Check the controller temperature.

2.

If the controller temperature is out of range, leave it cool or heat until it is within range.

3.

After the temperature is in range, check if the fault is still active.

4.

If the fault is still active after the controller temperature is within range, the controller temperature sensor may be damaged. Replace the controller.

1,4 UNDERVOLTAGE FAULT, 1,5 OVERVOLTAGE FAULT, and 4,5 BATTERY DISCONNECT FAULT 1.

Figure 95. Measure Voltage 5.

Record the value.

6.

If the voltage is out of range, check the 50 A fuse, emergency power disconnect switch, and emergency power disconnect wiring, and repair if necessary.

7.

Use a digital multimeter to measure voltage between wire 10# and B-.

Use a digital multimeter to measure voltage between B+ and B- on the batteries.

Figure 94. Measure Voltage 2.

Record the value.

3.

If the voltage is out of range, charge or replace the battery.

4.

Use a digital multimeter to measure voltage between B+ and B- connectors on the controller.

Figure 96. Measure Voltage 8.

Record the value.

9.

If the voltage is out of range, check the 10 A fuse, key switch, charger interlock switch, and associated wiring and repair if necessary.

39

Troubleshooting

8000 YRM 2405

1,2 THROTTLE FAULT, 3,1 WIRING FAULT, and 3,5 HPD FAULT 1.

Make sure the tiller handle is upright.

Figure 99. Lower Tiller Handle 5.

Figure 97. Check Tiller Handle Position 2.

Use a digital multimeter to measure voltage between pin A6 and B-.

The voltage should measure 24+/-3 V.

Use a digital multimeter to measure voltage between pin A6 and B-.

The voltage should measure 0+/-5 V.

Figure 100. Measure Voltage 6.

If the voltage is out of range, check the tiller switch and associated wiring and repair if necessary.

If the voltage is out of range, check the tiller switch and associated wiring and repair if necessary.

7.

Use a digital multimeter to measure voltage between pin A1 and B-.

Lower the tiller handle to the operating position.

8.

Figure 98. Voltage Measurement 3.

4.

The voltage should measure 0 V. Use a digital multimeter to measure voltage between pin A12 and B-.

The voltage should measure 0 V.

40

8000 YRM 2405

Troubleshooting

Figure 103. Voltage

Figure 101. Measure Voltage 9.

If either value is out of range, check the accelerator knob and associated wiring and repair if necessary.

10. Rotate the accelerator and hold it in position.

11. Use a digital multimeter to measure voltage between pin A1 and B-.

13. If either value is out of range, check the accelerator knob and associated wiring and repair if necessary.

3,2 BRAKE ON FAULT and 3,4 BRAKE OFF FAULT 1.

The resistance should measure 31+/-5 Ω.

The voltage should measure 5+/-0.5 V.

Figure 104. Resistance

Figure 102. Voltage 12. Use a digital multimeter to measure voltage between pin A12 and B-.

Use a digital multimeter to measure resistance between C1 and C2 on the controller.

2.

If the resistance is higher than the acceptable range, the electromagnetic brake or the associated wiring has an open circuit.

3.

If the resistance is lower than the acceptable range, the electromagnetic brake or associated wiring has a short circuit.

The voltage should measure 24+/-3 V.

41

Troubleshooting

8000 YRM 2405

3,3 PRECHARGE FAULT 1.

The resistance should measure 0+/-0.5 Ω.

Check the controller outputs as described in Check Controller .

4,2 HARDWARE FAIL SAFE 1.

Check all motor wiring and for short circuits, corrosion, broken wires, or other damage. See Electrical Schematic Diagram.

2.

Jack up the vehicle and retest to confirm diagnosis. Clean connections, inspect system wiring, and retest.

3.

If the error persists and the motor wiring is not damaged, replace the motor. See Driving System Repair.

4,4 MOTOR OPEN 1.

42

Use a digital multimeter to measure resistance between M1 and M2 on the controller.

Figure 105. Resistance 2.

If the resistance is greater than 0+/-0.5 Ω, the motor has an open circuit, the motor brushes may be damaged, or the motor wiring may be damaged.

8000 YRM 2405

Troubleshooting

HANDHELD PROGRAMMER The model 1313 handheld programmer is the tool used for getting troubleshooting information.

interfacing with a PC. It also has a battery compartment and a memory card slot.

Programmer Connectors The programmer has two connectors, one for communicating with the motor controller and one for

Item No.

Item

Description

1

System Connector

Use this connector with the supplied cable to connect the programmer to the motor controller.

2

USB Connector

Use this connector with a USB cable to connect the programmer to a PC.

3

Batteries

A compartment on the underside of the unit holds two AA batteries. Power is supplied to the programmer by the controller. The batteries in the programmer keep its real-time clock running.

4

SD Card

SD cards provide additional memory, which are a convenient interface between a PC and the programmer.

NOTE: SD CARD MUST BE INSERTED INTO THE PROGRAMMER WITH FACE DOWN.

Figure 106. Programmer Connectors

Pushbuttons Functions Press the pushbutton on the programmer keypad for navigation.

43

Troubleshooting

8000 YRM 2405

Item No.

Item

Description

1

Softkeys

These three keys are blank because their function is contextspecific. At any given time, their function is shown directly above them on the LCD screen. The symbol » indicates more options; pressing the softkey under the "»" to scroll to another set of options.

2

Arrow Keys

You can scroll up and down, and right and left to select the information in the display. In the Main menu, you can press the arrow keys to highlight one of the menus; you then open the highlighted menu using the Select softkey. Within menus (other than the Main menu), the left-arrow key is used to navigate backwards. Within menus (other than the Main menu), the right-arrow key is used to navigate forwards, that is, to open highlighted submenus or items.

3

+/- keys

These two keys allow you to increase or decrease the value of parameter settings. They also are used as + = Yes and - = No buttons. In some cases, they are used to scroll through several options (as in selecting an access level, or selecting a language).

4

Power Key

It is not necessary to use the Power key to turn on the programmer when you plug it into an active control system; it will turn on automatically. To turn off the programmer, press and hold the Power key for a few seconds. You will then be asked whether you want to power off the programmer, and the softkey text will offer you the choices Yes and No. If you have turned off the programmer, or if it has timed out and shut itself off, pressing the Power key will turn it on again.

5

Favourites Key

This key is an alternate way to bring up the Favourites menu.

You can access the Favourites menu by selecting its icon in the Main menu, or by using the Favourites key.

44

8000 YRM 2405

Troubleshooting

Item No.

Item

Description

4; 5

Screenshots

By pressing the Power key and then the Favourites key, you can take a screenshot of the LCD display.

6

Main Menu

This key will return you directly to the Main menu, from wherever you are. When the Main menu is displayed, you can also use this key to cycle through the individual menus. You can use either this key or the arrow keys to navigate within the Main menu, whichever you prefer.

7

Help Key

This key is used to display context-specific Help texts. It is a toggle key; you can press it again to close the Help text window. You can also close Help text windows with the Exit softkey or by pressing the left-arrow key.

Figure 107. Pushbuttons

Power up the Programmer 1.

Remove the box cover. Remove and Install the Box Cover.

2.

Plug the handheld programmer into the controller charger or programmer port to connect it with the control system.

3.

The programmer automatically powers up and displays the loading information.

Figure 109. Main Menu 5.

If the screen displays No System Detected, press the Power key on the handheld programmer to power up.

Display Programmer Information An LCD screen can display the selected programmer information.

NOTE: Figure 108. Loading Screen 4.

1. If the system connection indicator (Figure 110, item 8) is a green circle

Once loading is complete, the Main menu is displayed.

, the system is

connected; if the indicator is a red slash , the system is disconnected.

2. To perform an action suggested in the softkey text, press the blank softkey located below the LCD display.

1.

Press the arrow keys to highlight the icons in content area and press Select softkey to display the system information.

45

Troubleshooting 2.

Press Go Offline softkey to use the programmer when it is not connected to a controller.

8000 YRM 2405 2.

The System Info menu opens with information about the motor controller to which the programmer is connected.

Figure 112. System Info Manu 3.

1.

2.

3.

4.

5.

6.

TIME AND DATE CONTENT AREA ADDITIONAL TEXT LINE GO OFFLINE SOFTKEY TEXT LINE SELECT SOFTKEY TEXT LINE (OPTIONAL) 1313 BATTERY STATE-OFCHARGE 7. ACCESS LEVEL INDICATOR 8. SYSTEM CONNECTION INDICATOR

To return to the Main menu screen, press the Main menu key

.

Parameter Menu 1.

With the Main menu screen displayed, press the arrow keys to highlight the Parameters icon and press the Select softkey.

Figure 110. LCD Screen

System Info Menu 1.

With the Main menu interface displayed, press the arrow keys to highlight the System Info icon and press the Select softkey.

Figure 113. Select Parameters Icon

Figure 111. Select System Info Icon

46

2.

The Parameters menu opens with a list of truck parameters that can be adjusted from the handheld programmer.

3.

Press the arrow keys to select an item to adjust, then press the right-arrow key to open the selected screen.

8000 YRM 2405

Troubleshooting

Monitor Menu 1.

With the Main Menu screen displayed, press the arrow keys to highlight the Monitor icon and press the Select softkey.

Figure 114. Parameters Menu 4.

Use the + and – buttons to adjust the parameter up or down.

Figure 116. Select Monitor Icon 2.

The Monitor menu opens with a screen showing the input and output signals of the controller.

This data is real-time and can be useful for troubleshooting alongside a digital multimeter.

Figure 115. Adjust Parameters 5.

To return to the Main menu screen, press the Main menu key

.

Figure 117. Controller Input and Output Signals

47

Troubleshooting 3.

8000 YRM 2405

To return to the Main menu screen, press the Main menu key

.

Diagnostics Menu 1.

Press the arrow keys to highlight the Diagnostics icon and press the Select softkey to go to the Diagnostics menu.

Figure 120. Present Errors Folder Present Errors Folder lists all active faults in chronological order. The numerals in the upperright corner show the order of the selected fault and the total number of active faults. In this example, MISSING CONTACTOR is the first of three active faults, and so the screen reads 1/3.

Figure 118. Select Diagostics Icon 2.

NOTE: The fault in this folder can only be removed when it is fixed.

Two folders are displayed in Diagnostics menu.

Figure 121. Fault History Folder Figure 119. Folders in Diagnostics Menu

48

8000 YRM 2405

Troubleshooting

Fault History Folder lists all the faults encountered since the Fault History was last cleared. The numerals in the upper-right corner show the order of the selected fault and the total number of logged faults. In this example, MOTOR WARM is the fifth of five logged faults, and so the screen reads 5/5. You can clear the entire contents of this folder to allow Fault History to be started.

3.

To remove all faults from the Fault History, press the Clear All softkey.

4.

To return to the Main menu screen, press the Main menu key

Figure 122. Access Level

.

Programmer Access Level There are four access level in handheld programmer: OEM, Dealer, Service, and User. You can access data at the selected level and the levels below it.

49

Specifications

8000 YRM 2405

Specifications ELECTRICAL COMPONENTS SPECIFICATIONS Name

Specification

Emergency Stop Switch

24 V DC; 125 A

Fuse

180 A/10 A

Built-in Charger Plug

Each plug is a standard plug by region.

Horn

Rated Voltage

24 V

Hydraulic Station

Power

24 V DC; 800 W

Driving Motor

Rated Current

38 A±10%

Power

24 V DC; 650 W

Built-in Charger Input Voltage Lift Contact Brake

110 V/220 V AC; 60/50 HZ

Output Voltage

24 V; 5 A

Rated Voltage

24 V

Rated Current

125 V

Rated Voltage

24 V

Braking Torque

8 N•m (6 lbf ft)

Drive Controller Working Voltage (Permanent Maximum Working Magnet Brush current Controller)

24 V 70 A

CHARGER SPECIFICATIONS Item

Specification

Rated Input Voltage

100-240 V AC +/-10%

AC Frequency

50-60 HZ

CC

5.5 A +/-0.3 A

CV

29.6 V+/-0.2 V (2.46 VPC)

Equalization

30.5-31.5 V

Floating Charge Voltage Cut 27.0-27.8 V Off Totally cut off when the total float charge time reaches 4 hours.

Charging Time

CC+CV<=15 hours

Short Circuit Protection

Short circuit protection should automatically recover after removing the condition .

Reverse Polarity Protection

Reverse polarity protection should automatically recover after removing the condition .

Additional Protection

Sparkless protection; AC surge protection; Over temperature protection .

50

8000 YRM 2405

Specifications

CHARGER LED DISPLAY Condition

Indication

Blue Flash

There is an active charging fault.

Red Flash

No battery is connected to the truck.

Red On

Normal charging in progress.

Green On

Charging is complete, and battery is fully charged.

NOTE: When the lift truck is in charging, key switch is disabled.

MOTOR SPECIFICATIONS

Figure 123. Motor Label

1. ELECTRIC BRUSH 2. COMMUTATOR SEGMENT

3. ARMATURE IRON CORE 4. MAIN POLE Figure 124. Motor Components

51

Specifications

8000 YRM 2405

Figure 125. Motor Wiring Specification Model

Z130D650-24A1-26.5S

Rated Voltage

24 V DC

Rated Power

650 W

Rated Current

38 A

Rated RPM

2650 rpm

Rated Torque

2.34 N•m (1.77 lbf ft)

Current, Unload

<5 A

RPM, Unload

3100 rpm

Work System

S2 (45 min)

Insulation Resistance

>20 M Ω

Carbon Brush

1200 h

Electric Strength

660 V/S

Insulation Grade

F

IP Grade

IP44

Service Environment

-10-+40

Noise

<60 dB (L=100 cm)

52

8000 YRM 2405

Specifications

OIL AND GREASE SPECIFICATIONS WARNING Recycle or dispose of all liquids according to the local laws and regulations.

Name

Specification

Quantity

Hydraulic Oil

L-HV 32, conforms to GB/T11118.1, DIN 51524 N/A (II) standards

Gear Oil

Hypoid gear oil 85 W / 90 (GL-5)

320 ml (0.39 qt)

Grease

No. 3 lithium grease

N/A

PERFORMANCE SPECIFICATIONS Voltage

System Pressure

Current

24 V

No Load Capacity No Load Capacity Maximum Load Load Pressure

Current No Load

Full Load

No Load

Full Load

0.8 MPa 12 MPa (116 psi) (1740 psi)

65 A

4.4 s

4.4 s

3.1 s

9A

Lift Pressure and Current

34 A

16 MPa (2321 psi)

Lift Time

3.7 s

Lower Time

WHEELS SPECIFICATIONS Wheel Drive Wheel

Dimensions Φ 195 mm × 70 mm

Material Polyurethane

Item Hub bolt

Torque 49 N•m (36.1 lbf ft)

Φ 7.7 in. × 2.8 in.

Load Wheel

Φ 80 mm × 93 mm

Polyurethane

Φ 3.1 in. × 3.7 in. Φ 74 mm × 93 mm Φ 2.9 in. × 3.7 in. Φ 80 mm × 70 mm Φ 3.1 in. × 2.8 in. Φ 74 mm ×70 mm Φ 2.9 in. × 2.8 in.

53

Specifications

8000 YRM 2405

TORQUE SPECIFICATION For torque values of fastners that do not have special indication in this manual, refer to standard specification. See Table 2 and Table 3.

Table 2. Pipe Joint Torque Specification Metric Thread

54

American Standard Thread

English Thread

Thread Dimension

Torque (N•m)

Thread Dimension

Torque (N•m)

Thread Dimension

Torque (N•m)

M12 × 1.5

10-20

7/16 × 20

15-16

G1/8 × 28

11-12

M14 × 1.5

20-35

1/2 × 20

19-21

G1/4 × 19

25-28

M16 × 1.5

25-40

9/16 × 18

24-28

G3/8 × 19

41-48

M18 × 1.5

30-45

3/4 × 16

49-53

G1/2 × 14

72-82

M20 × 1.5

35-50

7/8 × 14

77-85

G5/8 × 14

96-110

M22 × 1.5

40-70

1(1/16) × 12

107-119

G3/4 × 14

124-137

M24 × 1.5

40-70

1(3/16) × 12

127-140

G1× 11

151-165

M26 × 1.5

60-100

1(5/16) × 12

147-154

G1(1/4) × 11

192-206

M30 × 2

80-120

1(5/8) × 12

172-181

G1(1/2) × 11

261-275

M36 × 2

100-150

1(7/8) × 12

215-226

G2 × 11

343-357

M42 × 2

150-220

1(1/2) × 12

332-350

M45 × 2

180-250

M52 × 2

200-300

8000 YRM 2405

Specifications

Table 3. Regular Thread Torque Specification Property Classes Thread Dimension

4.8

5.6

M2

0.17

0.21

M2.5

0.34

M3

8.8

10.9

12.9

0.3

0.4

0.45

0.41

0.6

0.8

0.9

0.6

0.8

1.2

1.5

1.8

M4

1.86

2.3

3.0

4.4

5.1

M5

3.7

4.5

5.9

8.7

10

M6

5.5

6

10

16

18

M8

11

14

25

36

43

M10

25

33

49

72

84

M12

43

53

86

126

145

M14

75

95

135

200

236

M16

115

150

210

310

365

M18

178

220

300

430

600

M20

230

272

425

610

710

M22

346

421

580

820

960

M24

433

540

730

1050

1220

M27

654

797

1100

1550

1800

M30

886

1080

1450

2100

2450

Torque (N•m)

NOTE: 1. The table is applicable to the thread fasteners with accuracy between 6 and 7.

2. For the thread fasteners made of nonferrous metal, the torque shall be 80% of the torque values in 4.8 peroperty class.

3. If the dimension of the cross section of conductor is 0.5-2mm², the thread torque of its terminal blocks shall be 0.5-0.7 N•m.

55

Storage and Transportation

8000 YRM 2405

Storage and Transportation LOADING AND UNLOADING Before loading the truck, check the nameplate for the total weight of truck to select appropriate hoisting handling equipment.

When hoisting the truck, connect the lifting gear to the points on the truck indicated as the “hoisting mark” labels on the covers.

When hoisting the truck, keep it level and lower it slowly and carefully. The personnel around shall watch for safety. Assign one person to guide the truck and watch for correct placement. If another lift truck is used for loading and unloading, watch the bottom of the truck. Take care to insert the fork arms to the bottom, to avoid damaging the drive wheel, casters, and load wheels.

TRANSPORTATION During transportation of the truck, please pay attention to the following items: •

Shut off the electric lock and unplug the battery.

•

Block the front and rear wheels.

•

Make sure that the tractor truck is tied down to the transport truck securely.

56

•

•

During hoisting of the tractor, lift the tractor truck only according to the hoisting marks on the covers.

Trucks used to load and transport the tractor should not run too fast and should avoid sharp turning and sudden braking to prevent damaging the tractor truck and avoid accidents.

STORAGE •

Shut off the electric lock and unplug the battery.

•

Block the front and rear wheels.

•

If the truck is not used for a long time, place blocks under the truck so that the wheels are suspended. Conduct complementary charge to the storage battery every month.

8000 YRM 2405

5/21