Download PDF: Yale Z945 Forklift (ESC030-050ZA) Service Manual

Truck 1. Operating Instructions 2. General Truck and Lubrication 3. Electrical System a) General b) Control Handle Assembly c) Acceleration Control d) Electric Motor Maintenance e) Test for a Damaged Field and Armature f) Operational Feedback Devices 4. Drive Unit Assembly 5. Brake System 6. Steering System 7. Hydraulic System a) General b) Steer Pump and Motor Assembly c) Checks and Adjustments d) Proportional Valve Cartridge e) Hydraulic Tank Repairs 8. Mast a) General b) Assembly c) Lift Cylinders d) Checks and Adjustments e) Hydraulic Components 9. Battery and Charging Systems 10. User Support Information

Hi-Vis Masts 1. Mast Assembly 2. Simplex Mast 3. Duplex Mast 4. Triplex Mast 5. Hydraulics 6. Forks 7. Chains 8. Lubrication 9. Identification 10. General

Sheet 1: Operating Instructions

OPERATING INSTRUCTIONS NAMEPLATE Familiarize yourself with the information contained on the nameplate located in the operator's compartment.

Capacities and cautions contained on the nameplate must be strictly followed. Information on this nameplate is as follows: A. Serial Number - This is an identification number assigned to this particular lift truck and should be used when ordering service parts or when requesting any information from your Yale industrial lift truck dealer. The serial number is a six digit number preceded by a letter and is stamped on the nameplate.

B. Model Code - An explanation of the model code is located on Page B of this manual.

C. Truck Weight - This is the approximate weight of the lift 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, elevators, etc.

D. Capacity Rating - This rating shows the max. capacity of the lift truck with relation to load center and fork height (see diagram on nameplate). Personal injury and damage to the lift truck can occur if the capacity rating is exceeded.

This lift truck meets all applicable mandatory requirements of ANSI B56.1 Safety Standard for Powered Industrial Trucks at the time of manufacture. In addition, these lift trucks are classified by Underwriters' Laboratories, Inc. for the type designation shown on the nameplate. Consult UL Index of Classified Products.

SAFETY AND INFORMATION LABELS Safety and information labels are located in conspicuous locations on this lift truck and should be strictly adhered to. These safety and information labels must be replaced immediately if missing or defaced. Labels will vary with type of lift truck and equipment installed. Refer to the Parts Manual for part number of labels. The following Warning to the Operator is a label that must be affixed to the lift truck:

WARNING: FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH! AUTHORIZED, TRAINED OPERATOR ONLY!

Sheet 1: Operating Instructions

Figure 1-1 - Nameplate Information and Label Location

Sheet 1: Operating Instructions

Figure 1-2 - Operator Warning Labels 1. LABEL-OPERATOR WARNING 2. LABEL-CONTROL HANDLE 3. UL PLATE 4. LABEL-DO NOT OVERLOAD 5. LABEL-OVERHEAD GUARD 6. LABEL-MAST WARNING 7. LABEL-BATTERY CONNECTOR 8. LABEL-BATTERY DISCONNECT 9. LABEL-BATTERY SIZE 10. LABEL-FORK WARNING 11. LABEL-PINCH POINT

Sheet 1: Operating Instructions KNOW THE EQUIPMENT: •

Know operating, inspection and maintenance instructions and warnings in Manual.

•

Inspect truck before use. Do not operate if truck needs repair. Tag truck and remove key. Repair truck before use.

•

Use attachments for intended purpose only.

•

Make sure truck is equipped with overhead guard and load backrest adequate for the load.

LOOK WHERE YOU ARE GOING: IF YOU CAN'T SEE, DON'T GO! •

Travel in reverse if load blocks forward vision.

•

Make sure tailswing area is clear before turning.

•

Sound horn at intersections or wherever vision is blocked.

•

Watch clearances, especially overhead.

KNOW YOUR LOADS: •

Handle only stable loads within specified weight and load center. See Nameplate on this truck.

•

Space forks as far apart as load allows and center load between forks.

•

Keep load against load backrest.

•

Do not handle loose loads higher than the load backrest.

KNOW THE AREA: •

Check dockboard width, capacity and security.

•

Never enter a trailer or railroad car unless its wheels are blocked.

•

Watch floor strength.

•

Charge battery only in designated area. Avoid sparks or open flame. Provide ventilation. When charging, keep vent caps clear. Disconnect battery during servicing.

USE COMMON SENSE: •

Never transport people on any part of the truck.

•

Do not use truck to lift people unless there is no other practical option. Then use only a securely attached special work platform. Follow instructions in manual.

•

Allow no one under or near lift mechanism or load.

•

Do not move truck if anyone is between truck and stationary object.

•

Keep arms, legs, and head inside operator's compartment.

•

Operate truck only from the designated operator's position.

•

Observe traffic rules. Yield right-of-way to pedestrians.

•

Be in complete control at all times.

•

Before dismounting, neutralize travel control, lower carriage, set brake.

•

When parking, also shut off power. Block wheels on inclines.

Sheet 1: Operating Instructions PROTECT YOURSELF: •

Avoid bumps, holes, loose materials, and slippery areas.

•

Avoid sudden starts or stops. Operate all controls smoothly.

•

Never turn on or angle across an incline. Travel slowly.

•

Travel on inclines with load uphill or unloaded with mast downhill.

•

Tilt mast slowly and smoothly. Lift and lower with mast or carriage vertical or tilted slightly back. Use minimum tilt when stacking elevated loads.

•

Travel with carriage as low as possible and tilted back.

•

Slow down before turning especially without load.

•

FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE THE LIFT TRUCK TO TIP OVER!

GENERAL

•

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

•

Know your lift truck. Do not operate this lift truck unless you are trained and authorized to operate this lift truck.

•

Do not operate this lift truck with wet or greasy hands.

• • • •

• • •

Do not operate this lift truck if it needs repair, if it is unsafe, or if it might contribute to an unsafe condition.

Remove the key and report the condition to the proper authority.

If the lift truck becomes unsafe in any way while you are operating it, stop operating the lift truck and immediately report the matter to the proper authority.

Only specifically authorized and qualified persons should make repairs and adjustments to the lift truck.

Be certain that your lift truck is the correct fire safety type for the area in which you are working. The proper type designation for this lift truck is shown on the model code, on the nameplate, and the Underwriters Laboratories, Inc. (UL) plate. An area of use label is required on the lift truck if it is used in areas classified as hazardous. Use only lift trucks approved for use in those areas. If you are unsure of the classification of the area you wish to enter, ask your supervisor before entering.

Do not remove overhead guard or load backrest extension unless specifically authorized.

Always set the forks as far apart as the load will permit. Make sure that fork length is at least 2/3 of load length.

Carry the load flush against the lift truck.

Allow no one under or near the load or mast. Do not put any part of your body into the mast area or between the mast and lift truck.

•

Be aware of pinch points on mast and attachments.

•

If a supplementary platform is used, make sure it is securely fastened to the lifting mechanism.

•

When attachments are used, extra care should be taken in securing, positioning and transporting the load.

Operate lift trucks equipped with attachments as partially loaded lift trucks.

Sheet 1: Operating Instructions

• • • •

Watch that your load does not exceed the capacity rating of the lift truck. The lift truck capacity is posted on the nameplate attached to the lift truck at the factory.

Do not handle unstable or loosely stacked loads.

Never allow anyone to ride on your lift truck and never allow anyone other than a qualified professional to operate your lift truck.

Refer to the lubrication section in this manual for the recommended hourly service intervals. Regular attention at the specified time will pay dividends in maximum efficiency and longer life of the lift truck.

OPERATOR PRE-CHECKS AND INSPECTION Before each shift, every 8 hours, it is the operator's responsibility to carry out the following checks and inspections.

Basic maintenance information and the Recommended Schedules of Maintenance are included in this manual, which is shipped with this lift truck.

For more detailed maintenance information see the Maintenance Manual for this model.

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

2. Make sure all capacity, safety and informational plates or labels are attached. This lift truck is not considered safe to use without a legible, properly filled out nameplate. Contact Yale Materials Handling Corporation or your local dealer for Yale industrial lift trucks if the nameplate is not present and legible. See label page for label and plate locations.

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

4. Inspect lift 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 unusual noises are investigated immediately.

OPERATING PRECAUTIONS

• • • •

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

Do not permit passengers to ride on the lift truck.

Observe and comply with instructions concerning floor loadings. Know the weight of your lift truck and load combined. Lift 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.

Sheet 1: Operating Instructions

• • • • •

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

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

If visibility is impaired by the load, operate the lift 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 lift 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 lift truck stability and steering may be adversely affected.

•

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

•

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

•

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

• • •

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

Do not push loads with the lift truck or reach mechanism.

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

•

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

•

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

• • • •

When leaving the lift truck unattended, lower the lifting mechanism, shut off power and remove key. Chock wheels if the lift 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."

Sheet 1: Operating Instructions

•

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

NOTE: This Daily Check List is available for the Operator. Some items on this list may not be applicable to your truck. This check list is in tablet form and can be ordered through your Yale industrial truck dealer. Order form number 944-6418-A.

Sheet 1: Operating Instructions DESCRIPTION The ESC 030-050 ZA three wheel electric rider lift trucks have lifting capacities of 3,000 lbs. to 5,000 lbs.

The trucks feature clean functional styling, low noise levels and an operator compartment designed for comfort and efficiency. Simplex, duplex, triplex and quadplex masts are available for this truck. Cushion tires are standard on this truck.

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.

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 and the load backrest extension are in place and properly secured.

Figure 1-3 - Electric Three Wheel Rider Truck Brake Pedal-The brake pedal is located on the floor, on the left side of the operator's compartment.

WARNING: Never use two feet on the brake pedal. Do not use the brake pedal to stop the lift truck except in an emergency.

When the operator steps on the brake pedal, the brake is released and the travel functions of the lift truck are enabled. To apply the brake and disable travel functions, the operator releases the pedal. If the multi-function handle is tilted forward or back before the operator has stepped on the pedal, travel functions will not enable. The multi-function handle must be released to the neutral position for travel functions to be enabled.

Sheet 1: Operating Instructions

Figure 1-4 - Operating Controls Steering-The Steering Tiller is used to maneuver the lift truck. With standard steering, traveling forward (forks first), turn the steering tiller clockwise to make the lift truck turn right; turn the steering tiller counterclockwise to make the lift truck turn left. Reverse steering is an option. If installed, when traveling forward (forks first), turn the steering tiller counterclockwise to make the lift truck turn right; turn the steering tiller clockwise to make the lift truck turn left.

This truck is equipped with on-demand steering. The steer pump will turn on when the steering tiller is moved forward or backward, and will remain on for 5 seconds after no movement of the steering tiller is detected. If on-demand steering is turned off, the steer pump will shut off after the brake pedal is released. The time increment can be adjusted between 5 to 20 seconds.

Multi-Function Handle-The multi-function handle allows the operator to control travel, lift, tilt, sideshift, horn, and auxiliary functions. Each function has an independent control device so that functions can be activated simultaneously.

The multi-function handle controls the direction and speed of the lift truck. Travel is activated by tilting the entire control handle in the direction of travel. Pushing the control handle toward the forks makes the lift truck travel toward the forks. To change direction, move the multi-function handle in the opposite direction the lift truck is traveling, regardless of travel speed. The lift truck will come to a stop, then accelerate in the opposite direction. This control is proportional; therefore, the farther the control handle is pushed, the faster the lift truck will accelerate or decelerate.

If the multi-function handle is released, it will return to neutral, and the truck will decelerate at a programmed rate to a stop.

Figure 1-5 - Multi-Function Handle The multi-function handle also controls the direction and speed at which the carriage moves vertically on the mast.

Sheet 1: Operating Instructions Lifting and lowering is activated by tilting the entire control handle toward the left or right side of the lift truck. If the control handle is tilted toward the right, the carriage lifts; if the control handle is tilted toward the left, the carriage lowers. This control is also proportional; the farther the lever is tilted, the faster the carriage lifts or lowers. The horn button is located on the side of the multi-function handle facing the operator, below the tilt/sideshift disk. The horn is activated by pressing the button.

The (optional) auxiliary buttons are located on the shaft of the multi-function handle. The auxiliary selector switch on the operator display panel is used to select the auxiliary hydraulic function to be activated and controlled by the auxiliary buttons, if more than one auxiliary hydraulic function is installed. When the upper button is pressed, the selected auxiliary hydraulic function (e.g., push) is activated at low speed. To continue the function at high speed, the operator simultaneously presses the upper and lower auxiliary buttons. To switch the direction of the auxiliary function (e.g., pull), the operator presses only the bottom auxiliary button. To continue the function at high speed, the operator simultaneously presses the lower and upper auxiliary buttons.

Tilt/Sideshift Disk - The Tilt/Sideshift disk, located at the top of the multi-function handle lever, controls the tilting of the mast and sideshifting of the carriage. The disk is operated with the thumb of the right hand. To tilt the mast forward, press the top of the disk. To tilt the mast back, press the bottom of the disk. On lift trucks equipped with a side-shifting carriage, press the left side of the disk to move the carriage to the left, and press the right side of the disk to move the carriage to the right. Unlike the variable speed travel and lift/lower functions, tilt and sideshift are single speed functions.

Figure 1-6 - Tilt/Sideshift Disk Operator's Display- The Operator's Display provides information about all lift truck functions. It consists of the key switch, the optional light and auxiliary function selector switches, an eight digit LED display and several LED indicator symbols. The LED indicator symbols are as follows: the Battery State of Charge, Speed, Wheel Position, Over-Weight Alert, Lift-Limit Alert, Over-Temperature Alert, and Service Alert.

Key Switch-The Key Switch is located on the left side of the operator's display panel. The key switch has three positions, "O", "I", and "II". No truck functions are enabled when the key switch is in the "O" (OFF) position. When the key is rotated clockwise to the "I" (ON) position, power is applied to the system controller but not to the traction system or hydraulic system. The operator can scroll through battery state-of-charge or hours on warranty, drive, lift, and steer systems, or enter the Performance and Diagnostics Menu (PERFDIAG). When the key is rotated further to the "II" (RUN) position, the system controller performs the electronic key function (if installed and enabled), then runs the Power-On Self-Test (POST). After all functions have been validated, the hydraulic system is enabled and, if the brake pedal is engaged, the traction system is enabled.

Figure 1-7 - Operator's Display and Key Switch

Sheet 1: Operating Instructions Light Switch (Optional)-The Light Switch is located on the operator's display panel adjacent to the key switch. The light switch operates the optional work lights when the top of the switch is pressed. The work lights are switched off when the bottom of the switch is pressed.

Auxiliary Function Selector Switch (Optional)-The Auxiliary Function Selector Switch is located on the operator's display panel adjacent to the light switch. The auxiliary switch selects the optional auxiliary function to be controlled by the auxiliary buttons on the multi-function handle.

Figure 1-8 - Battery State-of-Charge Battery State of Charge Indicator-The Battery State of Charge Indicator shows the percentage of usable charge remaining in the battery before lift-lockout occurs. The indicator contains ten LEDs that separate the charge into 10% increments. The first five LEDs are green, the next three down are yellow, and the bottom two are red. If the battery has 70% charge, seven LEDs are lit; two green, three yellow, and two red. When the state of charge is less than 5%, the last (red) LED will begin to slowly flash, and then flash more rapidly when the state of charge falls below 2%. When the battery is discharged to lift lockout level, all LEDs are off.

Wheel Position Indicator - The Wheel Position Indicator contains seven LEDs which light, one or two at a time, to indicate the position of the steer wheel. If the steer wheel is rotated 30* to the right, the LED at the one o'clock position will be illuminated. If the wheel position is between two LEDs, both will be lit.

Figure 1-9 - Wheel Position Indicator LED Display-The LED display is a bank of eight 5*7 dot matrix LED's. The display can show the battery state of charge, the hours on the brake, drive, lift, and steer systems, the load weight, travel speed, and fault messages.

Messages longer than eight characters scroll from right to left across the display.

Figure 1-10 - LED Display Service Alert Indicator-The Service Alert Indicator illuminates when a fault is detected or periodic maintenance is due. When the service alert illuminates, the LED display will scroll a message identifying the type of fault detected or the type of periodic maintenance required, as determined by the hours of use. Some fault conditions cause the affected system to be limited or disabled until the problem is corrected.

Sheet 1: Operating Instructions Figure 1-11 - Service Alert Indicator

CAUTION: Contact authorized service personnel immediately when overheating occurs.

Over-Temperature Alert Indicator-The Over-Temperature Alert Indicator warns the operator of a high-temperature condition on the motors or the controllers driving the motors. When a component becomes hot, the over-temperature alert indicator flashes and operation of the affected system is limited until the component temperature is lowered. The over-temperature condition is scrolled on the LED display identifying the affected component. If the temperature of the component continues to rise, the affected system is disabled and the over-temperature alert indicator remains lit.

CAUTION: Contact authorized service personnel immediately when overheating occurs.

Figure 1-12 - Over-Temperature Alert Indicator Lift-Limit Alert Indicator-The Lift-Limit Alert Indicator (when equipped) illuminates when the load is lifted beyond the load height restriction for the lift truck. The Lift-Limit Alert Indicator flashes and the lift function is disabled until the load is lowered below the height restriction or the lift-limit override is activated. On trucks equipped with the lift-limit alert, the horn switch acts as the lift-limit override. To lift beyond the height restriction, the operator must press the horn button while lifting.

Figure 1-13 - Lift Limit Alert Indicator Over-Weight Alert Indicator-The Over-Weight Alert Indicator illuminates when the load weight exceeds the specific load limit of the truck. In an over-weight condition, the lift and traction functions of the truck are disabled. Lift and traction functions are disabled until the over-weight condition is corrected. The over-weight condition message is scrolled on the LED display.

Figure 1-14 - Over-weight Alert Indicator Speed Indicator-The Speed Indicator consists of ten LEDs arranged to give a ramping effect. Each LED represents a 10% increment in speed, from zero to the programmed maximum speed. If the programmed maximum speed is 7.0 mph and the lift truck is traveling at 2.8 mph, the first four LEDs are illuminated. No LEDs are lit when the truck is stationary.

Sheet 1: Operating Instructions

Figure 1-15 - Speed Indicator Emergency Disconnect Lever-The Emergency Disconnect Lever is located on the top right side of the operator's compartment. Push the emergency disconnect lever forward to mechanically separate the battery connectors and disconnect power from the truck. To reconnect the battery, align the mating halves of the connector and push them together.

WARNING: A capscrew and locknut must be correctly fastened to the battery connector for the emergency disconnect lever to properly operate.

Figure 1-16 - Emergency Disconnect Lever Operating Manual - The Operating Manual is sent with the lift truck and is stored in the container located in the operator's compartment. The Operating Manual is a permanent reference and must be available for the operator's use at all times. Read and understand this manual before operating the lift truck.

STARTING SEQUENCE 1. Make sure a charged battery of the correct voltage is installed and connected.

2. Step into the operator's compartment.

Figure 1-17 - Starting Sequence 3. Turn the key switch to the "I" (ON) position. After the system controller performs internal checks, the following menu is available to the operator: Move through the menu by pressing tilt forward and tilt back on the tilt/sideshift disk.

The BSOC XX% (battery state-of-charge), when selected, will remain in the display until the operator switches to the next selection or turns the key to the "II" position. The WARRANTY, DRIVE, LIFT, and STEER hourmeter selections will scroll into the LED display from bottom to top (or top to bottom) and remain there for one second. The display will then flash between the message and 1234 HRS. The hours will remain in the screen for two seconds, then cycle back to the hourmeter (brake, drive, lift or steer) and the accumulated hourmeter hours. This cycle will continue until the operator switches to the next selection, turns the key to the "II" position, or after 10 seconds, will return to BSOC XX%.

Sheet 1: Operating Instructions The PERFDIAG selection is entered with either a low level or a high level password. If the operator is authorized with a low level password, he will have access to configure certain performance settings of the lift truck to suit the application requirements. If the user has a high level password, the entire performance and diagnostics menu is available. For more information on the high level password performance and diagnostics menu, refer to Section 3.

To change the performance settings in the Program menu with a load lever password, see PERFORMANCE PROGRAMMING. 4. Turn the key switch to the "II" (RUN) position and release it. The keyswitch contains a spring which returns it to the "I" (ON) position. If the electronic key function is installed and enabled, the LED display goes into the password entry mode. When "enabled", electronic key entry should prevent unauthorized or untrained individuals from operating the truck. To enable the electronic key entry, a high level password is required to enter the electronic key menu.

When the correct password is entered (or if no electronic key is required), the Power-On Self-Test (POST) begins. If a fault is detected during this testing, the fault code and warning message will appear on the LED display. See Section 3 for a listing of the WARNING MESSAGES/TROUBLESHOOTING that may appear on the LED display.

WARNING: If a fault code and warning message are displayed, contact authorized service personnel immediately. Do not operate a damaged or defective lift truck. If repairs are required, install a "DO NOT OPERATE" tag in the operator's compartment.

Figure 1-18 - Run Position 5. After all functions have been validated, the message "PASSED" appears on the display. The hydraulic functions are now enabled.

6. Use only one foot to depress and hold the brake pedal down.

7. Use left hand to steer truck and right hand to control travel, lift, tilt, and auxiliary functions.

PERFORMANCE PROGRAMMING Low Level Password To change the performance settings in the Program menu, press sideshift right when PERFDIAG appears in the display. Once you are in the password entry mode, pressing tilt forward and tilt back on the Tilt/Sideshift disk will scroll through the alphanumeric character available. Pressing sideshift right and sideshift left on the Tilt/Sideshift disk will move the cursor position right or left. When the entire password is displayed, pressing the horn button will accept it.

When a low level password is entered, the menu items listed below can be programmed. Move up or down the menu by pressing tilt forward and tilt back on the Tilt/Sideshift disk.

When sideshift right is pressed, the current setting for the selection will be displayed. To change the setting, press tilt forward or tilt back. To save the new setting and return to the Program menu, press the horn button. To return to the Program menu without changing the setting, press sideshift left.

PROGRAM MENU ITEMS FWDSPEED & REVSPEED

Sheet 1: Operating Instructions (3.0-7.0 MPH, DEFAULT*7) These selections allow the user to independently set the maximum forward and reverse speeds of the truck in increments of one-tenth MPH. DRIVEA/D (HARD, MEDIUM*, SOFT) The DRIVEA/D selection allows the user to set the acceleration and deceleration (plugging) characteristics of the truck.

LIFTA/D (HARD, MEDIUM*, SOFT) The LIFTA/D selection allows the user to set the acceleration characteristic of the lift system.

COASTDEC (SHORT, MEDIUM*, LONG) The COASTDEC selection allows the user to set the distance that the truck will coast when the control handle is released to the neutral position.

TILT SPD (FAST, MEDIUM*, SLOW) The TILT SPD selection allows the user to set the speed of the tilt function.

SIDESHFT (FAST, MEDIUM*, SLOW) The SIDESHFT selection will only appear in the PROGRAM menu if the truck is equipped with a first auxiliary (normally sideshift) option. The SIDESHFT selection allows the user to set the speed of the first auxiliary function.

AUX SPD (FAST, MEDIUM*, SLOW) POS HOLD (DISABLE, ENABLE*) The AUX selection will only appear in the PROGRAM menu if the truck is equipped with a second or second and third auxiliary function. The SPEED selection allows the user to set the speed of the second (and third) auxiliary function(s). The POS HOLD selection is effective only when the upper auxiliary button on the control handle is pushed. When POS HOLD is set to DISABLE, and the upper auxiliary button is pushed (AUX direction A), the ramp hold is disabled and the truck can roll. The POS HOLD selection should only be set to DISABLE when operating a push-pull attachment.

DEFAULT (RESET Y) The DEFAULT selection allows the user to return all selections to the default settings.

Default settings are listed or indicated by an asterisk (*).

STOPPING Stop the lift truck as gradually as possible. Hard braking and wheel sliding can cause the load to fall off of the forks and damage the load or hurt someone. Gradually stop the lift truck using plugging or the brake. Slowly releasing the brake pedal will stop the lift truck gradually. Releasing the brake pedal completely and quickly can make the lift truck stop abruptly.

PARKING 1. Before you leave the operator's position, be sure that the lifting mechanism is fully lowered, controls are placed in neutral and the brake is applied. Keep the lift truck clear of exits and access to stairways and fire equipment.

Sheet 1: Operating Instructions 2. If you move more than 25 ft. away from the lift truck or if you cannot see the lift truck shut the power off. When you leave your lift truck unattended the lift truck should be secured against operation by unauthorized personnel.

Remove the key.

3. If the lift truck must be parked on an incline, put chocks on the down hill side of the wheels so that the lift truck cannot move.

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. Powered industrial trucks may become hazardous if maintenance is neglected. Therefore, adequate maintenance facilities, personnel and procedures should be provided.

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 the lift mechanism 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 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.

Sheet 1: Operating Instructions 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: 1.

ANSI B56.1 - Safety Standard for Powered Industrial Trucks

This booklet can be obtained from: Society of Mechanical Engineers 345 E. 47th Street New York, NY 10017 2. ANSI/NFPA 505 - Type Designations, Area of Use, Maintenance and Operation of Powered Industrial Trucks This booklet can be obtained from: National Fire Protection Assoc.

Batterymarch Park Quincy, MA 02269 3. Code of Federal Regulations Title 29, Chapter XVII, Section 1910.178 (OSHA) Powered Industrial Trucks This booklet can be obtained from: Superintendent of Documents U.S. Government Printing Office Washington, DC

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.

HOW TO RAISE THE DRIVE TIRES 1. Put a block on each side (front and back) of the steer tire to prevent movement of the lift truck. Refer to Figure 1-19.

2. Put the mast in a vertical position. Put a block under each outer mast channel.

3. Tilt the mast fully forward until the drive tires are raised from the surface.

4. Put additional blocks under the frame behind the drive tires. Refer to Figure 1-19.

Sheet 1: Operating Instructions 5. If the hydraulic system will not operate, use a hydraulic jack under the side of the frame near to the front. Ensure that the jack has a capacity greater than half the weight of the lift truck. Refer to the capacity plate.

HOW TO RAISE THE STEER TIRE 1. Release the brake pedal to apply the brake. Put blocks on both sides (front and back) of the drive tires to prevent movement of the lift truck. Refer to Figure 1-19.

2. Put a hydraulic jack under the truck frame to raise the steer tire. Make sure that the jack has a capacity of at least 2/3 the total weight of the lift truck as shown on the capacity plate.

3. Put blocks under the truck frame to support the lift truck.

Figure 1-19 - Putting the Lift Truck on Blocks

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

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

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

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

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

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

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

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

Sheet 1: Operating Instructions 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 -8°C (+18°F) A fully charged battery with a specific gravity of 1.280 will freeze at -67°(-87°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.

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 3: General Truck and Lubrication

GENERAL TRUCK AND LUBRICATION GENERAL This chapter contains service procedures for parts of the frame of the ESC 030 ZA, ESC 035 ZA, ESC 040 ZA and ESC 050 ZA electric lift trucks. These parts include the overhead guard, access panels, battery compartment tray and label positions.

DESCRIPTION The frame is a single weldment. The frame provides mounting for the overhead guard, mast, steer fork assembly, traction motor drive assembly and the hydraulic tank. The battery compartment is equipped with a sliding roller tray for battery removal. An access door is located on the rear of the lift truck to allow for inspection and maintenance of the hydraulic lift pump and the power steering mechanism. An access panel in front of the operator's compartment allows for maintenance inspection of the motor controller, electrical components and the hydraulic control valve. The hydraulic tank is located on the front of the electric lift truck.

There are three frame sizes used for these lift trucks. Frame size is determined by the size of the battery compartment. The battery compartment on the standard ESC 030 ZA and ESC 035 ZA frames is 409.4 mm (16.12 in). An optional 460.2 mm (18.12 in) battery compartment is available on these models to accommodate a larger battery or offset capacity loss with the optional sideshift. The battery compartment on the standard ESC 040 ZA and ESC 050 ZA is 527 mm (20.75 in), which is slightly wider and higher than the ESC 030 ZA and ESC 035 ZA models.

For extra stability, all lift trucks with a triplex mast capable of lifting a load above 6248 mm (246 in) and all lift trucks with a quadplex mast, have a wide track frame that is 116.8 mm (4.6 in) wider than standard.

All models use solid tires. The ESC 030 ZA and ESC 035 ZA lift trucks come equipped with rubber tires as standard equipment. The ESC 040 ZA and ESC 050 ZA lift trucks come equipped with poly tires as standard equipment.

OVERHEAD GUARD Removal (See Figure 2-2) 1. Lower the forks completely.

2. Move the mast to the full forward position.

3. Turn the key switch to the off "O" position.

Sheet 3: General Truck and Lubrication

Figure 2-1 - Components Mounted on the Frame 1. OVERHEAD GUARD 2. MAST 3. LOAD BACKREST EXTENSION 4. CARRIAGE 5. FORKS 6. DRIVE WHEEL 7. BATTERY 8. STEER WHEEL (NOT SHOWN IN THIS VIEW) 9. OPERATOR'S COMPARTMENT

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component.

4. Disconnect the battery and discharge the capacitors. See Section 3 for CAPACITOR DISCHARGE PROCEDURE. 5. Remove the front cover and the top cover. Refer to FRONT COVER-REMOVAL and TOP COVER-REMOVAL. 6. Attach a lifting device to the top of the overhead guard and take up any slack.

NOTE: If the truck is equipped with a flashing light or work lights attached to the overhead guard, disconnect the two-pin connector (at the rear post for a flashing light; at the front for work lights) and remove any wire ties attaching the wires to the truck.

WARNING: The overhead guard assembly is heavy. Be sure that all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the overhead guard assembly.

7. Remove the two bolts securing the overhead guard to the front of the truck.

8. Remove the four bolts securing the rear post of the overhead guard to the rear frame of the truck.

CAUTION: When removing the overhead guard, do not allow the posts to swing and damage any

Sheet 3: General Truck and Lubrication components on the lift truck.

9. Using the lifting device, carefully lift the overhead guard straight up and away from the truck. It may be necessary to tap the front crossbar of the overhead guard with a rubber mallet to free the overhead guard from the frame.

Installation NOTE: If the truck is equipped with work lights or a flashing light attached to the overhead guard, special care should be used when installing the overhead guard to avoid damaging the wiring.

1. Lower the overhead guard assembly into position on the truck.

NOTE: The front crossbar of the overhead guard rests on supports on the inner surface of the frame, and is clamped between the front of the frame and angles welded within the frame. See Figure 2-2.

Figure 2-2 - Overhead Guard Assembly 1. OVERHEAD GUARD 2. REAR POST 2. Attach the front of the overhead guard to the front frame of the truck. Do not completely tighten the front attachment bolts at this time.

3. Lower the overhead guard until the bolt holes of the rear post align with the holes in the rear frame. Attach the rear post to the truck frame.

4. Tighten the front and rear bolts to 108 N m (80 lbf ft) torque.

5. Connect any light harness disconnected during the removal portion of this procedure.

NOTE: Ensure the top cover front clip is in place on the front crossbar of the overhead guard.

6. Replace the top cover and front cover. Refer to TOP COVER-INSTALLATION and FRONT COVER-INSTALLATION. 7. Connect the battery.

Sheet 3: General Truck and Lubrication OVERHEAD GUARD REAR POST Removal 1. Remove the overhead guard from the truck. Refer to OVERHEAD GUARD -REMOVAL. 2. Remove the capscrew, locknut, flat washer, bushings and grommets retaining each post to the overhead guard.

3. Remove the rear post for the overhead guard.

Installation 1. Align the rear post between the two tabs of the overhead guard. Install the flat washer, bushings, grommets machine screw and locknut for each post. See Figure 2-2.

2. Tighten the locknut to remove any excess movement.

3. Install the overhead guard. Refer to OVERHEAD GUARD-INSTALLATION.

FRONT COVER Removal (See Figure 2-3) 1. Lower the forks completely.

2. Move the mast to the full forward position.

3. Turn the key switch to the off "O" position.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component.

4. Disconnect the battery and discharge the capacitors. See Section 3 for CAPACITOR DISCHARGE PROCEDURE. 5. Locate the two cover latch handles on the front cover. See Figure 2-3.

6. Gently lift up on the latch handles and pull forward, away from the front of the truck.

7. Once the top of the cover is released, lift upward on the cover and remove from the truck.

Installation 1. Place the lower edge of the front cover into the support channels.

2. Gently press the upper portion of the front cover into place until the latches click into position.

3. Connect the battery connector.

TOP COVER Removal NOTE: The top cover is held in place with six frame-mounted spring-type retaining clips and one front clip on the overhead guard crossbar. See Figure 2-3. Normally this cover does not require any tools to remove. Care must be used when removing this cover to avoid possible breakage.

1. Lower the forks completely.

2. Move the mast to the full forward position.

Sheet 3: General Truck and Lubrication 3. Turn the key switch to the off "O" position.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component.

4. Disconnect the battery and discharge the capacitors. See Section 3 for CAPACACITOR DISCHARGE PROCEDURE. 5. Using the finger hole in the tool depression of the top cover, gently pull up until the first spring clips release the top cover.

6. As each spring clip on the left side releases the top cover, move the handhold as close as possible to the next spring clip. Gently pull up until the cover is released from all of the spring clips on the left side.

7. To release the right side of the cover, move the battery disconnect forward, grasp the rear edge of the opening, and gently pull upward.

8. Once the top cover is released from the spring clips, lift the rear edge of the cover up until it is clear of the rear leg of the overhead guard. Move the entire cover toward the rear of the truck until the top cover is free from the front clip and the overhead guard.

9. Remove the cover from the truck.

Installation 1. Tilt the top cover so that the front edge of the cover is lower than the rear edge and slide into place on the truck.

2. Align the cutouts on the front edge of the top cover with the front posts of the overhead guard. Move the front edge of the top cover into place, making sure the front clip is properly in place. Lower the rear of the top cover into place.

3. Align the cutouts in the lip of the cover with the spring clips on the truck frame.

Sheet 3: General Truck and Lubrication

Figure 2-3 - Pads, Covers and Floor Mat 1. TOP COVER 2. RIGHT PAD 3. FRONT PAD 4. CONTROL COVER 5. FLOOR MAT 6. FRONT COVER 7. FRONT COVER LATCH 4. Press downward at each spring clip until the cover is secured.

5. Connect the battery.

Sheet 3: General Truck and Lubrication CONTROL COVER Removal 1. Lower the forks completely.

2. Move the mast to the full forward position.

3. Turn the key switch to the off "O" position.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component.

4. Disconnect the battery and discharge the capacitors. See Section 3 for CAPACITOR DISCHARGE PROCEDURE. 5. Remove the top cover. Refer to TOP COVER-REMOVAL. 6. Remove the steering tiller.

7. Remove the seven screws securing the control cover.

8. Lift the control cover over the control handle and remove it from the truck.

Installation 1. Place the control cover into position over the control handle and secure in place.

2. Install the steering tiller.

3. Replace the top cover. Refer to TOP COVER-INSTALLATION. 4. Connect the battery.

OPERATOR COMPARTMENT PADS Removal NOTE: The pads in the operator compartment are secured in place with Velcro. When removing the pads, use care to avoid detaching the Velcro from either the pad or the frame of the truck. If the Velcro does come loose use a silicone adhesive to secure the Velcro to either the pad or the frame.

1. Grasp the outside edge of the pad and carefully separate the pad from the mating portion of the Velcro attached to the frame of the truck.

2. Rotate the pad outward until the remainder of the Velcro release.

3. Remove the pad.

Installation (See Figure 2-3) 1. Align the pad so the Velcro meet.

2. Firmly press the pad into place.

3. Gently pull on the outside edges of the pad to verify the attachment.

FLOOR MAT NOTE: Normal servicing of the truck does not require the removal of the floor mat.

Sheet 3: General Truck and Lubrication Removal and Installation To remove the floor mat, lift the mat out of the operator's compartment by using your hand through the opening for the brake pedal. To replace the floor mat, align the mat in the operator's compartment and press down on the mat.

BRAKE PEDAL PAD Removal NOTE: The floor mat in the operator compartment and the brake pedal pad are secured in place with a silicone adhesive. The pads will be damaged when removed. It is recommended that replacement pads be available prior to removal of the old pads. use a silicone adhesive to secure the floor mat to the frame or brake pedal pad to the brake pedal.

1. Using an appropriate scraper, pry up the outside edge of the pad.

2. Carefully peel the pad away from the floor or brake pedal.

3. Scrape the floor surface or brake pedal to remove as much of the old pad material as possible.

4. Clean any remaining residue from the floor of the operator compartment.

Installation 1. On a properly prepared surface, apply a thin film of adhesive on either the brake pedal or the floor of the truck. (Follow the manufacturer's instructions on the label of the adhesive.)

2. Align the proper pad with the compartment.

3. Firmly press the pad into position.

4. Allow the adhesive to cure per the manufacturer's recommendations.

TIRES AND WHEELS 1. Check the tires for damage and remove any objects such as nails, glass, and metal that will cause damage.

2. Smooth any cuts or tears to prevent further damage.

3. Check for bent or damaged rims. Check for loose or missing parts. Remove any wire, straps or other material that may have wrapped around the axle.

Figure 2-4 - Check Tires for Damage Removing Drive Tire and Wheel from Truck

Sheet 3: General Truck and Lubrication WARNING: Wheels must be changed and tires repaired by trained personnel only. Always wear safety glasses.

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

2. Disconnect the battery.

3. Remove the six socket head screws retaining the wheel cover. Remove the wheel cover.

4. Straighten the tab of the lock washer out of the slot of the slot in the spindle lock nut. Remove the lock nut from the spindle. Remove the lock nut from the spindle.

WARNING: The lifting and carrying of solid tires is not recommended because their weight could be in excess of 61 kg (134 lbs.). Where applicable use a wheel or tire dolly to assist in the removal and installation of the wheel.

5. Remove the drive wheel and tire assembly from the spindle.

CAUTION: Do not remove the ring gear from the inside of the drive wheel hub. The ring gear is not available as a separate part. Removal of the ring gear will necessitate the replacement of the entire drive wheel assembly.

Removing Tire from Drive Wheel Hub

CAUTION: 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 or wheels unless you have the proper tools, equipment and experience.

1. Use a press to push the wheel hub from the tire. The correct tools, equipment and a press ring must be used for each size of wheel. Standard tire sizes for both drive and steer tires are listed in the tire size chart in this section.

2. The correct tools, equipment and a press ring must be used for each size of wheel. Make sure the wheel hub is at least 150 to 200 mm (6 to 8 inches) from the bed of the press. Use a press to push the tire from the wheel hub.

3. Position the ring in the press. Put the wheel and tire on top of the ring with the wheel flange to the top. The tire can only be pressed of in one direction. Press the tire off of the wheel hub. See Figure 2-5.

Figure 2-5 - Removing Solid Tire 1. PRESS RING 2. TIRE 3. WHEEL HUB Installing the Tire on the Drive Wheel Hub

Sheet 3: General Truck and Lubrication WARNING: The lift truck capacity can change with different types of tires. Make sure the capacity on the Capacity Plate is for the type of tires installed on the truck.

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. Standard tire sizes for both drive and steer tires are listed in the tire size chart in this section.

3. A bottom pressing ring may be used. If a bottom ring is used, make sure that the pressing ring is at least as deep as the new tire's base band and larger than the diameter of the wheel hub. Figure 2-6 illustrates how to install a tire on the wheel hub without using a bottom ring.

Figure 2-6 - Installing Solid Tire 1. WHEEL HUB 2. NEW TIRE 3. WHEEL HUB O.D. 4. Place the new tire into the press and center the tire on top of the ring. Make certain that the base band is evenly aligned with the outside diameter of the ring and that the tire is level.

5. Center the wheel hub on the tire base band.

6. Carefully apply hydraulic pressure until the new tire is properly mounted on the wheel hub. The solid tire when properly installed will be flush to the inside edge of the wheel hub. See Figure 2-7.

Figure 2-7 - Solid Tire Pressed onto Drive Wheel Installing the Drive Tire and Wheel on the Lift Truck 1. Install the tire and wheel assembly on the spindle. Rotate the drive wheel so the ring gear engages the pinion gear located in the gear box.

2. Align and install the inner tab of the lockwasher with the slot in the spindle.

3. Install the locknut on the spindle and using a wrench, tighten the locknut to 81 N m (60lbf ft) to seat the bearings.

4. Loosen the locknut until a tab on the lockwasher can be bent into the locknut.

5. Install the wheel cover onto the drive wheel using the six socket head screws.

Sheet 3: General Truck and Lubrication 6. Raise the lift truck high enough to remove the blocks. Lower the lift truck to the floor.

Removing Steer Tire and Wheel To remove the steer wheel assembly from the lift truck, see Section 6-STEER WHEEL ASSEMBLY-REMOVAL. Removing Tire from Steer Wheel Hub

WARNING: The lift truck capacity can change with different types of tires. Make sure the capacity on the Capacity Plate is for the type of tires installed on the truck.

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. Standard tire sizes for both drive and steer tires are listed in the tire size chart in this section.

3. Position the new tire in the press. 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.

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

Figure 2-8 - Installing Solid Tire 1. PRESS RING 2. OLD TIRE 3. NEW TIRE 4. WHEEL HUB

Figure 2-9 - Solid Tire Pressed onto Wheel Installation Steer Tire and Wheel To install the steer wheel assembly on the lift truck, see Section 6-STEER WHEEL ASSEMBLY-INSTALLATION. MODEL

TIRE SIZE CHART DRIVE TIRE

STEER TIRE

Sheet 3: General Truck and Lubrication ESC ZA 30 ESC ZA 35 ESC ZA 40 ESC ZA 50

16 x 7 x 10.5 Rubber 16 x 7 x 10.5 Polyurethane

10 x 5 x 6.5 Rubber Dual 10 x 5 x 6.5 Polyurethane Dual

Table 2-1 - Tire Sizes

LABEL REPLACEMENT If the labels or information plates are missing or are damaged, they must be replaced.

WARNING: Labels that have WARNING or CAUTIONS must be replaced if they are damaged.

If a mast of a different size or an accessory carriage is installed, the capacity rating can change. Changes in the size or number of drive tires will change the capacity rating. See a Yale lift truck dealer for a replacement nameplate.

The nameplate information must be correct for safety.

NOTE: The nameplate is installed using rivets. The old rivets must be removed before installing the new nameplate.

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

1. Make sure the surface is dry and has no oil or grease. Do not use solvent on new paint. Clean the surface or old paint using a cleaning solvent.

2. Remove the paper from the back of the label. Do not touch the adhesive surface.

3. Carefully hold the label in the correct position above the surface. The label cannot be moved after it touches the surface. Put the label on the surface. Make sure all air is removed from under the label and the corners and edges are tight.

4. Install protective cover with rivets.

PAINTING INSTRUCTIONS

WARNING: Cleaning solvents can be flammable and toxic, and can cause skin irritation. Wear protection for eyes and skin. Always use solvents and paints in an area with ventilation. Do not use solvents or paints near heat, fire or electrical equipment that can make sparks. When using cleaning solvents, always follow the recommendations of the manufacturer.

NOTE: Protect all electronic controls and wiring from heat and moisture produced by steam cleaning or chemical solvents.

1. Remove all dirt from the surface to be painted. Clean the area to be painted. Use a solvent for painted surfaces.

Do not use solvent on new paint. Make sure all oil and grease is removed.

2. Use sandpaper to remove the top surface of the paint and rust from the metal. All metal surfaces where the paint is removed must be painted. Use a primer. Apply the primer before applying the final coat of paint.

CAUTION: Do not paint the pads, plastic covers or knobs, cables, electrical components, safety labels, mast chains and hoses or controls.

NOTE: Protect electrical components, wiring and battery connector contacts from overspray.

3. Protect all surfaces that will not be painted.

Sheet 3: General Truck and Lubrication 4. Paint the surfaces. Use the correct paint for Yale lift trucks. Follow the directions on the container.

5. Install new safety labels.

CHANGING THE BATTERY

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.

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 battery.

Adjust the capscrew legs of the battery stand so that the tops of the rollers are the same height as the bottom of the battery. Adjust all four capscrew legs of the stand so that the rollers are level. Stand on the base of the battery puller and pull the battery onto the battery stand.

Figure 2-10 - Changing the Battery 1. BATTERY 2. BATTERY STAND 3. ROLLERS 4. BATTERY PULLER 5. RATCHET LOCK LEVER

WARNING: Batteries are heavy. Use care to avoid injury. 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 unless equipped with insulated straps.

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

5. Before installing the battery, make sure the battery is cleaned and painted.

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.

CAUTION: The battery must fit the battery compartment correctly. Use spacers to prevent the battery from moving horizontally in the battery compartment. Make sure that the battery voltage and weight are correct as

Sheet 3: General Truck and Lubrication shown on the nameplate.

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

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

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

Figure 2-11 - Battery Connector

WARNING: The capscrew (2, above) and locknuts (3) must be correctly fastened to the battery connector (1) for the emergency disconnect lever to properly operate.

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.

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.

Sheet 3: General Truck and Lubrication

Table 2-2 - Battery Chart

BATTERY RETAINERS Removal NOTE: The battery retainers for the lift truck are not interchangeable from side to side.

1. Lower the forks completely.

2. Move the mast to the full forward position.

3. Turn the key switch to the off "O" position.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component.

4. Disconnect the battery and discharge the capacitors. See Section 3 for CAPACITOR DISCHARGE PROCEDURE. 5. Lift the battery retainer straight up until the tabs on the front of the battery retainer align with the cutouts in the truck frame.

6. Rotate the front edge of the battery retainer out until the tabs of the retainer clear the frame of the truck.

7. Move the battery retainer toward the front of the truck until the rear flange of the battery retainer is free from the frame of the truck.

Installation 1. Insert the rear tabs of the battery retainer into the slot at the rear of the battery compartment opening.

2. Rotate the front of the battery retainer toward the truck until the tabs on the front of the battery retainer enter the slots.

3. Lower the battery retainer to its normal position.

Sheet 3: General Truck and Lubrication NOTE: There should be no more than a 12.5 mm (0.5 inch) gap around the battery in any horizontal direction. If necessary, install shims to meet this specification.

4. Connect the battery.

BATTERY ROLLERS Removal 1. Lower the forks completely.

2. Move the mast to the full forward position.

3. Turn the key switch to the off "O" position.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component.

4. Disconnect the battery and discharge the capacitors. See Section 3 for CAPACITOR DISCHARGE PROCEDURE. 5. Remove the battery retainer and the battery.

6. Lift upward on the battery roller to remove the battery roller assembly from the holder.

7. Slide the washers and roller off the battery roller shaft.

Installation 1. Slide the battery roller onto the battery roller shaft and install one flat washer at each end.

2. Align the flats on the end of the shaft vertically above the slots in the floor of the battery compartment and lower the assembly into the slots.

3. Install the battery. Install the battery retainer. Connect the battery connector.

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.

LUBRICATION INSTRUCTIONS

WARNING: Yale industrial trucks are equipped with certain safety devices as standard equipment, for

Sheet 3: General Truck and Lubrication example: overhead guards, load backrest extensions, mast screens, etc. 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 reinstalled 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. 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.

WARNING: The service intervals referred to in these lubrication and maintenance instructions are based on normal operating conditions. If you have a light duty or low operating hour application, the maximum service interval should not exceed 90 days. If the vehicle is operated in areas of high contamination such as dust, corrosive vapors, etc., the service interval must be decreased from the recommended hours. Have a qualified Yale mechanic inspect the truck and repair any problems.

Refer to the Recommended Schedules of Maintenance and Lubrication Instructions when inspecting, lubricating or servicing this truck. 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 oils and grease recommended for use on these models.

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.

EVERY 8 HOURS 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 Apply lithium base, multi-purpose No. 2 grease to the following lube fittings or surfaces with a high pressure gun, as applicable. Clean the lube fittings before and after lubricating.

1. Mast Load Roller Wear Plugs Sliding Surfaces 2. Fork Guides and Locks, Sideshift Carriage 3. Wheel and Final Drive Pinion Bearings, Final Drive Gears Apply silicone spray lubricant to the following friction points: 4. Lift Chain Sheaves Apply engine oil (SAE 30) to the following friction points: 5. Lift Chains - Wipe off all old oil using a clean cloth, then use compressed air to blow off chains. With a clean brush, apply SAE 30 weight oil to the full length of chain. Oil must penetrate chain joints.

Apply anti-seize lubricating compound to the following friction points: 6. Drive Wheel Lug Nuts

Sheet 3: General Truck and Lubrication EVERY 350 HOURS 7. Brake Master Cylinder-The brake fluid reservoir is accessible by removing the top cover and the control cover from the operator's compartment. Remove the cap from the reservoir and check the fluid level. The correct level is 1/4" from top of reservoir. Add brake fluid if necessary. Use SAE J1705 hydraulic brake fluid, Federal Motor Vehicle Safety Standard DOT 5.

8. Hydraulic Oil Level-Remove and wipe the dipstick. With the forks fully lowered and oil at normal operating temperature, (above 100*F), measure oil level with dipstick. Add hydraulic oil, if necessary, to the "full" mark on the dipstick. Remove and clean breather/filler assembly and the breather with solvent. Blow dry with compressed air, replace and tighten. Replace the breather/filler assembly and the breather if they cannot be cleaned or are damaged. DO NOT OVERFILL. 9. Drive Unit Oil Level-Park truck on a level floor. Remove oil level plug. Oil should run out slightly. If low, remove fill plug and fill with SAE 80W-90 weight gear oil until oil runs out of oil level hole. Install plug. DO NOT OVERFILL.

EVERY 2000 HOURS 10. Brake Master Cylinder-Drain and flush the system and fill with new hydraulic brake fluid. After filling, bleed the brake system.

11. Hydraulic Oil Filter-Remove the oil filter canister. Remove the hydraulic oil filter. Install a new oil filter element.

Install the oil filter canister.

12. Hydraulic System-Lower the mast. There is no drain plug in this hydraulic tank. The hydraulic tank is drained at the supply hose. 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 and drain the oil. Pour the oil into a suitable container and discard in accordance with local regulations. Clean the 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 the mast, operate the 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.

13. Drive Unit-Park the truck on a level floor. Remove the drain plug. Drain the gear oil into a suitable container and discard in accordance with local regulations. Replace the drain plug and fill through the filler hole with gear oil. Drive the truck slowly to circulate the oil. Drive Unit Capacity 2.61 litres (.69 gallons).

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

Sheet 3: General Truck and Lubrication Figure 2-12 - Lubrication Locations

RECOMMENDED SCHEDULES OF MAINTENANCE 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.

LEGEND A - Every 8 Hours B - Every 350 Hours C - Every 2000 Hours ir - Initial Replacement

x - Visually Inspect, Test and Adjust as Required o - Drain and Fill r - Replacement co - Complete Overhaul NA-794

SAFETY AND OPERATIONAL CHECKS (Prior to each shift) Only the 8 hour checks are to be performed by the operator. Have a qualified mechanic correct all problems in accordance with appropriate YALE maintenance instructions.

Leaks - Hydraulic Fluid Tires - Condition Forks, Top Clip Retaining Pin and Heel - Condition Load Backrest-Attached Hydraulic Hoses, Mast Chains and Stops - Check Visually Finger Guards - Attached Overhead Guard - Attached Safety Labels - Attached (Refer to Parts/Operating Manual for Locations) Internal Checks: Battery - Water/Electrolyte Level and Charge Hydraulic Tank Fluid Level - Dipstick Operator's Compartment: Operating Manual - in Container Nameplate Attached - Information matches model, serial number, attachments Battery Restraint - in Place Brake Fluid - Check Level Controls - Turn Truck On & Immediately Check Noises that are not Normal Accelerator Linkage - Operates Correctly Brake - Operates Correctly Steering Operation - Operates Smoothly and Correctly Drive Control, Forward/Reverse - Operates Correctly Tilt Control - Operates Smoothly and Correctly Lift and Lower Control - Operates Smoothly and Correctly Reach Control - Operates Smoothly and Correctly Attachment Control - Operates Smoothly and Correctly Horn - Operates Correctly Warning Horn - Reverse Operated - Operates Correctly Lights - Operate Correctly Gauges: Hourmeter - Operates Correctly Battery Indicator - Operates Correctly Instrument Monitors - Operates Correctly

A

B

C

x x x x x x x x x x

o

x x x x

o

x x x x x x x x x x x x x x

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

LUBRICATION CHECK: Use compressed air to clean and inspect for damage Lubricate - Chassis (All Fittings) All Linkage Friction Surfaces on Mast

A

B x x x

C

Sheet 3: General Truck and Lubrication Friction Surfaces on Attachment Lift Chains - Clean and Lubricate Wheel Bearings - Clean and Repack with Grease Brake Fluid (Master Cylinder) Hydraulic Oil Filter Element Hydraulic Tank Breather Differential Oil Level

x x x ir x x B x x x x x x x x x x

x o r r o

HYDRAULIC SYSTEM CHECK: Lift, Tilt, Reach & Power Steer Cylinders for Leaks and Correct Operation Tilt Cylinder Rod End Adjustment Hydraulic Pump for Noise and Operation Power Steer Pump for Noise and Correct Operation Hydraulic Control Valve for Leaks and Correct Operation Relief Valve Settings All Hoses, Tubing and Fittings for Wear and Leaks Attachment - Correct Operation Attachment Cylinder for Leaks General Leaks Accumulators

A

C

DRIVE UNIT CHECK: Brake Adjustment Brake Drums and Linings for Wear Electric Motor and Drive Train Mounting Bolts (Torque to Specifications) Wheel Bolts or Nuts (Torque to Specifications) Wheel Brake Bolts (Torque to Specifications) Mast and Trunnion Cap Bolts (Torque to Specifications)

A

B x x x x x x

C

ELECTRICAL SYSTEM CHECK: Clean all Controls Interlock Switches - Check Operation Accelerator Switch and Potentiometer - Check Operation Electronic Card - Check Operation Time Delay - Check Operation Direction Switch - Check Operation Drive Resistor (Magnetic Control) - Check Operation Valve Lift and Jilt Switches - Check Operation All Motors - Clean with Compressed Air All Motors - Check Brushes and Springs All Motors - Check Power Wire Terminals Battery Box and Connectors - Neutralize and Clean Battery Condition - Physical and Electrical All Wire Connections Contactors - Tips and Wire Connectors

A

B x x x x x x x x x x x x x

C

MAST - CARRIAGE - ATTACHMENT CHECK: Mast and Carriage Safety Stops Mast Flange Wear Mast Rollers and Wear Plugs Carriage Rollers and Wear Plugs Chain Anchors Chain for Wear or Cracks (Use Wear Indicator 5180968-69) Pallet/Forks/Platform (Visual) Forks (See Note 2) Attachment - Sliding Surface Wear Attachment - Rotating Parts and Torque Bolts

A

GENERAL CHECK: Steering - king Pins and knuckles - Tightness Steering - Tie Rods and Wheel Alignment Steering - Drag Links Steering - Bellcrank All Bolts, Nuts, Cotter Pins, Etc.

A

x

x x B x x x x x x x

C

x x x B x x x x x

C

Sheet 3: General Truck and Lubrication Overhead Guard and Load Backrest - Cracks, Mounting, Etc. Articulation Adjustment

x x

ROAD AND LOAD TEST TRUCK: At initial installation and after every maintenance inspection or repair. Test the rated load in a clear area (See Notes 3 and 4). Report any questionable functions or unusual noises.

Steering Brake System Horn, Lights Emergency Disconnect Drive Power - Acceleration Mast - Verify All Stops are Installed and Limit Switches are Functioning Properly Lift - Full Lift and Lower (Do not tilt forward) (See Note 3) Tilt - With Load Lowered Operate Full Forward and Backward (See Note 4) Attachment - Operate all Functions

NOTES: 1. Tire 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 (24 in) load center, check lift cylinder drift. Lift drift must not exceed 25.4 mm (1.0 in) in 2 minutes, oil at 26ºC (79ºF). 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 26ºC (79ºF). Refer to Service Bulletin SE-1077 for procedure to measure hydraulic drift.

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

6. Recycle all waste oils.

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

ANTI-SEIZE LUBRICATING COMPOUND For Use as Specified

Application

Standard and Freezer 3101562-30

YALE Part Number

APPROVED SOURCES Loctite Corporation 76764 Bostik - Division of Emhart NSBT - 16 Permatex - Subsidiary of Loctite 80208 Field Personnel Note: The anti-seize compounds, as listed herein, are approved YALE Materials Handling Corporation sources that meet or exceed the specifications annotated. The use of anti-seize compounds other than the suppliers and products listed is unauthorized.

BRAKE FLUID For Brake System

Application

Standard and Freezer 1500303-04 J1705 - FMVSS 116 (DOT 5) -40ºto +120ºF (-40ºto +49ºC) Silicone

YALE Part Number SAE Type Anticipated Ambient Air Temperature Type of Fluid APPROVED SOURCES Dow Corning Corporation Delco Moraine Div.

Q2-1143 P1615-129

Sheet 3: General Truck and Lubrication General Electric Corporation 475-195 Union Carbide Corporation Y-7694 Field Personnel Note: The brake fluids, as listed herein, are approved YALE Materials Handling Corporation sources that meet or exceed the specifications annotated. The use of brake fluids other than the suppliers and products listed is unauthorized.

CHAIN OIL For Lift Chains

Application

Standard Freezer +32ºto +120ºF (0ºto +49ºC) -40ºto +32ºF (-40ºto 0ºC) 40W 20W APPROVED SOURCES Any supplier whose product meets or exceeds the above specifications

Anticipated Ambient Air Temperature SAE Grade Motor Oil

GEAR GREASE For Final Drive Gears

Application

Standard and Freezer 1500324-83 -40ºto +120ºF (-40ºto +49ºC) Lithium Complex—Synthetic Base Oil 00 Semi-fluid 2413 -40ºto +350ºF (-40ºto +178ºC) Container must be plainly marked with supplier's product identification APPROVED SOURCES Mobil Mobilith SHC 007 Synthetic Grease Texaco Starfak 00 Synthetic Grease Field Personnel Note: The greases, as listed herein, are approved YALE Materials Handling Corporation sources that meet or exceed the specifications annotated. The use of greases other than the suppliers and products listed is unauthorized.

YALE Part Number Anticipated Ambient Air Temperature Soap Type NLGI Grade Dropping Point Base Oil Viscosity (SUS @ +100ºF) Usable Temperature Range Identification

GEAR OIL For Gearbox

Application YALE Part Number Anticipated Ambient Air Temperature Base Oil Viscosity (SUS @ +100ºF) Viscosity Index Pour Point

Standard and Freezer 1500324-85 -40ºto +120ºF (-40ºto +49ºC) Synthetic 695 154 Below -40ºF (-40ºC)

APPROVED SOURCES Mobil Mobil SHC 50 Synthetic Gear Lub. Texaco Synstar TL 50 Synthetic Trans. Lub. Field Personnel Note: The gear oils, as listed herein, are approved YALE Materials Handling Corporation sources that meet or exceed the specifications annotated. The use of gear oils other than the suppliers and products listed is unauthorized.

HYDRAULIC OIL Application YALE Part Number Anticipated Ambient Air Temperature Viscosity (SUS @ +100ºF) Viscosity Index Pour Point

For Hydraulic System Standard 1500318-08 1500324-38 +32ºto +120ºF -20ºto +32ºF (0ºto +49ºC) (-29ºto 0ºC) 155 339 106 103 -25ºF (-32ºC) -20ºF (-29ºC) APPROVED SOURCES

Freezer 1500324-82 -40 to -20ºF (-40ºto -29ºC) 341 141 -40ºF (-40ºC)

Sheet 3: General Truck and Lubrication McCollister

No Product

Arctic Blue Hydraulic Oil Arctic Blue Hydraulic Oil 3028 3028 Mobil DTE 24 No Product No Product Shell Tellus 32 No Product No Product Texaco Rando HD-32 Rando HD-68 Rando HDZ-68 Field Personnel Note: The hydraulic oils, as listed herein, are approved YALE Materials Handling Corporation sources that meet or exceed the specifications annotated. The use of hydraulic oils other than the suppliers and products listed is unauthorized

WHEEL BEARING GREASE Application

For Final Drive Gears

Standard and Freezer 1500324-83 -40ºto +120ºF (-40ºto +49ºC) Lithium Complex—Synthetic Base Oil 2 Above +450ºF (+234ºC) 1143 -40ºto +350ºF (-40ºto +178ºC) Container must be plainly marked with supplier's product identification APPROVED SOURCES Mobil Mobilith SHC 007 Synthetic Grease Texaco Starfak 00 Synthetic Grease Field Personnel Note: The greases, as listed herein, are approved YALE Materials Handling Corporation sources that meet or exceed the specifications annotated. The use of greases other than the suppliers and products listed is unauthorized.

YALE Part Number Anticipated Ambient Air Temperature Soap Type NLGI Grade Dropping Point Base Oil Viscosity (SUS @ +100ºF) Usable Temperature Range Identification

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 2-3.

Threads, Nomenclature The thread design is specified by a series of numbers and letters for inch and metric fasteners. See Figure 2-13.

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)].

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.

Sheet 3: General Truck and Lubrication

Figure 2-13 - Thread Design 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: INCH 1/2 x 13 UNC x 1-1/2 AxBCxD A = Shank Diameter B = Number of Threads per Unit of Length C = Type of Thread D = Shank Length Table 2-3 - Capscrew Description

METRIC M12 x 12.75 x 50 AxBxC A = Thread Size B = Pitch C = Length

Strength Identification The most common property classes for metric fasteners are 8.8 and 10.9. The property class is marked with a number on the head of the 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.

Sheet 3: General Truck and Lubrication

Table 2-4 - Bolts and Screws

Sheet 3: General Truck and Lubrication

Table 2-5 - Studs and Nuts

Sheet 3: General Truck and Lubrication

Table 2-6 - Torque Nuts

Sheet 3: General Truck and Lubrication

Table 2-7 - Torque Nuts with Nylon Inserts

Sheet 3: General Truck and Lubrication

Table 2-8 - General Guide to Torque Values

Sheet 3: General Truck and Lubrication

Table 2-9 - General Guide to Torque Values JIC FLARED TYPE AND SAE STRAIGHT THREAD O-RING FITTINGS DASH THREAD MAXIMUM TORQUE SIZE SIZE N m (lbf ft) SWIVEL NUT LOCKNUT -2 5/16"-24 8 (6) 8 (6) -3 3/8"-24 8 (6) 8 (6) -4 7/16"-20 14 (10) 11 (8) -5 1/2"-20 20 (15) 14 (10) -6 9/16"-18 27 (20) 18 (13) -8 3/4"-16 41 (30) 28 (21) -10 7/8"-14 54 (40) 45 (33) -12 1 1/16"-12 95 (70) 65 (48) -14 1 3/16"-12 108 (80) 76 (56) -16 1 5/16"-12 122 (90) 85 (63) -20 1 5/8"-12 163 (120) -24 1 7/8"-12 178 (131) -32 2 1/2"-12 407 (300) -

SWIVEL ADAPTER UNIONS DASH SIZE

PIPE SIZE

-2 -4 -6 -8 -12 -16 -20 -24 -32

1/8"-27 1/4"-18 3/8"-18 1/2"-14 3/4"-14 1"-11-1/2 1-1/4"-11-1/2 1-1/2"-11-1/2 2"-11-1/2

MAXIMUM TORQUE N m (lbf ft) FEMALE PIPE MALE PIPE 18 (13) 16 (12) 27 (20) 34 (25) 34 (25) 54 (40) 64 (47) 73 (54) 114 (84) 106 (78) 175 (129) 152 (112) 206 (152) 209 (154) 206 (152) 286 (211) 407 (300) 407 (300)

Sheet 3: General Truck and Lubrication NOTE: Values shown are for zinc plated fittings.

Values for cadmium plated fittings may vary slightly, but not enough to be of any appreciabl e difference.

Torque Values furnished by Air-Way Manufactu ring Co., Olivet, Michigan Table 2-10 - Recommended Maximum Torque Values for Hydraulic Fittings* MULTIPLY

BY

inches2 (in2) feet2 (ft2)

x x

inches (in) feet (ft) yards (yd) miles (mi)

x x x x

ounces (oz) pounds (lb) tons (2,000 lb) tons (2,000 lb)

x x x x

horsepower (hp)

x

pounds/in2 (psi) pounds/in2 (psi)

x x

Fahrenheit - 32 (ºF)

x

pound inches (lbf in) x pound feet (lbf ft) x miles/hour (mph)

x

inches3 (in3) inches3 (in3) quarts, U.S. (qt) quarts, U.S. (qt) gallons, U.S. (gal) gallons, U.S. (gal) ounces (oz)

x x x x x x x

TO GET

MULTIPLY

AREA 6.452 = centimeters2 (0m2) centimetres2 (cm2) x 0.093 = meters2 (m2) metres2 (m2) x LINEAR 25.40 = millimeters (mm) millimetre (mm) x 0.305 = meters (m) metre (m) x 0.914 = meters (m) metre (m) x 1.609 = kilometers (km) kilometre (km) x MASS 28.35 = grams (g) grams (g) x 0.454 = kilograms (kg) kilograms (kg) x 907.18 = kilograms (kg) kilograms (kg) x 0.907 = metric tonne (t) metric tonne (t) x POWER 0.746 = kilowatts (kW) kilowatts (kW) x PRESSURE 6.895 = kilopascal (kPa) kilopascal (kPa) x 0.007 = megapascal (Mpa) Megapascal (Mpa) x TEMPERATURE 0.56 = Celcius (ºC) Celcius (ºC) x TORQUE 0.113 = Newton meter (Nm) Newton meter (Nm) x 1.356 = Newton meter (Nm) Newton meter (Nm) x VELOCITY 1.609 = kilometre/hour (km/h) kilometre/hour (km/h) x VOLUME 16.387 = centimeters3 (cm3) centimetres3 (cm3) x 0.016 = litres (I) litres (I) x 0.946 = litres (I) litres (I) x 0.83 = quarts, Imp. (qt) quarts, Imp. (qt) x 3.785 = litres (I) litres (I) x 0.83 = gallons, Imp. (gal) gallons, Imp. (gal) x 29.57 = milliliter (ml) milliliter (ml) x

Table 2-11 - Conversion Table for Metric and English Units

BY

TO GET

0.155 = inches2 (in2) 10.764 = feet2 (ft2) 0.039 3.281 1.094 0.621

= = = =

inches (in) feet (ft) yards (yd) miles (mi)

0.035 2.205 0.001 1.102

= = = =

ounces (oz) pounds (lb) tons (2,000 lb) tons (2,000 lb)

1.34

= horsepower (hp)

0.145 145.4

= pounds/in2 (psi) = pounds/in2 (psi)

1.8

= Fahrenheit - 32 (ºF)

8.851 0.738

= pound inches (lbf in) = pound feet (lbf ft)

0.621

= miles/hour (mph)

0.061 = 61.024 = 1.057 = 1.205 = 0.264 = 1.205 = 0.034 =

inches3 (in3) inches3 (in3) quarts, U.S. (qt) quarts, U.S. (qt) gallons, U.S. (gal) gallons, U.S. (gal) ounces (oz)

Sheet 3: General Truck and Lubrication

Sheet 7: Electric Motor Maintenance ELECTRIC MOTOR MAINTENANCE, GENERAL This section describes brush installation, 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.

A 36 volt battery is the power source for the drive motors, the hydraulic pump motor and the power steering pump motor. The drive system is regulated by the transistorized system controller. Each lift truck has two drive motors that are each controlled by its own traction amplifier. The controller senses when the control handle is moved and sends a pulse modulated signal to the traction amplifier. The traction amplifiers then convert these signals which are sent to the motors.

The hydraulic pump motor and the power steering pump motors are located in the front frame area, above the tilt cylinders. The hydraulic pump motor is connected directly to the hydraulic pump. The power steering pump motor is connected to the steering pump. The power steering pump motor is a permanent magnet type motor.

The hydraulic pump motor is activated through signals received from the lift potentiometer. When the lift or tilt control lever is moved, a pulse width modulated signal is sent to the amplifier. The lift amplifier converts the data signal into a 36VDC power signal and activates the hydraulic pump motor.

The power steering pump motor is controlled by the lift amplifier. The lift amplifier acts as an electronic relay which will turn the motor on when the brake pedal is depressed or the control handle is moved for forward or reverse.

The drive motors and hydraulic pump motors are similar in design. The hydraulic pump motors are smaller than the drive motors, but the disassembly and maintenance of these motors are similar. The cooling fan in the drive motors is fastened to the armature with three capscrews and can be removed from the armature. The cooling fan can be removed during disassembly of the drive motor.

The cooling fan in the hydraulic pump motor is normally a press fit on the armature shaft and is not easily removed during disassembly of the motor. The armature and cooling fan must be removed from the drive end of the motor during disassembly.

REPAIRS DRIVE MOTOR AND HYDRAULIC PUMP MOTOR See the Hydraulic System chapter for instructions to remove and install the hydraulic pump and motor and the power steering pump and motor. The power steering pump motor is a permanent magnet motor. See Section 4-DRIVE UNIT for instructions to remove and install the drive motor.

Refer to BRUSH AND COMMUTATOR INSPECTION and BRUSH INSTALLATION, DRIVE AND HYDRAULIC MOTORS for more information on these components of the motor.

Disassembly 1. Clean the outside surfaces of the motor before disassembly. Make index marks on the ends of the motor and the motor field ring so that correct assembly is possible.

2. Remove the brush cover. Remove the brushes and spring assemblies.

3. Remove the capscrews from the commutator end of the motor. Carefully slide the end cover from the motor and armature shaft. Do not damage the parts. A puller is often necessary to separate the pinion end cover from the motor field ring.

CAUTION: The pinion end cover and the armature are heavy components. Work carefully so that the field coils, pole pieces, and the armature are not damaged during disassembly and assembly.

Sheet 7: Electric Motor Maintenance

Figure 3-12 - Drive Motor 1. ARMATURE SHAFT 2. COOLING FAN 3. BRUSH COVER

Figure 3-13 - Typical Drive Motor Assembly 1. HALF MOON KEY 2. PINION END COVER-COMPLETE 3. OIL SEAL 4. ALLEN HEAD BOLT AND WASHER 5. 2 POLE BRACKET 6. BEARING 7. END COVER-COMPLETE 8. SQUARE NUT 9. CAPSCREW AND WASHER 10. SPACER 11. KEY 12. WASHER 13. HEX. NUT 14. SNAP RING 15. CLAMP 16. PIPE INSULATION 17. PLATE RATING WITH GROOVED NAIL 18. WASHER 19. CAPSCREW WITH WASHER 20. BRUSH

Sheet 7: Electric Motor Maintenance 21. SNAP RING 22. BALL BEARING 23. SNAP RING 24. BRUSH CARRIER-COMPLETE 25. BRUSH COVER 26. ALLEN HEAD BOLT WITH WASHER 27. HOUSING 28. ROTOR 29. POLE SHOE 30. COUNTERSUNK SCREW 31. FIELD COIL SET 32. CAPSCREW WITH WASHER 33. O-RING 34. SHIM WASHER 35. BALL BEARING 4. Remove the screws that fasten the pinion end cover to the motor field ring. Remove the end cover and armature. Use a plastic or rubber hammer as necessary to loosen the end cover.

5. Remove the pinion end cover from the armature.

6. Remove the screws that fasten the brush holder assembly to the commutator end cover.

7. Disassemble the components of the motor as necessary to make repairs.

Assembly 1. Make sure all of the components are clean. If the bearings are worn, install new bearings in the end covers.

2. If the cooling fan was removed, install it on the armature. Make sure the field coils and pole pieces are installed correctly in the motor field ring.

Sheet 7: Electric Motor Maintenance

Figure 3-14 - Hydraulic Pump Motor Assembly 1. PINNION END COVER 2. BRUSH PLATE 3. SPRING WASHER 4. BEARING 5. FIELD COIL PACKAGE 6. BRUSH COVER 7. BRUSH SPRING KIT 8. BRUSH SET 9. SNAP RING 10. END HEAD ASSEMBLY 11. BEARING 12. FAN 13. ARMATURE 14. POLE SHOE SCREW PACKAGE 15. MOTOR HOUSING 3. Install the brush holder assembly in the commutator end cover.

4. Install the pinion end cover on the armature.

5. Carefully install the armature and pinion end cover in the motor field ring. Make sure the index marks are aligned. Install and tighten the screws.

6. Carefully install the commutator end cover on the armature and fasten it to the motor field ring. Install and tighten the capscrews.

7. Install the brushes and spring assemblies. Refer to DRIVE AND HYDRAULIC MOTORS-BRUSH INSTALLATION.

Sheet 7: Electric Motor Maintenance

Figure 3-15 - Power Steering Pump Motor 1. FRONT END BELL ASSEMBLY 2. BEARING 3. ARMATURE ASSEMBLY 4. WAVE WASHER 5. SHELL AND MAGNET ASSEMBLY 6. BRUSH SPRING 7. BRUSH ASSEMBLY 8. REAR END BELL ASSEMBLY 9. TERMINAL COVER 10. TIE BOLT 11. MOUNTING BRACKET 12. CAPSCREW

POWER STEER PUMP MOTOR

CAUTION: The motor used on this assembly is the permanent magnet type. It is recommended that all jewelry be removed. Use care when disassembling. Keep fingers from between shell and magnet assembly and the rear end bell assembly.

NOTE: Brushes and springs for the power steer pump motor are only funished as part of the rear end bell assembly.

Disassembly 1. Clean the outside surfaces of the motor before disassembly. Make index marks on the end bell assemblies of the motor and the shell and magnet assembly so that correct assembly is possible.

2. Remove the capscrews retaining the mounting bracket to the shell and magnet assembly. Remove the mounting bracket.

3. Remove the tie bolts and the terminal cover.

4. Remove the rear end bell assembly with the brush assembly and springs.

5. Remove the front end bell cover assembly.

Sheet 7: Electric Motor Maintenance 6. Carefully remove the armature assembly from the shell and magnet assembly.

7. If necessary remove the bearings from either the front and/or rear end bell assemblies. On the rear end bell assembly, if the bearing is removed, make certain to remove the wave washer.

8. Repair or replace the components as necessary.

Assembly 1. Make certain all the components are clean. If the bearings were removed, install the wave washer and bearing into the rear end bell assembly. Install the bearing in the front end bell assembly.

2. Carefully install the armature assembly in the shell and magnet assembly.

3. If the brushes and brush springs are being replaced, install them in the rear end bell assembly. Align the rear end bell and carefully install it on the armature assembly. Align the front end bell assembly with the index marks on the shell and magnet assembly and install the front end bell assembly on the opposite end of the armature assembly.

4. Align the terminal cover and install the tie bolts to retain the cover to the motor. 5. Install the mounting bracket on the shell and magnet assembly using the capscrews.

5. Check the brush and spring assemblies. Refer to BRUSH AND COMMUTATOR INSPECTION.

BRUSH AND COMMUTATOR INSPECTION

WARNING: Do not work under a raised carriage. Lower the carriage before servicing the lift truck.

1. Lower the forks completely.

2. Move the mast to the full forward position.

3. Turn the key switch to the off "O" position.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

4. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 5. Remove the battery.

6. Raise the drive wheels from the surface. See Section 2-GENERAL TRUCK AND LUBRICATION. 7. Remove the front cover. See Section 2-GENERAL TRUCK AND LUBRICATION. 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.

8. Inspect the commutator surface. Carefully rotate the armature. DO NOT damage the commutator if you use a tool to rotate the armature.

9. 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.

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.

Sheet 7: Electric Motor Maintenance

Figure 3-16 - Raise The Drive Wheels From The Surface Normal Commutator Surface 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 7: Electric Motor Maintenance

Figure 3-17 - Normal Commutator Surfaces Commutator Problems Commutator and motor problems are shown in Figure 3-18 through 3-25.

Sheet 7: Electric Motor Maintenance

Figure 3-18 - Commutator Problems Heavy streaks and fine grooves indicate the beginning of damage to the commutator.

Possible Causes: •

Operation of the motor in dirty and abrasive conditions

•

Continuous operation of a motor with a light load

•

Brush pressure is too low

•

Worn brushes

Figure 3-19 - Commutator Problems Grooves and lines that have followed the heavy streaks and fine grooves shown in Figure 3-19. The armature must be removed from the motor so that the commutator can be repaired. A commutator with this condition will cause the brushes to wear rapidly.

Possible Causes: •

Operation of the motor in dirty and abrasive conditions

•

Continuous operation of a motor with a light load

•

Brush pressure is too low

•

Worn brushes

Sheet 7: Electric Motor Maintenance

Figure 3-20 - Commutator Problems Grooves that are the width of the brushes.

Possible Causes: •

Operation of the motor in dirty and abrasive conditions

•

Wrong type of brushes for this motor and operation

•

Brush pressure is too high

Figure 3-21 - Commutator Problems A condition called "copper drag" occurs when copper from the commutator bar is pulled into the slot between the commutator bars. This condition will cause a short-circuit between the commutator bars if it is not corrected. The brushes will wear rapidly.

Possible Causes: •

Operation of the motor in dirty and abrasive conditions

•

Brush holder is not adjusted electrically correct for the motor

•

Wrong type of brushes for this motor and operation

•

Brush pressure is wrong (too high or too low)

Sheet 7: Electric Motor Maintenance

Figure 3-22 - Commutator Problems Electrical burns on commutator bars on opposite sides of the commutator.

Possible Causes: •

Open armature winding

•

Motor has been stalled

Figure 3-23 - Commutator Problems Copper wears rapidly at the edge of the commutator bars.

Possible Causes: •

Operation of the motor in dirty and abrasive conditions

•

Wrong type of brushes for this motor and operation

Sheet 7: Electric Motor Maintenance

Figure 3-24 - Commutator Problems 1. Flashover causes burning of the ends of the commutator bar.

2. Open circuit in winding causes deep burning of adjacent commutator bars.

3. Overheating causes damage to varnish insulation.

Possible Causes: •

Motor has been too hot-Wrong lift truck for the application

•

Motor has been stalled

•

Open armature winding

•

Open field coil

Figure 3-25 - Commutator Problems Check for loose or high commutator bars.

Possible Causes: •

Motor has been stalled

•

Motor has been too hot

Sheet 7: Electric Motor Maintenance DRIVE MOTOR BRUSHES NOTE: Specialized tools, fixtures, and training are required to service the drive motor. See Section 4-DRIVE UNIT REBUILD. Removal 1. Put the truck on blocks or stands so the drive wheels are off the ground. See Section 1-HOW TO PUT A LIFT TRUCK ON BLOCKS.

WARNING: Do not work under a raised carriage. Lower the carriage before servicing the truck.

2. Lower the forks completely.

3. Move the mast to the full forward position.

4. Turn the key switch to the off "O" position.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

5. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 6. Remove the front cover. See Section 2-FRONT COVER-REMOVAL. 7. Remove the mast assembly from the truck. See Section 8-MAST-REMOVAL. 8. Disconnect the brake line from the disc brake unit.

9. Disconnect the wire harness and four power cables from the drive motor, noting their location for correct replacement.

10. Remove the four capscrews securing the drive unit to the truck frame.

11. Tilt the drive unit forward approximately 90*, until the capscrews can be installed. Install two capscrews to secure the drive unit in the tilted position.

12. Remove the screws securing the brush leads to the brush holder.

13. Rotate the brush holder spring away from the brush.

14. Remove the brush.

Sheet 7: Electric Motor Maintenance

Table 3-2 - Checking the Brushes 1. TAPERED END 2. WEAR END Installation 1. Insert the brush into the brush holder in the correct orientation.

2. Reposition the end of the brush spring on the brush and attach the brush lead to the brush terminal. Tighten the screw to 1.7-2 N m (15-18 lbf in) torque.

3. Remove the two capscrews securing the drive unit in the tilted position and return the drive unit to the operating position.

NOTE: The drive unit is mounted to the frame with four capscrews. Three capscrews are 38 mm (1-1/2 in) long and one is 32 mm (1-1/4 in) long. The 32 mm (1-1/4 in) capscrew goes in the lower front hole.

4. Install the four capscrews securing the drive unit to the frame and tighten to 108 N m (80 lbf ft) torque.

5. Connect the brake line to the disc brake unit and bleed the brakes. See Section 5-BLEEDING THE BRAKE SYSTEM. 6. Install the wire harness and power cables to the drive motor in the correct locations.

7. Install the mast assembly. See Section 8-MAST-INSTALLATION 8. Install the front cover. See Section 2-FRONT COVER- INSTALLATION. 9. Connect the battery.

LIFT PUMP MOTOR BRUSHES Removal

Sheet 7: Electric Motor Maintenance NOTE: Two of the lift pump motor brushes may be inspected without removing the lift pump motor from the truck.

WARNING: Do not work under a raised carriage. Lower the carriage before working on the truck.

1. Lower the forks completely.

2. Move the mast to the full forward position.

3. Turn the key switch to the off "O" position.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

4. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 5. Remove the battery.

6. Remove the front cover. See Section 2-FRONT COVER-REMOVAL. 7. Remove the lift pump and motor assembly. See Section 7-LIFT PUMP AND MOTOR ASSEMBLY-REMOVAL. 8. Release the spring tension on the brush by rotating the brush holder spring away from the brush.

9. Remove the screw securing the brush lead to the brush holder.

10. Remove the brush.

Installation NOTE: If any brush needs replacing, replace all the brushes on the motor.

1. Insert the brush assembly into the brush holder.

2. Position the end of the brush spring on the brush.

3. Attach the brush lead to the brush terminal and tighten the screw.

4. Install the lift pump and motor assembly.

5. Replace the front cover. See Section 2-FRONT COVER-INSTALLATION. 6. Install and connect the battery.

STONING THE COMMUTATOR

WARNING: Wear eye protection. Raise the drive wheels. Operate the motor at low speed. Protect your fingers. You are doing work close to moving parts of the motor. Do not use a brush seater stone less than 60 mm (2.5 in) in length.

New brushes made by the manufacturer are normally made to fit the surface of the commutator when they are installed. This contact surface must be checked when new brushes are installed. If the contact surface is not approximately 85% of the brush surface where it touches the commutator, an abrasive process called "Stoning the Commutator" is used to make the brushes fit the commutator better.

If new brushes do not fit the surface of the commutator when they are installed, 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

Sheet 7: Electric Motor Maintenance quickly.

Sheet 4: General

ELECTRICAL SYSTEM GENERAL This sectiion has the diagnostic, adjustment and repair procedures for the electrical systems of the ESC 030 ZA, ESC 035 ZA, ESC 040 ZA and ESC 050 ZA trucks.

Checks, adjustments and repairs to electrical parts that are not covered in this section may be found in the BATTERY AND CHARGING SYSTEM, Section 9.

WARNING: Do not operate a lift truck that needs adjustments or repairs. Report the need for adjustments or repairs immediately. If adjustment or repair is necessary, put a "DO NOT OPERATE" tag in the operator's area. Remove the key from the key switch.

WARNING: Some of the checks and adjustments are done with the battery connected. Never have any metal on your fingers, arms or neck. These metal items can accidentally make an electrical connection and cause an injury.

WARNING: Discharge the capacitor bank prior to performing any service on the electronic circuits of the lift truck. Failure to follow proper discharging procedure can result in personal injury or damage to the electronic circuitry of the truck. DO NOT short the capacitor bank to the frame or ground.

Refer to this section for the correct procedures for replacement, checks and adjustment of these components: 1. Fuses 2. Control Handle Assembly 3. Control Handle Potentiometers 4. Horn Button 5. System Controller/Operator Display 6. Operator Display Board 7. Battery-State-of-Charge Indicator 8. Key Switch 9. Auxiliary Switches 10. Horn 11. Acceleration Control 12. Traction Controller 13. Lift Controller 14. Brake Switch 15. Contactor and Contactor Tips 16. Battery Disconnect Programming, calibration, and diagnostic information, and a troubleshooting guide are provided at the end of this section.

Sheet 4: General THEORY OF OPERATION The ESC 030 ZA, ESC 035 ZA, ESC 040 ZA and ESC 050 ZA lift trucks are sophisticated microprocessor based units. All features of the trucks are controlled through the computers in the system controller. The system controller is responsible for distributing all power throughout these trucks.

POWER DISTRIBUTION DC power is provided to the lift truck by a 36 volt industrial battery. A bank of 5 capacitors is connected in parallel with the battery to eliminate power spikes and to filter the power supplied to the truck's electrical system. When the battery is plugged in, DC power is provided to the main contactor and the system controller. When the key switch is turned to the "I" position, the system controller is powered up and power is supplied to the coil of the main contactor. At this time, the contactor does not energize, since the system controller has not provided a low signal to the coil.

When the key switch is turned to position "II" and released, a low signal is provided to the amplifiers and all of the motors. As with the main contactor, the system controller provides the negative signal to close the circuit and provide the power necessary to operate each of the devices. It is necessary to note that full battery positive is present on all of the wires labeled as B* when the system controller is on. Extreme care must be taken when the covers are removed from the truck and the system power is turned on.

START-UP When the key is turned to the "I" position, the microprocessor and its associated circuits are powered-up. The operator display is illuminated and the initial test routine is started. If no faults are found, the operator display will indicate BSOCXX% (Battery-State-of-Charge xx%). This indicates the system is ready to function. If a fault is found during this pretest, a warning message will be displayed. Refer to page 3-41.

When the key switch is turned to position "II" and released, the lift truck starts a test of the external systems of the truck. The main contactor is energized and "POST" is displayed on the operator display while all of the electrically powered components of the unit are tested. A signal is sent to each device in the truck and the feedback monitored. If no difficulties are encountered, the operator display will indicate "PASSED". The truck is now ready for operation. If a problem is encountered, an error code will be displayed indicating the component causing the problem.

STEERING CONTROL The signal from the steering position potentiometer is monitored by the system controller. As the steer tire moves away from the center position, the system controller reacts by decreasing the maximum speed of the drive wheels. As the truck is turned into a sharper turn, the power to the inside drive wheel is gradually reduced. As the steer tire nears the 90* position, the power to the inside drive unit is reversed and the tire rotates in the opposite direction. This allows the truck to maneuver more effectively in tight places.

DESCRIPTION Instruments/Controls The Key Switch is located on the far left side of the operator's display panel. See Figure 3-1. The key switch has three positions, "O", "I", and "II". No truck functions are enabled when the key is in the "O" (OFF) position.

When the key is rotated clockwise to the "I" (ON) position, power is applied to the system controller but not to the traction system or to any of the hydraulic functions. The operator can scroll through the battery-state-of-charge, hours on brake, drive, lift and steer or enter Program mode. When the key is rotated to the "II" (RUN) position (then released), the system controller performs the electronic key function (if installed and enabled). The system then runs a Power-On Self-Test. After all functions have been checked, the hydraulic functions are enabled (traction is also enabled if the brake pedal is engaged).

Sheet 4: General

Figure 3-1 - Key Switch The ESC 030 ZA, ESC 035 ZA, ESC 040 ZA and ESC 050 ZA lift trucks are equipped with a multi-function control handle. The multi-function handle allows the operator to control travel, lift, tilt, sideshift, horn and auxiliary functions.

Each function has an independent control device so that functions can be activated simultaneously.

Multi-Function Controls The multi-function handle controls the direction and speed of the lift truck. See Figure 3-2. Travel Proportional Control is activated by tilting the entire control handle in the desired direction of travel. Pushing the control handle toward the forks makes the lift truck travel toward the forks. To change direction, move the multi-function handle in the opposite direction of lift truck travel, regardless of travel speed. The lift truck will come to a stop, then accelerate in the opposite direction. This control is proportional; therefore, the farther the control handle is pushed, the faster the lift truck will decelerate or accelerate. If the multi-function handle is released, it will return to neutral, and the truck will coast to a stop.

Figure 3-2 - Multi-Function Control 1. HORN 2. TILT/SIDESHIFT 3. AUXILIARY FUNCTIONS (OPTIONAL) The multi-function handle also controls the direction and speed of vertical movement of the carriage on the mast.

Lift/Lower Proportional Control is activated by tilting the control handle toward the left or right side of the lift truck.

If the control handle is tilted toward the right, the carriage lifts; if the control handle is tilted toward the left, the carriage lowers. This control is proportional. The farther the lever is tilted, the faster the carriage lifts or lowers.

The Tilt/Sideshift Disk, located at the top of the multi-function handle lever, controls the tilting of the mast and sideshifting of the carriage. See Figure 3-3. The disk is operated with the thumb of the right hand. To tilt the mast forward, press the top of the disk. To tilt the mast back, press the bottom of the disk. On lift trucks equipped with a sideshifting carriage, press the left side of the disk to move the carriage to the left and press the right side of the disk to move the carriage to the right. Unlike the variable speed travel and lift/lower functions, tilt and sideshift are single speed functions.

Sheet 4: General

Figure 3-3 - Tilt/Sideshift Disk 1.

2.

3.

4.

SIDESHIFT LEFT TILT FORWARD SIDESHIFT RIGHT TILT BACK

The Horn button is located on the side of the multi-function handle facing the operator, just below the tilt/sideshift disk. The horn is activated by pressing the button with the thumb.

The Auxiliary buttons are located on the shaft of the multi-function handle. The auxiliary buttons are used to control any additional hydraulic functions, such as a push/pull clamp attachment, etc. The auxiliary selector switch on the operator display panel is used to select which auxiliary function (if two are installed) will be activated by the auxiliary buttons. When the upper button is pressed, the selected auxiliary hydraulic function (for example, push) is activated at low speed. To continue the function at high speed, the operator simultaneously presses the upper and lower auxiliary buttons. To switch the direction of the auxiliary function (for example, pull), the operator presses only the bottom auxiliary button. To continue the function at high speed, the operator simultaneously presses the lower and upper auxiliary buttons.

REPAIRS AND ADJUSTMENTS NOTE: None of the electrical components in this section can be repaired. All bad components must be replaced.

Some components are adjustable.

WARNING: Discharge the capacitor bank prior to performing any service on the electronic circuits of the lift truck. Failure to follow proper discharging procedure can result in personal injury or damage to the electronic circuitry of the truck. DO NOT short the capacitor bank to the frame or ground.

CAPACITOR Discharge Procedure 1. Turn the key switch to the off position, as indicated by the "O" symbol.

2. Disconnect the battery.

3. Turn the key switch to the "I" position. The operator display will illuminate then slowly dim. When the operator display is no longer illuminated, the capacitor bank is fully discharged.

FUSES Removal and Installation

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and

Sheet 4: General discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

Use the procedure below to remove and replace 600 amp, 500 amp, 300 amp, 250 amp and 80 amp fuses. See Table 3-1.

1. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 2. Remove the top cover. See Section 2-TOP COVER-REMOVAL. 3. Loosen the fasteners holding the fuse into place.

4. Remove the fuse and replace with the appropriately rated fuse.

5. Tighten the fasteners holding the fuse in place.

6. Install the top cover. See Section 2-TOP COVER- INSTALLATION. 7. Connect the battery.

Use the procedure below to remove and replace 5 amp and 15 amp fuses. See Table 3-1.

1. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 2. Remove the top cover. See Section 2-TOP COVER-RE MOVAL. 3. Using a fuse puller, remove the fuse from the holder.

4. Install a new fuse by aligning it with the fuse holder and pressing it into place.

5. Install the top cover. See Section 2-TOP COVER- INSTALLATION. 6. Connect the battery.

Table 3-1 - Fuses

Sheet 5: Control Handle Assembly CONTROL HANDLE ASSEMBLY

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

Removal 1. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 2. Remove the top cover. See Section 2-TOP COVER-RE MOVAL and CONTROL COVER-REMOVAL. 3. Loosen the four mounting screws on the system controller/operator display box and tilt it upward.

4. Disconnect the cable from the system controller at connector J8 (refer to decal), and free the cable from the wiring harness.

5. Remove the socket head screws and lockwashers securing the control handle to the frame and remove the control handle assembly.

Installation NOTE: Control handles for forward stance and side stance models are not mounted in the same location. On forward stance trucks, the control handle is mounted at the rightmost set of four holes.

1. Position the control handle assembly on the frame and secure in place with four screws and lockwashers.

2. Route the cable through the harness and connect it to J8 (refer to decal) at the system controller.

3. Install the top cover and control cover. See Section 2-TOP COVER-INSTALLATION and CONTROL COVER-INSTALLATION. 4. Connect the battery.

5. Calibrate the control handle. Refer to CALIBRATION MENU (CALIBRAT) .

CONTROL HANDLE POTENTIOMETER Removal 1. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 2. Remove the top cover. See Section 2-TOP COVER-RE MOVAL and CONTROL COVER-REMOVAL. 3. Grip the bottom of the control handle boot and roll it upward to access the dual axle mechanism. See Figure 3-4.

4. Remove the locknut on the collar of the potentiometer and remove the potentiometer from the mounting bracket.

5. Remove the clear silicone sealant from the back of the potentiometer. Using a low wattage pencil type soldering iron, remove the wires from the potentiometer.

6. Loosen the setscrew holding the potentiometer in the dual axle.

7. Remove the screw holding the bracket to the dual axle mechanism.

8. Remove the potentiometer assembly from the dual axle mechanism.

Installation 1. Place the mounting bracket over the collar of the potentiometer and secure with the locknut.

2. Using an ohmmeter set to the 2K ohm scale, measure the resistance between pin 1 and pin 3 of the

Sheet 5: Control Handle Assembly potentiometer. Divide the resistance value by 2.

3. Connect the ohmmeter (still on the 2K ohm scale) to pins 1 and 2 of the potentiometer. Turn the shaft of the potentiometer to adjust to potentiometer's resistance to the value calculated in Step 2.

4. Install the potentiometer and bracket onto the dual axle mechanism.

Figure 3-4 - Control Handle Potentiometers 1. DUAL AXLE MECHANISM 2. CONTROL HANDLE BOOT 3. BRACKET 4. WASHER 5. SCREW 6. TRAVEL POTENTIOMETER 7. LOCKNUT 8. SETSCREW 9. BRACKET 10. LIFT POTENTIOMETER 11. SCREW 12. WASHER 13. SETSCREW 5. Tighten the setscrew securing the shaft of the potentiometer in the dual axle.

6. Connect an ohmmeter between pin 1 and pin 3 on the potentiometer. With the control handle in the neutral position, verify the resistance reading has remained at the value set in Step 3.

7. If the resistance has changed, loosen the hex. nut securing the potentiometer to the mounting bracket and rotate the body of the potentiometer slightly while monitoring the resistance. Once the calculated value is reached, tighten the hex. nut.

8. Using a low wattage pencil type soldering iron, and an electronic grade solder, attach the wires to the pins of the potentiometer.

9. Allow the solder joints to cool before applying a clear silicone sealant over the connections on the back

Sheet 5: Control Handle Assembly of the potentiometer. Apply sufficient sealant to ensure adequate insulation between the wire harness and the potentiometer. Insert a temporary spacer between the wiring harness and the potentiometer while the silicone cures, to avoid the possibility of the wiring harness contacting the potentiometer before the silicone has cured.

10. When the silicone has cured, remove the temporary spacer and, if wire ties were removed, install new wire ties to the potentiometer brackets only.

11. Return the control handle boot to the normal operating position.

12. Install the top cover. See Section 2-TOP COVER- INSTALLATION and CONTROL COVER-INSTALLATION. 13. Connect the battery.

14. Calibrate the control handle. Refer to CALIBRATION MENU (CALIBRAT).

Figure 3-5 - Control Handle Potentiometer Wiring Schematic 1. LIFT (FIXED) POTENTIOMETER 2. +5V (BLACK) 3. TRAVEL (MOVEABLE) POTENTIOMETER 4. TRAVEL (WHITE) 5. BLACK (P10) 6. WHITE (P2) 7. BLACK (P1) 8. WHITE (P9) 9. GROUND (WHITE) 10. LIFT (BLACK)

Sheet 5: Control Handle Assembly

Figure 3-6 - Horn Button and Spring 1.

2.

3.

4.

5.

6.

7.

LOCKWASHER BEZEL ROCKER KEYPAD SWITCH HORN BUTTON HORN BUTTON SPRING BUTTON HEAD SCREW

HORN BUTTON Removal

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 2. Locate the horn button on the front of the control handle. See Figure 3-6.

3. Remove (2) button head bezel attaching screws from under the control handle.

4. Remove the bezel, rocker and keypad switch.

5. Lift out the horn button and spring.

Installation 1. Install the horn button and spring. See Figure 3-6.

2. Install the keypad switch, rocker and bezel.

3. Install and tighten the two button head screws to attach the bezel.

4. Connect the battery.

Sheet 5: Control Handle Assembly 5. Verify the operation of the horn.

SYSTEM CONTROLLER/OPERATOR DISPLAY ASSEMBLY

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

If the operator display intermittently flickers or in severe cases, the unit resets or completely shuts down, especially when the unit is under a near capacity load, the problem may be due to electrical noise being generated in the wiring harness. To remedy this problem, relocate the negative supply line to the system controller (wires B*, B*, 5 and 6) from the negative stud on the buss bar next to the right traction controller to the negative stud next to the lift controller. Proceed as follows: 1. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 2. Remove the nut securing the ring terminal containing wires 8A and 8B to the negative buss bar next to the lift controller and remove the ring terminal.

3. Remove the nut securing the ring terminal containing wires B*, B*, 5 and 6 to the negative buss bar next to the right traction controller and remove the ring terminal.

4. Install the ring terminal containing wires 8A and 8B on the stud next to the right traction controller.

5. Install the ring terminal containing wires B*, B*, 5 and 6 on the stud next to the lift controller.

Removal 1. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 2. Remove the top cover. Refer to TOP COVER-REMOVAL, Section 2.

3. Loosen the screws securing the operator display assembly to the mounting bracket. See Figure 3-7.

4. Rotate the top of the display assembly upward, until the connectors on the back of the assembly can be reached.

5. Disconnect the ten connectors from the back of the assembly.

6. Remove the assembly from the mounting bracket.

Installation 1. Line up the lower mounting screws with the slots in the mounting bracket (position the nylon shoulder washer inside the bracket and the two nylon flat washers outside the bracket) and tighten the two screws.

NOTE: The controller assembly must be isolated electrically from the frame of the truck. This is done at the controller mounting bracket.

CAUTION: Pay careful attention to assure the proper connector is attached to the proper plug. Severe damage to the electronic circuitry can occur if the connectors are not properly attached.

2. Attach the ten connectors to the back of the operator display assembly.

NOTE: As above, position the plastic washers correctly to isolate the controller assembly electrically from the frame.

3. Loosen the two lower mounting screws and rotate the operator display assembly down until the upper mounting screws are seated in the slots in the mounting bracket. Tighten the four mounting screws securely.

4. Remove the top cover. See Section 2-TOP COVER-REMOVAL.

Sheet 5: Control Handle Assembly 5. Connect the battery.

Figure 3-7 - Operator Display 1. KEY SWITCH 2. DISPLAY DECAL 3. DISPLAY COVER 4. SCREWS 5. OPERATOR DISPLAY 6. SYSTEM CONTROLLER 7. SOCKET HEAD SCREW 8. MOUNT BRACKET 9. NYLON FLAT WASHERS 10. NYLON SHOULDER WASHER 11. HEX. NUT 12. AUXILIARY SELECTOR AND LIGHT SWITCHES

OPERATOR DISPLAY BOARD Removal

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 2. Remove the system controller/operator display assembly. Refer to SYSTEM CONTROLLER/OPERATOR DISPLAY ASSEMBLY-REMOVAL. NOTE: When removing the plastic cover from the system controller/operator display assembly, be careful not to break the wires from the key switch and light or auxiliary selector switches, if so equipped.

3. Remove the Torx screws that attach the plastic cover and lift the cover from the system controller.

Sheet 5: Control Handle Assembly 4. Disconnect the wires from the key switch and light or auxiliary selector switches, if so equipped.

CAUTION: The operator display board and system controller are connected by a 32-pin connector.

Be careful not to damage the pins or connector when removing the operator display board. Refer to the proper procedures for handling static sensitive components.

5. Remove the four hex. nuts securing the operator display board to the standoffs on the system controller board.

6. Gently lift the operator display board off of the system controller.

Installation

CAUTION: The operator display board and system controller are connected by a 32-pin connector.

Be careful not to damage the pins or connector when removing the operator display board. Refer to the proper procedures for handling static sensitive components.

1. Line up the 32-pin connector on the operator display board with the mating connector on the system controller board.

2. Slide the operator display board onto the standoffs on the system controller and secure it with four hex. nuts.

3. Attach the wires to the key switch and light or auxiliary selector switches, if so equipped.

4. Install the plastic cover over the system controller/operator display assembly.

5. Install the system controller/operator display assembly Refer to SYSTEM CONTROLLER/OPERATOR DISPLAY- INSTALLATION.

BATTERY-STATE-OF-CHARGE INDICATOR The battery-state-of-charge indicator displays a pictorial representation of the percentage of charge remaining in the battery before lift cutout occurs. The indicator contains ten LEDs that separate the total state-of-charge before lift cut-out into increments of 10 %. The top five LEDs are green, the next three are yellow, and the bottom two are red. If the battery has a 70% charge, seven LEDs are lit-two green, three yellow, and two red. When the state-of-charge drops to less than 5%, the last illuminated red LED will begin to slowly flash. When the state-of-charge drops to less than 2%, the last illuminated red LED will flash quickly. All LEDs will be off when the state-of-charge reaches the lift cutout point.

Figure 3-8 - Operator Display

KEY SWITCH Removal

Sheet 5: Control Handle Assembly WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 2. Remove the operator display assembly. Refer to OPERATOR DISPLAY ASSEMBLY-REMOVAL. NOTE: When removing the top cover of the operator display assembly, avoid straining the wires connected to the switches that remain in the cover.

3. Remove the top cover of the operator display assembly and install the eight screws.

4. Disconnect the 5-pin connector to the key switch assembly at P7 on the system controller.

5. Remove the locknut and washer from the back of the key switch assembly.

6. Remove the key switch assembly from the front of the operator panel.

Installation 1. Install the key switch from the front of the operator display assembly.

NOTE: Verify the key switch is lined up properly before tightening the locknut. The key switch should be open when the key is lined up with the "O" indicator on the operator panel.

2. Install the washer and locknut on the key switch.

3. Tighten the locknut.

4. Connect the 5-pin connector to P7 on the system controller.

5. Install the top cover of the operator display assembly and install the eight screws.

6. Install the operator display assembly. Refer to OPERATOR DISPLAY ASSEMBLY-INSTALLATION. 7. Connect the battery.

AUXILIARY SELECTOR SWITCH AND LIGHT SWITCH Removal

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 2. Remove the operator display assembly. Refer OPERATOR DISPLAY ASSEMBLY-REMOVAL. NOTE: When removing the top cover of the operator display, avoid straining the wires connected to the switches that remain in the cover.

3. Remove the eight screws from the top cover of the operator display assembly.

4. Disconnect the three wires from the terminal on the switch.

5. From the back of the operator display cover release the switch retainers.

6. Remove the switch from the display cover.

Sheet 5: Control Handle Assembly Installation 1. From the front of the operator display cover, insert the switch into the opening.

2. Gently press the switch into the opening until the switch is fully seated and locked into place.

3. Connect the three wires to the terminals on the switch.

4. Replace the top cover on the operator display assembly and install the eight screws.

5. Install the operator display assembly. Refer to OPERA TOR DISPLAY ASSEMBLY-INSTALLATION. 6. Connect the battery.

HORN Removal

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 2. Remove the top cover. See Section 2-TOP COVER-RE MOVAL. 3. Locate the horn just inside the battery connector.

4. Disconnect the horn wires.

5. Remove the attaching screws and lift out the horn.

Installation 1. Align the replacement horn in the same position as the old horn.

2. Install the attaching two screws, washers and lockwashers.

3. Connect the wires.

4. Install the top cover. See Section 2-TOP COVER- INSTALLATION.

Sheet 6: Acceleration Control ACCELERATION CONTROL NOTE: Acceleration is controlled by traction (motor) controllers. The traction controllers (one for the right hand motor and one for the left) receive input from the travel potentiometer on the dual axle mechanism of the control handle assembly. The dual axle assembly also has the lift potentiometer mounted on it.

Controller Failure Checklist 1. Perform diagnostic output tests 17 and 18 and verify movement in both directions (if movement is present in both directions, the controller is probably not defective). Refer to PROGRAMMING AND DIAGNOSTICS (Page 3-38).

2. Verify that all fuses are in good condition.

3. Inspect the drive motor terminals for tightness.

4. Measure the resistance of drive motor field windings at cables F1 and F2 at each traction controller. If the resistance measures greater than 1.5 ohms or less than 0.9 ohms, disconnect the field cables from the motor terminals and measure across the terminals. If the reading is still out of range contact your factory service representative.

5. Verify there is no continuity between battery positive to chassis, and battery negative to chassis.

6. In the Program Menu, verify that the software version is greater than 2.02.

7. Verify the controller design. Note the serial number of the controller should have a suffix of -D, -DB, -DE, -DEC, -E, -EE, or -EEC. 8. Verify the encoder pulleys are secure to the shaft and that the belt tension is correct.

9. Inspect the diodes for opens or shorts.

10. Verify the static strap is intact and in good condition.

11. Check the steering potentiometer adjustment.

12. Check the brakes for clearance and drag.

13. Check for motor gearbox noise and resistance in output test 17 and 18.

14. Ensure the battery is charged.

TRACTION CONTROLLER Removal

CAUTION: Tampering with the traction controller may void the warranty.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 2. Remove the top cover. See Section 2-TOP COVER-RE MOVAL. 3. Disconnect plugs J1 and P2 on the top of the controller.

4. Remove the locknuts securing the negative bus bar to the B* terminals of the three (or two) controllers.

Sheet 6: Acceleration Control 5. Disconnect the FB* cable from the controller to be replaced.

6. Disconnect the two field coil leads (F1 and F2) from the front of the controller.

7. Disconnect the bus bar and the cable from the A2 terminal of the controller and the diode module.

8. Remove the screws, lockwashers, and flat washers securing the controller assembly to the frame of the truck and remove the controller.

Installation 1. Apply an even film of heat sink compound to the bottom of the controller before installation.

2. Position the controller in the truck and align the mounting holes in the controller base with the holes in the truck frame. Install the mounting screws, lockwashers and flat washers.

3. Install the FB* lead from the fuse FS6 (80 amp) to the FB* terminal on the rear of the controller.

4. Attach the negative bus bar to the B* terminals on the rear of all of the controllers.

5. Attach the motor A2 cable and small bus bar between the A2 terminal and the diode module.

6. Connect the field leads from the motor to the proper terminals on the controller.

7. Connect plugs J1 and P2 to the connectors on the top of the controller.

8. Install the top cover. See Section 2-TOP COVER- INSTALLATION. 9. Connect the battery.

10. Test the truck for proper operation.

LIFT CONTROLLER Removal

CAUTION: Tampering with the lift controller may void the warranty.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 2. Remove the top cover and control cover. See Section 2-TOP COVER and CONTROL COVER-REMOVAL. 3. Disconnect plugs J1 and P2 on the side of the controller.

4. Remove the locknuts securing the negative bus bar to the B* terminals of the three (or two) controllers.

5. Disconnect the FB* cable from the controller to be replaced.

6. Disconnect the two cables (SA1 and SA2) from the F1 and F2 terminals at the front of the controller.

7. Disconnect the bus bar from the A2 terminal of the controller and the diode module.

8. Remove the six screws, lockwashers, and flat washers securing the controller to the frame of the truck.

Installation

Sheet 6: Acceleration Control 1. Apply an even film of heat sink compound to the bottom of the controller before installation.

2. Position the controller in the truck and align the mounting holes in the controller base with the holes in the truck frame. Install the mounting screws, lockwashers and flat washers.

3. Install the FB* lead from the fuse FS3 (80 amp) to the FB* terminal on the rear of the controller.

4. Attach the negative bus bar to the B* terminals on the rear of all of the controllers.

5. Attach the small bus bar between the A2 terminal and the diode module.

6. Connect SA1 to the F1 terminal, and SA2 to the F2 terminal of the controller.

7. Connect plugs J1 and P2 to the connectors on the side of the controller.

8. Install the control cover and top cover. See Section 2-CONTROL COVER-INSTALLATION and TOP COVER- INSTALLATION. 9. Connect the battery.

10. Test the truck for proper operation.

BRAKE SWITCH Removal

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Disconnect the battery and discharge the capacitors. Refer to the CAPACITOR DISCHARGE PROCEDURE. 2. Remove the top cover and the control cover. See Section 2-TOP COVER-REMOVAOL and CONTROL COVER-REMOVAL. 3. Locate the brake actuator assembly to the left of the operator compartment.

4. Disconnect the wiring from the switch.

5. Remove the two limit switch mount retaining screws, lockwashers and washers. See Figure 3-9.

6. Lift the limit switch mount from the brake mount plate and remove the two machine screws holding the brake limit switch onto the limit switch mount. See Figure 3-9.

Installation 1. Install the switch onto the limit switch mount with the two machine screws. See Figure 3-9. Do not tighten the screws at this time.

2. Connect the wires from the switch to the truck wiring harness.

3. Install the limit switch mount onto the brake mount plate, using the two hex. head screws.

4. With the brake pedal released, move the brake switch toward the brake lever arm until it actuates. Tighten the two machine screws at this time.

5. Slowly press the brake pedal while watching the brake lever arm. The brake switch must deactuate after the pedal moves about one inch. Adjust as needed. Refer to BRAKE SWITCH-ADJUSTMENT. 6. Replace the control cover and the top cover. See Section 2-CONTROL COVER-INSTALLATION and TOP COVER- INSTALLATION. 7. Connect the battery.

Sheet 6: Acceleration Control 8. Test the brake operation of the lift truck.

Adjustment

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 2. Remove the top cover and control cover See Section 2-TOP COVER-REMOVAL and CONTROL COVER-REMOVAL. 3. With the brake pedal released, loosen the machine screws securing the brake limit switch to the limit switch mount.

4. Move the brake limit switch toward the brake lever arm until it actuates. Tighten the screws securing the switch, while holding it in the actuated position.

5. Slowly press the brake pedal while watching the brake lever arm. The brake switch must deacuate after the pedal moves about one inch. Adjust as needed.

6. Replace the control cover and the top cover. See Section 2-CONTROL COVER-INSTALLATION and TOP COVER- INSTALLATION. 7. Connect the battery.

8. Test the brake operation of the lift truck.

Sheet 6: Acceleration Control

Figure 3-9 - Brake Limit Switch 1. SEE DETAIL BELOW 2. LOCKWASHER 3. HEX. HEAD SCREW 4. LOCKWASHER 5. WASHER 6. BRAKE MOUNT PLATE 7. BRAKE LEVER ARM 8. MACHINE SCREWS 9. LIMIT SWITCH MOUNT 10. BRAKE LIMIT SWITCH 11. HEX. NUT

STEER POSITION POTENTIOMETER Removal

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE.

Sheet 6: Acceleration Control 2. Remove the top cover and control cover. See Section 2-TOP COVER-REMOVAL and CONTROL COVER-REMOVAL. 3. Locate the steering above the steer motor next to the operator area of the truck.

4. Disconnect the 3-pin connector between the steering potentiometer and the truck wiring harness.

5. Loosen the setscrew securing the flexible coupler to the steer position potentiometer shaft. See Figure 3-10.

6. Remove the two hex. head screws holding the potentiometer mounting bracket to the hydraulic motor mounting bracket (upper plate).

7. Remove the jam nut and lift the steer position potentiometer from its bracket.

Installation 1. Install the steer position potentiometer on the steering potentiometer mounting bracket and tighten the jam nut. See Figure 3-10.

2. Slide the flexible coupler over the steer position potentiometer shaft and tighten the setscrew.

3. Install the steer position potentiometer mounting bracket on the hydraulic motor bracket using the two hex. head screws, two flat washers and four interlocking fasteners.

4. Connect the 3-pin connector from the potentiometer to the truck wiring harness.

5. Install the steering tiller using the hex. socket head shoulder bolt.

6. Connect the battery.

7. Perform the steer position potentiometer voltage adjustment. Refer to STEER POSITION POTENTIOMETER-ADJUSTMENT. 8. Disconnect the battery.

9. Remove the hex. socket head shoulder bolt and the steering tiller.

10. Install the control and top cover. See Section 2-CON TROL COVER-INSTALLATION and TOP COVER-INSTAL LATION. 11. Connect the battery.

Adjustment 1. Manually center the steering tire in the straight forward position.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

2. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 3. Remove the top cover. See Section 2-TOP COVER-REMOVAL. 4. Loosen the setscrew securing the potentiometer coupling to the steering fork shaft.

5. Using the 2K ohm scale of a digital multimeter, attach the leads to pin A and pin C of the female end of the 3-pin connector. Note the reading obtained.

6. The center value for the potentiometer is half of the value found in Step 7.

7. Connect the digital multimeter to pin A and pin B of the female end of the 3-pin connector.

8. Manually adjust the potentiometer until the value calculated in Step 8 is displayed on the meter.

Sheet 6: Acceleration Control 9. Tighten the setscrew on the potentiometer coupling.

10. Connect the battery.

11. Turn the truck on and enter the high-level password.

12. Enter the CALIBRAT subroutine and select STEERPOT prompt.

13. Follow the display prompts to calibrate the steer position potentiometer. Refer to STEERING POTENTIOMETER-CALIBRATION. 14. Install the top cover. See Section 2-TOP COVER- INSTALLATION.

MAIN POWER CONTACTOR Removal

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 2. Remove the top cover. See Section 2-TOP COVER-REMOVAL. 3. Disconnect the B* and capacitor supply cables from the terminal of the main power contactor (the terminal toward the front of the truck).

4. Disconnect the power cables from the fuses FS3, FS4, FS5, and FS6.

5. Disconnect the wiring from FS1 and FS2.

6. Remove the screws securing the panel to the frame of the truck.

7. Disconnect the two wires from the coil of the contactor.

8. Disconnect the bus bar between the contactor and FS5.

9. Remove the screws securing the contactor to the bracket and remove the contactor.

Sheet 6: Acceleration Control

Figure 3-10 - Steer Position Potentiometer 1. GEAR BOX 2. JAM NUT 3. FLEXIBLE COUPLING 4. FASTENER 5. WASHER 6. UPPER PLATE 7. HYDRAULIC MOTOR 8. HEX. SOCKET HEAD SHOULDER BOLT 9. STEERING TILLER 10. SCREW 11. STEERING POTENTIOMETER 12. MOUNT BRACKET 13. JAM NUT 14. STEER AXLE INSERT 15. BUSHING 16. SPUR GEAR Installation 1. Align the mounting holes of the contactor with the holes in the panel and install the screws.

2. Attach the wires to the coil of the contactor.

3. Attach the bus bar between the contactor and FS5.

4. Mount the contactor fuse panel assembly to the frame.

NOTE: For ease of cable installation, attach the wires to the bottom fuses first.

5. Install the electrical cables on fuses FS3, FS4, FS5, and FS6.

6. Install the wires on fuses FS1 and FS2.

7. Install the B* and capacitor bank supply cables to the contactor.

8. Install the top cover. See Section 2-TOP COVER- INSTALLATION.

Sheet 6: Acceleration Control 9. Connect the battery.

10. Check the truck for proper operation.

CONTACTOR TIPS Removal

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 2. Remove the top cover. See Section 2-TOP COVER-REMOVAL. 3. Tag and remove the cables and wires from the bus bars of the contactor.

4. Remove the nylon locknuts securing the upper contactor tips in place.

5. Remove the insulators and springs from the armature. Remove the contactor tips.

6. Remove the locknuts securing the insulator block to the contactor body. Remove the insulator and bus bars.

Installation 1. Install the bus bars on the insulating base. Be sure the holes in the bus bars engage the locators on the insulating base.

2. Install the insulator on the bus bars and secure with locknuts.

3. Install the upper tips over the insulators attached to the armature.

4. Install the springs and insulating washers and secure with locknuts.

NOTE: Use caution when tightening the nuts securing the cables and wires to the bus bars to avoid causing the bus bars to bend, misalignment of the contactor tips and over heating.

5. Install the B* and capacitor bank supply cables to the bus bar closest to the front of the truck.

6. Install the bus bar between the contactor terminal and FS5.

7. Install the top cover. See Section 2-TOP COVER- INSTALLATION. 8. Connect the battery. Check the truck for proper operation.

BATTERY DISCONNECT LEVER

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

Removal 1. Disconnect the battery and discharge the capacitors. Refer to CAPACITOR DISCHARGE PROCEDURE. 2. Remove the top cover. See Section 2-TOP COVER-REMOVAL. 3. Disconnect the return spring from the handle.

Sheet 6: Acceleration Control 4. Remove the retaining ring and flat washer from the shaft.

5. Remove the battery disconnect lever.

Installation NOTE: When replacing the battery disconnect lever, ensure that the flange side of the bushing is toward the frame.

1. Slide the battery disconnect lever over the shaft.

2. Install the flat washer and the retaining ring.

3. Connect the return spring.

4. Install the top cover. See Section 2-TOP COVER- INSTALLATION. 5. Connect the battery.

Figure 3-11 - Battery Disconnect Lever 1. BATTERY DISCONNECT LEVER ASSEMBLY 2. LEVER 3. EMERGENCY KNOB 4. BRONZE BUSHING 5. MACHINE BUSHING 6. SNAP RING 7. SPRING 8. CAPSCREW 9. FLAT WASHER 10. HEX. STANDOFF 11. LOCKWASHER 12. CAPSCREW 13. MACHINE SCREW 14. LOCKNUT

Sheet 6: Acceleration Control 15. BATTERY CONNECTOR

Sheet 8: Test for a Damaged Field and Armature TESTS FOR A 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.

Test for an Open-Circuit in the Armature The armature windings in large electric motors normally have less than one ohm of resistance. The two commutator bars for a winding are found 180* apart on the commutator. If an ohmmeter (R*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.

Test for a 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. Special equipment is necessary 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.

Sheet 8: Test for a Damaged Field and Armature

Figure 3-26 - Stoning the Commutator 1.

2.

3.

4.

RAISE DRIVE WHEELS JUMPER BATTERY BRUSH SEATER STONE

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 persons that have the special equipment required. Connect the battery so that the motor can be operated. Use a jumper cable if necessary to connect the battery to the lift truck. Raise the drive wheels. See "How to Raise the Drive Wheels" in the OPERATOR'S MANUAL. 2. Close the seat switch and key switch so that the motor will operate.

Sheet 8: Test for a Damaged Field and Armature 3. Operate the motor so that the commutator rotates slowly. 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.

Do not permit the brush seater stone to stay in contact with the commutator too long and cause more wear than necessary.

4. 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 stoning procedure normally requires approximately 15 to 45 minutes.

5. When the brushes have the correct contact surface with the commutator, use a vacuum cleaner to remove the abrasive dust from the commutator area and the motor.

6. 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.

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

Figure 3-27 - Test for an Armature Short-circuit 1. ARMATURE SHAFT 2. COMMUTATOR 3. PROBES TO OHMMETER

Test for a Short-Circuit in the Armature An 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 3-27. 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.

Test for an Open-Circuit in a Field Coil The field windings in large electric motors normally have less than one ohm of resistance. If an ohmmeter (R*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 3-28.

Test for a 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. Special equipment is necessary to check for a short-circuit in a motor winding. A motor with a short-circuit in a field 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.

Sheet 8: Test for a Damaged Field and Armature

Figure 3-28 - Test for an Open Field Circuit 1. FIELD COIL TERMINAL 2. OHMMETER 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.

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

Brush Holder Test Make sure the carbon dust has been removed from the brush holders. Use an ohmmeter (R*10,000 scale) to measure the resistance between the brush holder and the motor case. The correct resistance is an indication of infinity ( ).

PROGRAMMING AND DIAGNOSTICS INTRODUCTION Information pertaining to the operator interface (from pre-operational information to operational modes), calibration of control input hardware, configuration of the performance characteristics to suit individual operators/applications, and diagnostic testing is detailed in the following paragraphs.

PRE-OPERATION INFORMATION When the key switch is rotated from the "O" position to the "I" position, power is applied to the controllers. After performing internal checks, the following menu is available to the user:

Sheet 8: Test for a Damaged Field and Armature

Figure 3-29 - Initial Menu Move up or down through the menu by pressing tilt forward or tilt back on the Tilt/Sideshift disk.

BSOC XX% is the battery-state-of-charge.

WARRANTY, DRIVE, LIFT, and STEER, display the total operational hours of the respective systems.

PERFDIAG: To enter the Performance and Diagnostics menu, press sideshift right when PERFDIAG appears in the display. A password is required to access the Performance and Diagnostics menu (see below).

PASSWORD ENTRY When in password entry mode, pressing tilt forward and tilt back on the Tilt/Sideshift disk will scroll through the alphanumeric characters available. Pressing sideshift right and sideshift left on the Tilt/Sideshift disk will move the cursor position right or left. When the entire password is displayed, pressing the horn button will accept it.

PERFORMANCE AND DIAGNOSTICS MENU The Performance and Diagnostics menu consists of three submenus; CALIBRAT (calibration of control input functions), PROGRAM (performance configuration), and DIAGNSTC (diagnostic input and output tests).

To enter the Performance and Diagnostics Menu, the user must enter a password. If the password is a low-level password, the user has access only to the PROGRAM menu. Certain settings will not be available when the PROGRAM menu is entered with a low-level password. If the password is a high-level password, the entire Performance and Diagnostics menu is available.

MENU CONVENTIONS The Tilt/Sideshift disk on the control handle is used to scroll through the menu structure. To scroll up or down through the menu, press tilt forward or tilt back, respective. To view or change selection settings, press sideshift right. Press the horn button to make a selection and go back to the menu or press sideshift left to leave a selection unchanged.

CALIBRATION MENU (CALIBRAT) The Calibration menu is available only if the Performance and Diagnostics menu is entered with a high-level password. This menu is used to calibrate the travel and lift/lower potentiometers, steer position potentiometer, and the weight and center of gravity transducers (if so equipped).

Sheet 8: Test for a Damaged Field and Armature

Figure 3-30 - Calibration Menu

Sheet 8: Test for a Damaged Field and Armature

Figure 3-31 - Performance and Diagnostic Menu Traction Calibration To adjust the travel potentiometer in the control handle, refer to CONTROL HANDLE POTENTIOMETER-INSTALLATION. To calibrate the travel function: 1. From the main menu, select the PERFDIAG option and enter a high-level password.

2. Select the CALIBRAT option.

Sheet 8: Test for a Damaged Field and Armature 3. From the CALIBRAT menu, select TRACTION. A voltage reading will be displayed.

4. Move the control handle forward until it reaches the stop. Press the horn button to accept the reading (the display will flash if it is accepted).

5. Return the control handle to the neutral position and press the horn button to accept this reading (the display will flash if the reading is accepted).

6. Pull the control handle toward the rear until it reaches the stop. Press the horn button to accept the reading. The display will read "CALIBRATION SUCCESSFUL".

7. Return the control handle to the neutral position and return to the main menu.

Lift Calibration To adjust the lift potentiometer in the control handle, refer to CONTROL HANDLE POTENTIOMETER-INSTALLATION. To calibrate the lift function: 1. From the main menu, select the PERFDIAG option and enter a high-level password.

2. Select the CALIBRAT option.

3. From the CALIBRAT menu, select LIFT. A voltage reading will be displayed.

4. Move the control handle right until it reaches the stop. Press the horn button to accept the reading (the display will flash if it is accepted).

5. Return the control handle to the neutral position and press the horn button to accept this reading (the display will flash if it is accepted).

6. Move the control handle toward the left until it reaches the stop. Press the horn button to accept the reading. The display reads "CALIBRATION SUCCESSFUL".

7. Return the control handle to the neutral position and return to the main menu.

Steer Position Potentiometer Calibration To adjust the steer position potentiometer, refer to STEER POSITION POTENTIOMETER-ADJUSTMENT. To calibrate the steer position indicator: 1. From the main menu, select the PERFDIAG option and enter a high-level password.

2. Select the CALIBRAT option.

3. From the CALIBRAT menu, select STEERPOT. A voltage reading will be displayed.

4. Rotate the steering tiller in the direction which increases the voltage reading on the display.

5. When the steering tiller stops rotating, press the horn button to accept the voltage reading (the display will flash if the reading is accepted).

6. Rotate the steering tiller in the opposite direction, decreasing the voltage reading. When the steering tiller stops rotating, press the horn button to accept the reading (the display will flash if it is accepted).

7. Rotate the steering tiller until the steer wheel(s) are centered and press the horn button. The display will read "CALIBRATION SUCCESSFUL".

8. Return to the main menu.

Weight Transducer Calibration To calibrate the weight indication: 1. From the main menu, select the PERFDIAG option and enter a high-level password.

2. Select the CALIBRAT option.

Sheet 8: Test for a Damaged Field and Armature 3. From the CALIBRAT menu, select WTXDCR. A voltage reading will be displayed.

4. With no load, lift the forks off the ground but do not lift the second stage of the mast.

5. Wait for about 1 to 2 seconds for the forks to settle. Press the horn button to accept the voltage reading (the display will flash if it is accepted).

6. Lift the forks up until the second stage of the mast is engaged. Let the forks settle for 1 to 2 seconds.

7. Press the horn button to accept the voltage reading.

8. Lower the forks to the floor and press the horn button. The display will read "CALIBRATION SUCCESSFUL".

Figure 3-32 - Program Menu

Sheet 8: Test for a Damaged Field and Armature PROGRAM MENU The Program menu is available when the Performance and Diagnostics menu is entered with either a low-level or a high-level password. However, certain selections are not available when the Performance and Diagnostics menu is entered with a low-level password.

The Program menu is used to configure the performance of the lift truck to suit the operator or application. Scroll through the menu as described under MENU CONVENTIONS. When sideshift right is pressed, the current setting for the selection will be displayed. To change the setting, press tilt forward or tilt back. To save the new setting and return to the Program menu, press the horn button. To return to the Program menu without changing the setting, press sideshift left.

FWDSPEED & REVSPEED (3.0-7.0 MPH, DEFAULT=7) These selections allow the user to independently set the maximum forward and reverse speeds of the truck in increments of one-tenth MPH. DRIVEA/D (HARD, MEDIUM*, SOFT) The DRIVEA/D selection allows the user to set the acceleration and deceleration (plugging) characteristics of the truck.

LIFTA/D (HARD, MEDIUM*, SOFT) The LIFTA/D selection allows the user to set the acceleration characteristic of the lift system.

COASTDEC (SHORT, MEDIUM*, LONG, OFF) The COASTDEC selection allows the user to set the distance that the truck will coast when the control handle is released to the neutral position. When set to OFF, the lift truck will free-wheel when the control handle is in neutral, and Position Hold (RAMP HOLD) is disabled.

TILT SPD (FAST, MEDIUM*, SLOW) The TILT SPD selection allows the user to set the speed of the tilt function.

SIDESHFT (FAST, MEDIUM*, SLOW) The SIDESHFT selection will only appear in the PROGRAM menu if the truck is equipped with a first auxiliary (normally sideshift) option. The SIDESHFT selection allows the user to set the speed of the first auxiliary function.

AUX-SPD (FAST, MEDIUM*, SLOW) POSHOLD (DISABLE, ENABLE*) The AUX-SPD selection will only appear in the PROGRAM menu if the truck is equipped with a second or second and third auxiliary function. The AUX SPD selection allows the user to set the speed of the second (and third) auxiliary function(s). The POSHOLD selection is effective only when the upper auxiliary button on the control handle is engaged. When POSHOLD is set to DISABLE, and the upper auxiliary button is pushed (Aux direction A), the ramp hold is disabled and the truck can roll. The POSHOLD selection should only be set to DISABLE when operating a push-pull attachment.

STEEROFF (5-20 SEC OR ONDEMAND*, DEFAULT=ONDEMAND) The STEEROFF selection allows the user to set the time delay before the steer pump shuts off after the brake pedal is released. When set to ONDEMAND, the steer pump will activate when the control handle is moved forward or backward, and will remain on for 5 seconds after no movement of the control handle is detected.

Sheet 8: Test for a Damaged Field and Armature LANGUAGE (ENGLISH, ESPANOL, FRENCH, DEUTSCH) The LANGUAGE selection will only appear in the PROGRAM menu if the option is enabled. This selection allows the user to change the language in which the display presents information. (At the time of printing the only options offered are ENGLISH and ESPANOL).

UNITS (English*, Metric) The UNITS selection allows the user to set the display to show values in English or Metric units.

SPEEDLIM (0-100%, DEFAULT=50) This selection allows the user to set the speed limit when the controller detects a fault which restricts, but does not shut down traction. The maximum speed is reduced in both forward and reverse directions by the percentage SPEEDLIM is set to.

CAPLIMIT (50% MAX WT-MAX WT, DEFAULT=MAX WT) This selection allows the user to set the speed limit when the controller detects a fault which restricts, but does not shut down traction. The capacity limit is set in pounds from 50% of the truck's maximum capacity to the maximum capacity.

LCUTOUT (10-30%, Default=20%) This selection allows the user to set the minimum battery state-of-charge before lift functions are disabled.

IDLETIME (5-60 MIN or OFF, DEFAULT=15) The IDLETIME selection allows the user to set the time delay before the truck resets to the pre-operational mode (BSOC XX% displayed) after the truck has been idle. When set to OFF, the truck will not reset.

LIFTINT-BRK/LIFT, REV/LIFT, BYPASS (DISABLE, ENABLE) The BRK/LIFT selection allows the user to set the lift system to operate only when the brake pedal is depressed (ENABLE), or independent of the brake pedal (DISABLE). The REV/LIFT selection allows the user to set the lift system to shut down when the truck is traveling in reverse (ENABLE), or independent of the brake pedal (DISABLE).

The BYPASS selection, when set to ENABLE, allows the user to lift beyond the lift height restriction by holding the horn button and lifting when the restriction is reached. When BYPASS is set to Disable, it acts as a lift/travel interlock; when the mast is at or above the limit switch, the truck's maximum speed is the LIMITSPD setting.

BALARM-DIRCTION (REVERSE, FORWARD, OFF*,BOTH) DURATION (LONG, MEDIUM, SHORT) The BALARM selection will only appear in the PROGRAM menu if the truck is equipped with the backup alarm. The DIRCTION selection allows the user to set the backup alarm to operate when the lift truck is traveling forward, reverse, both or not at all. The DURATION selection allows the user to set the length of the backup alarm tone.

SHCKSENS-THRESHLD (2-12G or OFF, DEFAULT*4) (Shock Sensor) selection will only appear in the PROGRAM menu if the lift truck is equipped with a shock sensor.

The SHCKSENS sensor allows the user to set the G-force necessary to trigger the impact alarm and reset it once it has been triggered.

PMI-TRACTION, LIFT, STEER (100-400 HRS, DEFAULT*350) The PMI (Periodic Maintenance Interval) selection allows the user to set the time interval between service reminders

Sheet 8: Test for a Damaged Field and Armature for the traction, lift, and steer systems. This selection is only available when the PROGRAM menu is accessed with a high-level password. The user can reset only the triggered PMI reminder or all of the PMI reminders.

PASSWORD-HIGH LVL, LOW LVL, ELEC KEY The PASSWORD selection allows the user to change the passwords required for menu access as well as the electronic key password. Only the LOW LVL selection is available when the PROGRAM menu is accessed with a low-level password.

INFO-SERIAL NO, MAST, SOFT VER The INFO selection displays information about the System Controller software. The SERIAL NO selection displays the last four digits of the lift truck serial number for which the System Controller was programmed. The MAST selection displays the type of mast for which the System Controller was programmed. (SIMPLEX, DUPLEX, TRIPLEX, OUAD, CASQUAD). The SOFT VER selection displays the software version of the System Controller program.

DEFAULT (RESET Y) The DEFAULT selection allows the user to return all selections to the default settings. Default settings are listed or indicated by an asterisk (*).

Figure 3-33 - Diagnostic Menu

DIAGNOSTIC MENU (DIAGNSTC) The Diagnostic menu is available only if the Performance and Diagnostics menu is entered with a high-level password. Refer to the Diagnostic Input Tests and the Diagnostic Output Tests on the following pages.

DIAGNOSTIC INPUT TESTS

Sheet 8: Test for a Damaged Field and Armature

DIAGNOSTIC OUTPUT TESTS

WARNING: Jack the truck and block the wheels before performing any Diagnostic Output tests. See Section 1-HOW TO PUT A LIFT TRUCK ON BLOCKS.

Sheet 8: Test for a Damaged Field and Armature

Sheet 9: Operational Feedback Devices OPERATIONAL FEEDBACK DEVICES The operator's display provides visual feedback on all functions of the truck. It consists of an eight-digit dot matrix display and several LED indicator symbols.

Dot Matrix Display The display is a bank of eight 5*7 dot matrix LEDs. The display is used to show the Battery-State-of-Charge, hours on warranty, drive, lift, and steer, menus, load weight and center of gravity, travel speed, and error messages.

Messages which are longer than eight characters scroll from right to left across the display.

Battery-State-of-Charge Indicator with Lift Interrupt The Battery-State-of-Charge indicator contains ten LEDs; five green, three yellow and two red. The number of LEDs lit indicates the amount of charge remaining before lift cutout occurs. When the last LED starts to slowly flash, the battery has less than 5% charge remaining before lift cutout. When this changes to a faster flash, less than 2% remains. When lift cutout occurs, all LEDs are off, and the dot matrix display scrolls an error message. The lift system, except lower is disabled.

Wheel Position Indicator The Wheel Position indicator contains seven LEDs arranged in a semi-circle which light to indicate the position of the steer wheel(s).

Speed Indicator The Speed Indicator consists of ten LEDs arranged to give a ramping effect. Each LED represents a 10% increment in speed, from zero to the programmed maximum in both forward and reverse directions. For example, if the maximum forward speed is 7.0 mph, and the truck is traveling forward at 4.9 mph, seven LEDs will be lit. If the maximum reverse speed is 3.0 mph and the truck is traveling in reverse at 3.0 mph, all ten LEDs will be lit. When the truck is stationary, no LEDs are lit. Speed is also indicated in the dot matrix display whenever the truck is traveling over 1.0 mph.

Overweight Alert Icon The Overweight icon informs the operator when the lift and traction functions are disabled due to the weight on the forks exceeding the specified limit of the truck. When the indicator is lit, the dot matrix display will scroll an error message. If the alarm was caused by an overweight condition, the lift system, except lower, and traction system are shut down until the condition is cleared.

Sheet 9: Operational Feedback Devices Lift Limit Alert Icon (Optional) The Lift Limit Alert icon informs the operator when the load has reached the height restriction. The icon will light and the dot matrix display will scroll an error message. Lift is disabled until the lift limit override (if so equipped) is activated.

Over-Temperature Alert Icon The Over-Temperature Alert icon warns the operator of a high-temperature condition on the motors or on the amplifiers controlling the motors. If a component becomes HOT, the icon is lit, and the dot matrix display will scroll an error message indicating which component is affected. If the temperature of the component continues to rise to a level where it could damage the equipment, the icon remains lit, and the dot matrix display scrolls an error message indicating the system that OVERHEATED. If the lift motor or lift amplifier is OVERHEATED, the lift system, except lower, is shut down. If either traction motor or amplifier is OVERHEATED, the traction system is shut down.

Service Alert Icon The Service Alert icon informs the operator of either a fault detected in the truck, or (if the truck is equipped with the Periodic Maintenance Interval reminder, see PROGRAM MENU in this section) when a system should be serviced due to hours of use. Some faults may cause systems to be derated or shut down. If the Service Alert icon is lit, the dot matrix display will scroll the fault code and description, or the system which is due for periodic maintenance. System fault codes are listed. If the icon is lit due to a Periodic Maintenance Interval, it can be turned off with the RESETPMI selection in the PROGRAM menu.

OPERATIONAL MODES Power-On Self Test (POST) When the key switch is rotated to the "II" position and released, the dot matrix display will show eight underscores (_) for the Electronic Key password. When the password has been entered, the Power-On Self Test begins and the display reads POST. When all tests are complete, and no failures have occurred, the message PASSED is shown in the dot matrix display. If any of the tests fail, a message indicating the specific error will be scrolled through the display. If there is more than one error, the user can scroll through the errors by pressing tilt forward or tilt back on the Tilt/Sideshift disk.

Run Mode When the POST is passed, the truck is in RUN mode. The display will indicate the weight on the forks (weight and center of gravity on trucks equipped with CG transducer), when the truck is stationary or moving at less than 1 mph.

The display switches to speed when the truck is moving at 1 mph or greater.

Restricted Mode The truck will enter a restricted operational mode when the controller detects a situation where potential damage could occur to a component. If the fault is one which affects travel, speed will be restricted to the SPEEDLIM setting (refer to PROGRAM MENU). If the lift system is the source of the fault, the lifting speed will be reduced by approximately 12%. The dot matrix display will scroll an error message identifying the fault. When the fault which caused the restriction is eliminated, the truck returns to Run mode. If the problem gets worse, the truck will enter Shutdown mode (see below). Refer to SYSTEM FAULT CODES/TROUBLESHOOTING.

Sheet 9: Operational Feedback Devices

Figure 3-34 - Power-on Self Test Shutdown Mode When certain faults occur, the truck will shut down the function until the fault is repaired. Either the lift system or the travel system may be shut down independently, or the shutdown may be total. In some cases, when the lift system is shut down, lowering is still available. The dot matrix display will scroll the error message identifying the fault. Refer to SYSTEM FAULT CODES/TROUBLESHOOTING. WARNING MESSAGES/TROUBLESHOOTING

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

SYSTEM FAULT CODES/TROUBLESHOOTING

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Figure 3-35 - Wiring Diagram - ESC 030 ZA, ESC 035 ZA, ESC 040 ZA, ESC 050 ZA

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Figure 3-36 - Schematic - ESC 030 ZA, ESC 035 ZA, ESC 040 ZA, ESC 050 ZA ELECTRICAL SYSTEM LEGEND

Sheet 9: Operational Feedback Devices

Sheet 9: Operational Feedback Devices

Figure 3-37 - Wiring Diagram - ESC 030 ZA, ESC 035 ZA, ESC 040 ZA, ESC 050 ZA

Sheet 10: Drive Unit Assembly

DRIVE UNIT ASSEMBLY DESCRIPTION The ESC 030-050 ZA lift trucks are equipped with dual independent drive trains. Each drive train consists of a drive unit (drive motor and gearbox) and a drive wheel. See Figure 4-1. Traction drive is transmitted from the drive motor to the gearbox through a pinion gear that is enclosed in the gearbox. From the gearbox, the traction drive is transmitted to the drive wheel by a pinion gear on the output end of the gearbox which meshes with a ring gear mounted on the inside of the drive wheel. The drive wheel rotates on a spindle attached to the frame of the truck.

Each drive train is independently controlled by its own traction amplifier. This allows the truck to monitor and control the power output from each of the drive units, improving the maneuverability of the truck in tight areas. Motor speed is constantly monitored. On tight turns, the inside drive motor decreases speed to improve the turning radius. The system controller does not allow stalling of the motors. In addition, each drive motor is equipped with a disc-type brake for positive stopping. Normal braking is accomplished through "plugging" of the motors.

NOTE: Specialized tools, fixtures and training are required to service any part of the drive unit assembly.

DRIVE UNIT REPAIRS Removal

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 2. Remove the mast. See Section 8-MAST-REMOVAL. 3. Put the truck on blocks or stands. See Section 1-HOW TO PUT THE LIFT TRUCK ON BLOCKS. Put the blocks or stands under the frame so the drive wheels are completely off the ground.

4. Remove the front cover. See Section 2-FRONT COVER-REMOVAL.

CAUTION: Disposal of lubricants and fluids must meet local environmental regulations.

5. Drain the oil from the gearbox. Refer to GEARBOX OIL CHANGE. 6. Remove the encoder assembly. Refer to ENCODER ASSEMBLY-REMOVAL.

CAUTION: When removing the brake hose from the disc brake unit, do not allow brake fluid to drip into the drive motor.

7. Disconnect the brake line from the disc brake unit.

8. Disconnect the 3-pin connector and four power cables from the motor, noting their location for correct installation.

WARNING: The drive unit is heavy. Ensure the lifting device has adequate capacity to handle the weight of the drive unit. The drive unit with the brakes installed can weigh approximately 74 kg (163lbs).

9. Remove the drive unit. a. Attach a lifting device to the drive unit for support.

Sheet 10: Drive Unit Assembly b. Remove the slack from the lifting mechanism.

NOTE: There are four capscrews securing the drive unit to the frame. Three are 38 mm (1-1/2 in) long and one is 31.5 mm (1-1/4 in) long. Note the location of the one short capscrew for correct installation. c.

Remove the four socket head capscrews with lockwashers securing the drive unit to the frame.

d. Move the drive unit toward the center of the truck, being careful not to damage the hydraulic connection block in the center of the frame. e. Rotate the drive unit to clear the pinion gear from the frame of the truck. Use caution when rotating the drive unit to prevent the pinion gear from contacting the frame of the truck. f.

Remove the drive unit from the truck.

10. Place the drive unit on a clean, secure work surface.

Installation 1. Install the drive unit into the truck.

CAUTION: The drive unit is heavy. Ensure the lifting device has adequate capacity to handle the weight of the drive unit. a. Connect a lifting device to the drive unit. b. Lift the drive unit into position in front of the truck. c.

Carefully rotate the gearbox so the pinion gear enters the opening in the frame.

d. Rotate the drive wheel to engage the pinion teeth with the ring gear, then align the holes in the gearbox flange with the holes in the frame.

NOTE: The drive unit is mounted to the frame with four capscrews. Three capscrews are 38 mm (1-1/2 in) long and one is 31.5 mm (1-1/4 in) long. The 31.5 mm (1-1/4 in) capscrew goes in the lower front hole.

Sheet 10: Drive Unit Assembly

Figure 4-1 - Drive Train Assembly 1. DRIVE MOTOR 2. PINION GEAR 3. HEX. CAPSCREW 4. LOCKWASHER 5. O-RING 6. PINION GEAR SEAL 7. ARBOR SHIM 8. 4-HOLE SHIM 9. LOCKNUT 10. SOCKET HEAD SCREW 11. LOCKWASHER

Sheet 10: Drive Unit Assembly 12. SOCKET HEAD SCREW 13. SPINDLE 14. HEX. HEAD SCREW 15. V-RING SEAL 16. CONE BEARING 17. DRIVE WHEEL AND TIRE ASSEMBLY 18. LOCKWASHER 19. LOCKNUT 20. WHEEL COVER 21. SOCKET HEAD SCREW 22. GEARBOX 23. PINION SHAFT 24. CONE BEARING 25. BEARING CUP 26. SEALS 27. CARRIER 28. BEARING CUP 29. CONE BEARING 30. BEVEL GEAR 31. SHIM 32. CAP 33. CAPSCREW 34. CAPSCREW 35. 6-HOLE SHIM 36. HOUSING 37. PLUG e. Install the four mounting capscrews with lockwashers through the flange of the gearbox. Tighten the capscrews to 108 N m (80 lbf ft) torque.

2. Install the 3-pin connector and four power cables to the drive motor in the correct locations.

3. Attach the brake line to the disc brake unit and bleed the brake system. See Section 5-BLEEDING THE BRAKE SYSTEM. 4. Install and adjust the encoder assembly. Refer to ENCODER ASSEMBLY-INSTALLATION. 5. Fill the gearbox with the proper lubricant as specified in the LUBRICATION CHARTS, Section 2. Refer to-GEARBOX OIL CHANGE. 6. Lower the truck off the blocks or stands.

7. Install the mast. See Section 8-MAST-INSTALLATION. 8. Install the front cover. See Section 2-FRONT COVER- INSTALLATION. 9. Connect the battery.

DRIVE MOTOR NOTE: Specialized tools, fixtures and training are required to service the drive motor. Refer to DRIVE UNIT-REBUILD. Brush Removal and Installation For brush removal and installation procedures, See Section 3-DRIVE MOTOR BRUSHES-REMOVAL.

GEARBOX NOTE: Specialized tools, fixtures and training are required to service any part of the gearbox. Refer to DRIVE UNIT-REBUILD. Oil Change

Sheet 10: Drive Unit Assembly WARNING: Do not work under a raised carriage. Lower the carriage before servicing the lift truck.

1. Lower the forks completely.

2. Tilt the mast to the full forward position.

3. Turn the key switch to the off "O" position.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

4. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 5. Chock the wheels of the truck to prevent movement.

CAUTION: Disposal of lubricants and fluids must meet local environmental regulations.

6. Place a clean drain pan under the appropriate drive unit.

7. Remove the fill plug from the front of the gearbox.

8. Remove the drain plug from the bottom of the gearbox and allow the oil to drain completely.

9. Clean the threads of the drain plug, apply pipe thread sealant (Yale 5059705-92 or equivalent) to the plug threads and install the drain plug.

10. Remove the fluid level plug from the side of the gearbox.

11. Fill the gearbox through the fill plug hole with proper oil until the fluid level is even with the bottom of the fluid level plug hole. The proper oil is specified in the LUBRICATION CHARTS, Section 2.

12. Clean the old sealant from the threads of the fluid level plug, apply new pipe thread sealant (Yale 5059705-92 or equivalent) to the plug and install the plug.

13. Remove the chocks from the wheels and connect the battery.

DRIVE WHEEL ASSEMBLY Removal and Installation See Section 2-REMOVING TIRE AND WHEEL FROM TRUCK. See Section 2-INSTALLING TIRE AND WHEEL ON THE LIFT TRUCK.

DRIVE WHEEL SEAL Removal

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 2. Remove the drive wheel. Refer to DRIVE WHEEL ASSEMBLY-REMOVAL AND INSTALLATION.

Sheet 10: Drive Unit Assembly 3. Gently grasp the V-ring seal with needle nose pliers and remove it from the seal groove.

Installation NOTE: Before installing a new seal, completely clean the seal groove and the surrounding area.

1. Gently insert the V-ring seal into the groove in the frame of the truck.

2. Apply a thin film of the same lubricant used for the final drive gears. The proper lubricant is specified on the LUBRICATION CHARTS, Section 2.

3. Install the drive wheel. Refer to DRIVE WHEEL ASSEMBLY-REMOVAL AND INSTALLATION. 4. Connect the battery.

DRIVE WHEEL SPINDLE Removal

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 2. Remove the drive wheel. Refer to DRIVE WHEEL ASSEMBLY-REMOVAL AND INSTALLATION.

CAUTION: When removing the capscrews securing the spindle to the frame of the truck, do not drop or damage the spindle. The spindle is heavy and should be supported when removing the screws.

3. Remove the ten capscrews and lockwashers attaching the spindle to the frame of the truck.

4. Remove the spindle.

Installation 1. Align the flange of the spindle with the screw holes in the frame.

2. Insert two capscrews with lockwashers into the holes and tighten them by hand.

3. Install the remaining capscrews with a small amount of thread lock compound. Tighten each capscrew to 108 N m (80 lbf ft) torque.

4. Remove the first two capscrews, apply Loctite 242 (blue) (Yale 5059655-18) or equivalent to the threads and install. Tighten each capscrew to 108 N m (80 lbf ft) torque.

5. Install the drive wheel. Refer to DRIVE WHEEL ASSEMBLY-REMOVAL AND INSTALLATION. 6. Connect the battery.

ENCODER ASSEMBLY (See Figure 4-2) Removal

WARNING: Do not work under a raised carriage. Lower the carriage before servicing the lift truck.

Sheet 10: Drive Unit Assembly 1. Lower the forks completely.

2. Tilt the mast to the full forward position.

3. Turn the key switch to the off "O" position.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

4. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 5. Remove the front cover. See Section 2-FRONT COVER-REMOVAL. 6. Remove the protective cover over the encoder.

7. Remove the two standoffs and the encoder mounting plate.

8. Remove the encoder drive belt.

9. Disconnect the 3-pin connector from the motor thermal sensor.

10. Remove the wire ties holding the sensor harness in place.

11. Disconnect the motor sensor harness from the traction amplifier.

12. Remove the encoder assembly and the harness from the truck.

Installation 1. Route the motor sensor harness behind the traction motors to the left side of the truck and up to the traction amplifier. Use wire ties to secure the harness in place.

Sheet 10: Drive Unit Assembly

Figure 4-2 - Encoder Assembly 1. MOUNTING PLATE 2. INSERT-DRIVE SHAFT 3. PULLEY-TIMING BELT 4. STANDOFF 5. LOCKWASHER 6. WASHER 7. LOCKNUT 8. COVER 9. ENCODER 10. CAPSCREW 11. LOCKWASHER 12. WASHER 13. TIMING BELT 2. Attach the encoder assembly to the drive motor with two standoffs.

3. Install the encoder drive belt on the pulleys on the drive motor and the encoder. Set tension on the drive belt.

Refer to ENCODER BELT ADJUSTMENT. 4. Install the protective cover over the encoder and secure it with two nylon locknuts and flat washers.

5. Connect the 3-pin connector in the sensor harness to the motor thermal sensor and brush wear indicator (if equipped).

6. Connect the sensor harness to the system controller.

7. Install the front cover. Refer to FRONT COVER-INSTAL LATION, Section 2.

8. Connect the battery.

Sheet 10: Drive Unit Assembly ENCODER BELT ADJUSTMENT

WARNING: Do not work under a raised carriage. Lower the carriage before servicing the lift truck.

1. Lower the forks completely.

2. Tilt the mast to the full forward position.

3. Turn the key switch to the off "O" position.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

4. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 5. Remove the front cover. See Section 2-FRONT COVER-REMOVAL. 6. Remove the protective cover over the encoder.

7. Check the deflection of the belt to determine if it matches the specification listed below.

Specification: The timing belt should deflect 2 mm (0.08 in) when a 567 g (20 oz.) force is applied to the center of the span of the belt.

8. If the belt tension is incorrect, adjust the belt tension by: a. Loosen the studs securing the encoder assembly to the motor. b. Move the encoder in the indicated direction: 1) If the tension is too great, move the encoder assembly toward the center of the motor.

2) If the tension is not sufficient, move the encoder assembly away from the center of the motor. c.

Secure the encoder assembly by tightening the studs.

d. Check the tension of the encoder belt to verify the adjustment.

9. Install the protective cover over the encoder assembly.

10. Install the front cover. See Section 2-FRONT COVER- INSTALLATION. 11. Connect the battery.

DRIVE SHAFT INSERT 1. Remove the encoder belt and drive pulley to access the insert.

2. Before installing the insert, apply Loctite 242 (blue) (Yale 5059655-18) or equivalent.

3. Tighten the insert to 5.4 N m (4 lbf ft) torque. DO NOT over tighten.

DRIVE UNIT REBUILD Disassembly 1. Remove the drive unit from the lift truck. Refer to DRIVE UNIT-REMOVAL.

Sheet 10: Drive Unit Assembly 2. Remove the brake unit from the drive unit. See System 5-Brake System.

CAUTION: When disassembling the drive unit, do not pry the carrier and housing apart-this may damage the machined surfaces. If necessary, use a rubber mallet to separate the carrier and the housing.

3. Remove the six capscrews from the carrier and separate the carrier from the housing. Discard the shims.

CAUTION: Do not pry the housing and motor apart, this may damage the machined surfaces. If necessary, use a rubber mallet to separate the housing and motor.

4. Remove the four nylon locknuts from the housing and separate the housing from the drive motor. Discard the shims.

5. Use the drive motor crank tool (Yale Part No. 5204248-71) to hold the motor shaft while loosening the capscrew from the pinion gear.

6. Remove the capscrew, interlocking fasteners and pinion gear from the motor shaft. Discard the capscrew and fasteners.

NOTE: There may be shims under the pinion gear, if so, discard them.

7. Remove the pinion seal and the O-ring and discard them.

Pinion Gear to Motor Assembly NOTE: Before assembling the drive unit, all components and machined surfaces must be thoroughly cleaned of any dirt, grime, gasket compound, etc. Machined surfaces must be cleaned only by using a soft cloth and mild, non-abrasive cleaning solvent.

NOTE: BEFORE INSTALLING THE PINION GEAR, use a non-lubricating, fast-drying degreaser (such as Loctite 7070) to remove any oil from the threads in the motor pinion shaft. Wait at least one minute, then use clean, dry compressed air to dry the threads.

1. Clean and closely inspect the end of the pinion gear. If there is a number etched or stamped into the pinion gear end (such as 2.115), record it.

2. If there are any shims or spacers around the motor pinion shaft, discard them. Assemble the pinion gear to the motor using a 3/8-16 capscrew and the tab lockwasher. See Figure 4-3. Apply Loctite 242 (blue) (Yale 5059655-18) or equivalent to the capscrew. Tighten the capscrew to 60 N m (45 lbf ft) torque.

To tighten the pinion, use the drive motor crank tool (Yale Part No. 5204248-71) to hold the motor shaft on the brake end. See Figure 4-4. This tool's thumbscrew is to be tightened into the keyway of the motor shaft. The tool can be used as an opposing wrench while tightening the capscrew on the pinion end as well as a crank to turn the motor shaft in later assembly procedures.

Sheet 10: Drive Unit Assembly

Figure 4-3 - Pinion Gear to Motor Assembly 1. DRIVE MOTOR 2. ARBOR SHIM 3. PINION GEAR 4. LOCKWASHER 5. HEX. CAPSCREW 6. O-RING 7. PINION GEAR SEAL 3. Check the drive motor shaft for excessive end play: a. Install an O-ring around the motor pilot flange. b. Fasten the motor shaft end play tool (Yale Part No. 5204248-73) to the brake end of the motor using the three 5/16-18 capscrews furnished with the tool. c.

Wearing a glove, while holding the pinion end secure, thread the special 5/8 capscrew into the tool and tighten slightly with a wrench until you feel that the motor shaft bearings are about to be loaded in the forward direction-DO NOT OVER TIGHTEN!

d. Using the pinion height dial indicator (Yale Part No. 5204248-74), measure and record the distance from the pinion end to the motor mounting surface. e. Back the 5/8 capscrew off one to two turns. While maintaining sufficient clearance between the 5/8 capscrew and the motor shaft, and again gripping the pinion gear to prevent it from turning, insert the 1/4-20 hex. socket head capscrew through the 5/8 capscrew and thread it securely into the motor shaft until the 1/4 capscrew head is tight against the 5/8 capscrew head. See Figure 4-4. This will pull the motor's shaft to the rear position. Again, tighten only enough to move the motor shaft yet not enough to load the bearings-DO NOT OVER TIGHTEN! f.

Use the pinion height dial indicator (Yale Part No. 5204248-74) to measure and record the distance from the pinion gear end to the motor mount surface.

4. Note and record the difference in pinion height in Step 4f as compared to what was recorded in Step 4d. This difference is the motor shaft end play distance. You may or may not need to shim between the pinion gear and motor depending upon which type of motor you are using.

Sheet 10: Drive Unit Assembly a. If the motor part number is 5068975-34 (Vendor No. 7600021) or 5068975-35 (Vendor No. 7600022) and the end play is greater than 0.127 mm (0.005 in), the motor is to be rejected and cannot be used. Start this procedure over using a new motor.

Figure 4-4 - Measuring End Play 1. MOTOR SHAFT END PLAY TOOL 2. MOTOR SHAFT CRANK 3. PINION HEIGHT DIAL INDICATOR b. If the motor part number is 5068975-34 (Vendor No. 7600021) or 5068975-35 (Vendor No. 7600022) and the end play is less than 0.13 mm (0.005 in), no shimming under the pinion is necessary. However, remove the pinion gear; then assemble using a permanent thread locking compound with a minimum temperature rating of at least 232°C (450°F). Tighten to 60 N m (45 lbf ft) torque. c.

If the motor part number is 5068975-36 (Vendor No. 7600023), 5068975-37 (Vendor No. 7600024), or 5068975-38 (Vendor No. 7600025) and the end play is greater than 0.05 mm (0.002 in), an arbor shim package of 0.00-0.05 mm (0.000-0.002 in) less than the measured end play will have to be installed under the pinion gear. Remove the pinion gear, then assemble with the shim package between the pinion gear and drive motor. Tighten to 54 N m (40 lbf ft) torque and retest end play. Shim and test until an end play of 0.05 mm (0.002 in) or less is achieved. Once the condition is met, remove the pinion gear then assemble using a permanent thread locking compound with a minimum temperature rating of at least 232°C (450°F). Tighten to 60 N m (45 lbf ft) torque.

d. If the motor part number is 5068975-36 (Vendor No. 7600023), 5068975-37 (Vendor No. 7600024), or 5068975-38 (Vendor No. 7600025) and the end play is less than 0.05 mm (0.002 in), no shimming under the pinion gear is necessary. However, remove the pinion gear then assemble using a permanent thread locking compound with a minimum temperature rating of at least 232°C (450°F). Tighten to 60 N m (45 lbf ft) torque.

5. Use a synthetic grease to grease the inner diameter of the appropriate seal and seat it around the pinion base.

See Section 2-LUBRICATION CHARTS. Gear Housing to Motor Assembly NOTE: Before assembling the gear housing to the motor, you must first determine whether you are to build a left or a right drive unit. As an assembler holds a drive unit with the brake end of the motor up and the terminal lugs pointing forward, a right drive unit would be assembled with the gearbox pointing to the right; a left drive unit would be assembled with the gearbox pointing to the left. See Figure 4-5.

To assemble the gear housing to the motor, first determine which method to use. Look on the back side of the gear housing casting. If there is a number stamped or etched into the back of the casting (such as 4.612 or .612), record it.

Follow procedure I if: You do not have one or both of the numbers from the pinion gear end or the gear housing

Sheet 10: Drive Unit Assembly or the motor part number is 5068975-36 (Vendor No. 7600023), 5068975-37 (Vendor No. 7600024), or 5068975-38 (Vendor No. 7600025).

Figure 4-5 - Drive Unit Orientation Follow procedure II if: You have both numbers on the pinion gear end and gear housing and the motor part number is 5068975-34 (Vendor No. 7600021) or 5068975-35 (Vendor No. 7600022).

PROCEDURE I Gear Housing to Motor Assembly 1. Apply a thin coat of grease to the outer diameter of the motor pilot flange. See Section 2-LUBRICATION CHARTS, Section 2. Disconnect the carrier assembly from the gear housing and loosely fasten the gear housing to the motor using four 3/8-16 nuts as a right or a left drive unit.

2. Insert the 4-hole shim setting fixture (Yale Part No. 5204248-75) so that its guide arm is aligned over the pinion gear and the fixture's mounting surface is flush with that of the gear housing flange. See Figure 4-6.

3. Carefully tighten the gear housing to the motor until the fixture's guide arm makes contact with the top of the pinion gear. Tighten each nut the same distance and torque to ensure the gear housing and tool are parallel to the mounting surface of the motor.

4. Using a feeler gauge set, measure and record the distance between the gear housing mounting flange and the motor. This is the thickness of the 4-hole shim package to install between the gear housing and motor.

5. Remove the gear housing from the motor and set the fixture aside. Assemble a 4-hole shim package equal to the distance determined in Step 4. Install the shim package on the motor mounting face and reconnect the gear housing using four 3/8-16 nylon locknuts tightened to 40 N m (30 lbf ft) torque.

PROCEDURE II Gear Housing to Motor Assembly 1. Determine the thickness of the shim package required between the motor and gear housing. The thickness of the shim package is determined by the following formula: A + B - C = Shim Package A. Using the pinion height dial indicator (Yale Part No. 5204248-74), or a suitable metric dial indicator zeroed at 60.96 mm (2.400 in), measure the distance from the end of the pinion gear to the mounting face of the

Sheet 10: Drive Unit Assembly motor. Record as Distance A. B. The setting distance etched on the pinion gear end rounded to the nearest 0.03 mm (0.001 in).

NOTE: When working in metric units, convert the setting distance etched on the pinion gear end by multiplying that number by 25.4 to get the distance in millimeters. For this example, the etched number, 2.115, multiplied by 25.4 equals 53.72 mm.

C. C The number stamped on the back of the gear housing casting. This number may or may not begin with a four. If the number reads 4.612, for example, record this number as Distance C. If the number reads only .612, for example, we must assume a four at the beginning. Distance C would therefore be 4.612.

NOTE: When working in metric units, convert the number stamped on the back of the gear housing casting by multiplying that number by 25.4 to get the distance in millimeters. For this example the stamped number, 4.612, multiplied by 25.4 equals 117.14 mm.

Example: Distance A = 64.39 mm (2.535 in) Distance B = 53.72 mm (2.115 in) Distance C = 117.14 mm (4.612 in) A + B = 118.11 mm (4.650) 118.11 (4.650) - 117.14 (4.612) = 0.97 mm (0.038 in)

_ Shim Package = 0.97 mm (0.038 in) 2. Assemble a 4-hole shim package as determined in Step 1 (verify with micrometer) and install to the motor mounting face.

3. Disconnect the carrier assembly from the gear housing. Apply a thin coat of grease to the outer diameter of the motor pilot flange and secure the gear housing to the motor using four 3/8-16 nylon locknuts as either a left or right drive unit as required. Tighten the nylon locknuts to 40 N m (30 lbf ft) torque. See Section 2-LUBRICATION CHARTS.

Figure 4-6 - 4-Hole Shim Fixture

Sheet 10: Drive Unit Assembly

Figure 4-7 - Carrier to Housing Alignment Carrier to Gear Housing Assembly 1. Place 0.64 mm (0.025 in) to 0.76 mm (0.030 in) 6-hole shim package over the mounting flange on the gear housing.

2. Coat an approximately 30* area of the ring gear with marking compound for checking the tooth contact pattern.

NOTE: When installing the carrier to the gear housing, ensure the alignment of the flange mounting holes is correct.

See Figure 4-7.

3. Place the carrier on the gear housing ensuring the gear teeth are meshed. Temporarily fasten by tightening at least three of the six capscrews supplied with the gearbox.

4. Attach the drive unit backlash tool (Yale Part No. 5204248-72) to the gearbox. See Figure 4-8. Fasten with the three wing nuts supplied with the tool.

5. Install the flag assembly on the spur gear with the flag in the upright position.

Figure 4-8 - Backlash Tool 1. BACKLASH TOOL 2. FLAG ASSEMBLY 3. WING NUT 6. Carefully rotate the flag until it moves about halfway into the dial indicator's range of motion. Then, slightly rotate the flag back and forth and observe the dial indicator readings. The recorded difference between these two measurements is the backlash reading. Backlash should be greater than 0.05 mm (0.002 in) but should not exceed 0.15 mm (0.006 in). If this condition is not met, disassemble the carrier from the gear housing and add or remove shims as required (if backlash is too great, add shims; if backlash is too small, remove shims). Repeat these steps as necessary until backlash conditions are met.

Sheet 10: Drive Unit Assembly 7. Once backlash conditions are met, remove the flag assembly and backlash tool. Rotate the motor shaft several revolutions both forward and reverse using the drive motor crank tool (Yale Part No. 5204248-71). Remove the carrier from the gear housing and observe the contact pattern on the gear: a. The correct pattern, as shown in Figure 4-9, Example 1, is well centered on the bevel gear tooth with lengthwise contact clear of the toe. The length of the pattern in an unloaded condition is approximately one-half to two-thirds of the bevel gear tooth. The backlash (6-hole) and motor to gear box (4-hole) shims are correct. b. Figure 4-9, Example 2, indicates an incorrect 4-hole shimming package between the motor and the gear housing. The contact pattern in the left illustration indicates that the pattern is too close to the root of the gear tooth or off the tooth root. If this condition occurs, add some 4-hole shims between the motor and the gearbox and test again. The illustration to the right shows a pattern that is too close to the tooth top land and off center. If this condition exists, remove some 4-hole shims between the motor and gearbox and test again. c.

Figure 4-9, Example 3, indicates a backlash error caused by an incorrect 6-hole shim package between the carrier and the gear housing. The illustration to the left shows the pattern too far off the tooth toe. As was noted in Figure 4-9, Example 1, there should be an area between the contact pattern and the tooth toe that is not in contact with the gear set. To correct for this condition, remove the carrier from the gear housing, add additional shims, assemble and test again. The illustration to the right however shows the pattern moving too far along the tooth toward the tooth heel. To correct for this condition, remove the carrier, remove some shims, assemble and test again.

8. Once gear teeth pattern conditions are met, remove the carrier from the gear housing and set the shim package aside. Apply a thin coat of suitable gasket compound to the gear mounting surfaces of the carrier and gear housing then replace the shim package. Attach the carrier to the gear housing using the six capscrews supplied with the gearbox and a permanent thread locking compound with a minimum temperature rating of at least 232°C (450°F). Tighten to 54 N m (40 lbf ft) torque.

9. Using a grease gun containing the recommended grease, ensure that the cone bearing on the gear shaft is lubricated. See Section 2-LUBRICATION CHARTS.

Sheet 10: Drive Unit Assembly

Figure 4-9 - Gear Contact Patterns 10. Ensure the motor terminal lugs are tightened.

11. The oil fill plug nearest the motor terminal lugs is the fill plug that will be used for filling the gearbox with hydraulic oil.

12. Install the drive unit into the truck. Refer to DRIVE UNIT-INSTALLATION.

CARRIER REBUILD Carrier Disassembly (See Figure 4-10) NOTE: Disassembly is recommended only when one of the carrier's bearings or seals need to be replaced or the carrier has excessive end play (greater than .05 mm (0.002 in)). Refer to DRIVE UNIT REBUILD for disassembly of the drive unit.

1. Place the carrier assembly with the spiral bevel gear facing up.

2. Remove the cap and any shims underneath.

3. Lift the spiral bevel gear off of the pinion shaft.

4. Slide the pinion shaft out of the carrier housing.

5. Remove bearings, bearing cups and seals as necessary, being careful not to damage gear teeth or machined surfaces.

Sheet 10: Drive Unit Assembly Carrier Assembly 1. Ensure castings and machined surfaces are clean and free of foreign material. Clean only with a rag and mild non-abrasive solvents.

Figure 4-10 - Carrier Assembly 1. HEX. SCREW 2. CAP 3. SHIM 4. BEVEL GEAR 5. CONE BEARING 6. BEARING CUP 7. CARRIER 8. SEALS 9. BEARING CUP 10. CONE BEARING 11. PINION SHAFT 2. Stand carrier housing, on end with large mounting flange down.

3. Lubricate the outside diameter of the seals and carefully press into the housing individually. Ensure that the lip of the first seal is downward. Ensure that the lip of the second seal is pointing upward.

4. Lubricate outside diameter of the bearing cup and press evenly into the carrier housing until properly seated against the stop.

5. Turn the carrier housing over so that the large flange is pointing up. Lubricate bearing cup and press evenly into the carrier housing until properly seated against the stop.

6. Pack the cone roller bearing with the recommended grease. See Section 2-LUBRICATION CHARTS. Stand the pinion shaft on end with the spur gear down. Lubricate the inside diameter of the packed cone roller bearing and press evenly onto pinion shaft as shown until properly seated against the spur gear.

7. Remove the three capscrews securing the bevel gear to the pinion shaft (some drive units may have a lock wire securing the three screws).

8. Place the bevel gear face down with support under the center section opposite the bearing seat preventing the gear teeth from being damaged. See Figure 4-11. Lubricate the inside diameter of the cone roller bearing and press onto the bevel gear as shown until properly seated against the stop. This bearing should not be packed with heavy grease. It will eventually be lubricated by gearbox oil in the gear housing.

9. Lubricate the inner diameter of the seals installed in Step 3. Using a twisting motion, insert the pinion shaft through the carrier housing.

10. With the gear end of the shaft in the downward position on the table, install the bevel gear over the splined end of the shaft.

Sheet 10: Drive Unit Assembly 11. Apply light pressure to the bevel gear and shaft. Spin the carrier housing several times to seat the bearings.

Figure 4-11 - Support Spiral Bevel Gear 12. Place the cap over the spiral bevel gear and secure using three 5/16-18 capscrews. Tighten the capscrews to 27 N m (20 lbf ft) torque to ensure bearings and bearing cups are seated properly. Remove the three capscrews and the cap.

13. Using a depth micrometer, measure and record the depth from the face of the bevel gear to the end of the pinion shaft. See Figure 4-12. A carrier shaft shim package should be assembled 0.08 mm (0.003 in) greater than the recorded bevel gear to pinion shaft depth. Verify the shim package using a micrometer; then place the package on the pinion shaft end.

Figure 4-12 - Measure Shim Depth Example: Measured Depth Add 0.08 mm (0.003 in.)

0.25 mm (0.010 in.) + 0.08 mm (0.003 in.)

————————————

Sheet 10: Drive Unit Assembly Total Shim Package

= 0.33 mm

(0.013 in.)

14. Place the cap over the shim package and secure using three 5/16-18 capscrews. Tighten the capscrews to 27 N m (20 lbf ft) torque.

15. Again, spin the housing to seat the bearings.

16. Invert the carrier so the ring gear is down and place supporting blocks on the mounting flange at the capscrew circle diameter. This will suspend the ring gear.

17. Place a magnetic base indicator on the small flange end of the carrier with indicator probe on end of spur gear.

18. Using grease gun containing the recommended grease, ensure the cone bearing on gear shaft is greased. See Section 2-LUBRICATION CHARTS. 19. Ensure motor terminal lugs are tightened using a wrench.

20. The oil fill plug nearest the motor terminal lugs is the fill plug that will be used for filling the gearbox with hydraulic oil.

21. Install the drive unit into the truck. Refer to DRIVE UNIT INSTALLATION. 22. Pry upward on the cap to observe the end play. Add or remove shims as necessary until an end play of 0.00 to 0.05 mm (0.000 to 0.002 in) is obtained.

23. Remove the retaining capscrews and assemble using a permanent thread locking compound with a minimum temperature rating of at least 232°C (450°F).

If there are wire tie holes in the capscrews, tighten the capscrews to 20 N m (15 lbf ft) torque and correctly install a wire tie through the three capscrews.

If there are no wire tie holes in the capscrews, tighten the capscrews to 27 N m (20 lbf ft) torque.

24. Assemble the drive unit. Refer to DRIVE UNIT REBUILD.

Sheet 11: Brake System

BRAKE SYSTEM GENERAL This chapter contains the description and operation of the braking system for the ESC 030 ZA, ESC 035 ZA, ESC 040 ZA and ESC 050 ZA electric lift trucks. The repairs and checks and adjustments required for maintaining the brake system is also included.

WARNING: This brake system is designed to use DOT 5 brake fluid. Using fluid other than DOT 5 could cause premature wear of some of the parts in the brake system which could lead to a brake failure.

DESCRIPTION AND OPERATION The brake system is designed to mechanically apply the brakes when the brake pedal is released. The brakes are hydraulically released when the operator stands on the brake pedal.

The master cylinder consists of a housing and a piston assembly. When releasing the brakes, the brake pedal moves the piston assembly in the housing. The primary cup pushes the fluid through the check valve and then to the brake units. A return spring pushes the piston back to the stop plate. The primary cup slides past the compensator port in the housing. The reservoir then fills the bore with fluid. When the pedal is released quickly, the fluid behind the cup moves to the pressure side of the housing. The compensator port lets fluid move to and from the system when the temperature changes. See Figure 5-3.

The truck can be stopped by using the brakes. The brake system is designed to mechanically apply the brakes when the operator removes his foot from the pedal. The brakes are hydraulically released when the operator depresses the pedal.

The brake system consists of a brake pedal, a master cylinder, and two self-contained disc brake units. The disc brake units incorporate the functions of the traditional slave cylinders and the mechanical actuators into one unit.

They are attached to the commutator end of the drive motors to take advantage of the increase in torque supplied by the gearbox.

The internal operation of the disc brake unit is the reverse of an automotive type disc brake. Twenty-four coil springs supply the force which clamps the top and bottom pads to the rotor. Fluid pressure from the master cylinder is applied against these springs to spread the brake pads and release the brakes.

The disc brake assembly is a free floating unit. Bushings are inserted into the mounting holes in the brake assembly through which the mounting capscrews are installed. This allows the brake assembly to float and apply equal pressure to both sides of the rotor. The rotor is attached to the traction motor with a key.

When the operator releases the brake pedal, a micro-switch informs the system controller of the application of the brakes. At this point, the system controller removes the current flow to the traction motors. This action also disables the traction motor circuit whenever the operator is not standing on the brake pedal.

Sheet 11: Brake System

Figure 5-1 - Brake Assembly 1. CYLINDER AND UPPER BRAKE PAD 2. SOCKET HEAD SCREW 3. O-RING 4. ADAPTER 5. SPACER 6. SNAP RING 7. SHIM 8. SPACER 9. ROTOR 10. BOTTOM BRAKE PAD 11. CAPSCREW 12. WOODRUFF KEY 13. DRIVE MOTOR

DISC BRAKE UNIT-REPAIRS Removal

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Check that the key switch is in the off "O" position.

2. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 3. Remove the mast. See Section 8-MAST-REMOVAL. 4. Remove the encoder assembly. See Section 4-ENCOD ER ASSEMBLY-REMOVAL.

CAUTION: DO NOT allow brake fluid to drip into the motor when removing the brake line from the disc brake unit.

5. Remove the brake line from the disc brake unit.

WARNING: The drive unit is heavy. Ensure the lifting device has adequate capacity to handle the weight of

Sheet 11: Brake System the drive unit. The drive unit with the brakes installed can weigh approximately 74 kg (163lbs).

6. Attach a lifting device to the drive unit.

7. Remove the capscrews securing the gearbox to the frame and rotate the drive unit to a vertical position. Install one of the capscrews to hold the drive unit in position.

8. Remove the three capscrews securing the brake assembly to the traction motor.

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.

9. Remove the brake rotor snap ring from the traction motor shaft.

10. Remove the shim(s) and spacer from the traction motor shaft.

11. Attach a two-bolt puller to the two 1/4-20 threaded holes in the brake rotor (Item 9, Figure 5-1) and remove the rotor and brake assembly from the traction motor shaft.

NOTE: Be careful not to lose the woodruff key or the lower shims on the motor shaft.

12. Remove the woodruff key from the traction motor shaft.

13. Remove the spacers from the traction motor shaft. (Note the number and thickness of the spacers removed from the traction motor shaft. The spacers maintain the clearance between the rotor and the lower brake pad surface.)

NOTE: Yale recommends replacing the entire disc brake unit rather than replacing the pads or seals.

Installation 1. Verify the lower retaining ring is in place on the traction motor shaft.

2. Install shims on top of the lower snap ring. Use two 0.13 mm (0.005 in) shims or one 0.25 mm (0.010 in) shim to start.

3. Install the disc brake unit on the motor shaft.

NOTE: Do not install the woodruff key in the motor shaft at this time.

4. Connect the brake line and remove any air from the brake system. Refer to BLEEDING THE BRAKE SYSTEM. DO NOT tighten the bleeder plug to more than 12 N m (9 lbf ft) torque.

5. With the brake pedal pressed, check the gap between the rotor and the bottom pad. The gap must be 0.25 mm (0.010 in) to 0.38 mm (0.015 in).

6. Add or remove shims below the rotor to achieve the proper gap.

7. Remove the disc brake unit and install the woodruff key in the drive motor shaft.

8. Align the keyway in the rotor with the woodruff key in the motor shaft and slide the disc brake unit into proper position.

9. Rotate the brake housing until the mounting holes in the housing align with the mounting holes in the top of the traction motor. Verify the brake line connection on the brake unit is aligned with the brake line. Fasten the brake unit to the drive motor with three capscrews and attach the brake line.

10. Remove the capscrew temporarily retaining the drive unit in place. Rotate the drive unit until it is aligned in its original position. Install the capscrews and lockwashers. Tighten the capscrews to 109 N m (80 lbf ft) torque.

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

Sheet 11: Brake System and face protection during removal and installation.

11. Install the spacer and add shims until the top of the shims are flush with the lower surface of the upper snap ring groove. Install the snap ring.

12. Bleed any air from the brake system. Refer to BLEEDING THE BRAKE SYSTEM. DO NOT tighten the bleeder plug to more than 12 N m (9 lbf ft) torque.

13. Adjust the pedal position. Refer to BRAKE ADJUSTMENTS. 14. Adjust the brake switch. Refer to BRAKE ADJUSTMENTS. 15. Connect the battery.

16. Replace the mast. See Section 8-MAST-INSTALLATION. 17. Test the truck for proper stopping distance. If stopping distance or holding capacity do not meet specifications, adjust the brake pressure. Refer to BRAKE ADJUSTMENTS.

BRAKE ACTUATOR ASSEMBLY Removal

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Check that the key switch is in the off "O" position.

2. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 3. Remove the top cover and the control cover. See Section 2-TOP COVER-REMOVAL and CONTROL COVER-REMOVAL. 4. On forward stance models, remove the mounting bracket for the steering control valve and move it out of the way.

5. Disconnect the brake pedal rod from the brake lever arm by removing the capscrew, flat washer, spacer and nylon locknut.

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

6. Disconnect and cap the brake line from the master cylinder.

7. Remove three capscrews, flat washers and nylon locknuts and remove the brake actuator assembly.

8. Clean the area around the cap of the master cylinder and remove the cap. Drain the brake fluid from the master cylinder.

Installation 1. Install the brake actuator assembly and attach it with three capscrews, flat washers and nylon locknuts.

2. Attach the brake line to the master cylinder.

3. Connect the brake pedal rod to the brake lever arm with the capscrew, flat washer, spacer and nylon locknut.

4. On forward stance models, install the mounting bracket for the steer control valve.

Sheet 11: Brake System CAUTION: Brake fluid damages paint. Immediately remove any brake fluid that is on a painted surface.

5. Fill the master cylinder with the recommended DOT 5 brake fluid as specified in the LUBRICATION CHART, Section 2 and install the cap.

6. Remove the air from the brake system. Refer to BLEEDING THE BRAKE SYSTEM. 7. Adjust the brake pedal height. Refer to BRAKE ADJUSTMENTS. 8. Install the control cover and the top cover. See Section 2-TOP COVER-INSTALLATION and CONTROL COVER- INSTALLATION. 9. Connect the battery.

MASTER CYLINDER Removal 1. Remove the brake actuator assembly. Refer to BRAKE ACTUATOR ASSEMBLY REMOVAL. 2. Remove the master cylinder from the mounting plate by removing the capscrews and lockwashers and sliding the master cylinder off of the push rod.

NOTE: The master cylinder may be rebuilt using the available seal kit. Refer to MASTER CYLINDER-DISASSEMBLY and MASTER CYLINDER-ASSEMBLY. Installation 1. Install the master cylinder on the mounting plate by sliding the master cylinder onto the push rod and securing it with two capscrews and lockwashers.

2. Install the brake actuator assembly. Refer to BRAKE ACTUATOR ASSEMBLY-INSTALLATION. 3. Attach the brake line to the master cylinder.

4. Connect the brake pedal rod to the brake lever arm with a capscrew, flat washer, spacer and nylon locknut.

5. On forward stance models, reinstall the mounting bracket for the steer control valve.

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

6. Open the top of the master cylinder and fill the master cylinder with the recommended DOT 5 brake fluid as specified in the LUBRICATION CHART, Section 2. Install the cap.

7. Remove the air from the brake system. Refer to BLEEDING THE BRAKE SYSTEM. Periodically verify the brake fluid level in the master cylinder throughout this procedure.

8. Adjust the master cylinder push rod length. Refer to BRAKE ADJUSTMENTS. 9. Adjust the brake pedal height. Refer to BRAKE ADJUSTMENTS. 10. Adjust the brake switch. Refer to BRAKE ADJUST MENTS. 11. Test the braking distance. Refer to BRAKE ADJUST MENTS.

Sheet 11: Brake System

Figure 5-2 - Removing Master Cylinder 1. BRAKE PEDAL ROD ATTACHMENT 2. BRAKE LINE 3. BRAKE ACTUATOR ASSEMBLY 4. CAPSCREWS 5. FLAT WASHER 6. NYLON LOCKNUT 7. CAPSCREWS 8. LOCKWASHER

Sheet 11: Brake System

Figure 5-3 Master Cylinder 1. BOOT 2. LOCK WIRE 3. PISTON STOP PLATE 4. PISTON 5. PRIMARY CUP 6. SPRING RETAINER CUP 7. RETURN SPRING 8. SPRING SEAT CUP 9. MASTER CYLINDER BODY 10. FILLER CAP GASKET 11. FILLER CAP 12. PUSH ROD Cleaning and Inspection

CAUTION: Do not use solvent to clean the parts of the master cylinder. Solvent will damage the rubber parts. Clean all parts with alcohol. Use compressed air to dry the parts. Do not get oil or grease in the brake fluid.

1. Check the master cylinder bore for damage. If any damage is found, replace the master cylinder.

2. Check for water, oil or grease in the system. Remove all the fluid in the system if oil is found. Fill the master cylinder with clean DOT 5 brake fluid.

Disassembly 1. Put the master cylinder in a vise with soft jaws. Put the end of the housing with the piston away from the vise.

Hold the piston against the return spring with a screwdriver. See Figure 5-3.

WARNING: The piston return spring will push the piston from the cylinder with great force.

2. Remove the lock ring and piston stop plate. Slowly remove the piston from the cylinder.

Sheet 11: Brake System 3. Remove the spring and check valve.

Assembly

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

1. Lubricate all parts with clean DOT 5 brake fluid.

2. Use a repair kit. Install the parts in the order shown in Figure 5-3. Hold the piston in the cylinder with a screwdriver. Make sure the lock ring is in position.

3. Install the master cylinder in the lift truck. Refer to MASTER CYLINDER-INSTALLATION.

Figure 5-4 - Removing the Piston 1. LOCK RING 2. PISTON 3. VISE 4. MASTER CYLINDER

BRAKE PEDAL Removal

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Check that the key switch is in the off "O" position.

2. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 3. Remove two button head screws and lockwashers. Remove the access panel at the front-lower-left corner of the operator compartment.

4. Remove the cotter pin then the clevis pin from the brake pedal rod clevis.

5. Remove the button head screw and nylon locknut and remove the brake pedal pivot shaft.

Sheet 11: Brake System 6. Remove the brake pedal.

Installation 1. Position the brake pedal in the pivot bracket.

2. Install the brake pedal pivot shaft and fasten it with a button head screw and nylon locknut.

3. Attach the brake pedal rod to the brake pedal with one clevis pin and cotter pin.

4. Install the access panel into the opening in the bottom of the operator compartment and fasten it with two button head screws and lockwashers.

5. Connect the battery.

BLEEDING THE BRAKE SYSTEM 1. Tilt the mast to the full forward position.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

2. Check that the key switch is in the off "O" position.

3. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 4. Remove the front cover, top cover and control cover. See Section 2-FRONT COVER, TOP COVER and CONTROL COVER-REMOVAL. 5. Clean the area around the top of the master cylinder to prevent dirt from entering the master cylinder when opened.

CAUTION: DO NOT allow brake fluid to get onto the brake pads or rotor.

WARNING: The ESC 030 ZA, ESC 035 ZA, ESC 040 ZA, and ESC 050 ZA lift trucks use DOT 5 brake fluid. Failure to use the correct fluid can cause brake failure and/or component damage.

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

6. Open the top of the master cylinder and fill with clean brake fluid (use DOT 5 brake fluid only). Periodically verify the level of brake fluid in the master cylinder throughout this procedure.

7. Install a hose on the bleeder plug on the top of the disc brake unit and place the other end in a small container of clean brake fluid.

8. Loosen the bleeder plug.

9. Slowly press the brake pedal and hold it down. DO NOT tighten the bleeder plug to more than 12 N m (9 lbf ft) torque.

10. Release the brake pedal.

11. Repeat Steps 11 and 12 until a solid stream (no bubbles) flows from the hose.

12. Repeat Steps 8 to 12 on the other disc brake unit.

Sheet 11: Brake System 13. Fill the master cylinder to 5 to 6 mm (0.18 to 0.25 in) below the cap with clean brake fluid (use DOT 5 brake fluid only).

14. Install the cap on the master cylinder. DO NOT tighten the bleeder plug to more than 12 N m (9 lbf ft) torque.

15. Install the control cover, top cover and front cover. See Section 2-TOP COVER, FRONT COVER and CONTROL COVER-INSTALLATION. 16. Connect the battery.

CHECKS AND ADJUSTMENTS NOTE: Many of the brake adjustments interact with one another. When performing any adjustments in the brake area of the lift truck, please follow the order of the list below. When servicing the brakes, check all of the adjustments listed below: a. Brake Pedal Height b. Brake Switch c.

Brake Push Rod Length

d. Disc Brake Clearance e. Brake Pressure The brakes must stop a fully loaded lift truck on a dry, level floor in 0.3 metres (1.1 feet) for every mph of truck speed. For example a fully loaded truck traveling at 11.3 km/h (7 mph) must stop within 2.3 metres (7.7 feet).

The truck must be able to hold a full load on a 15% grade.

Brake Pedal Height Specification: 119.6 mm (4.71 in) (see Figure 5-5)

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Check that the key switch is in the off "O" position.

2. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 3. Remove the top cover and control cover. See Section 2-TOP COVER-REMOVAL and CONTROL COVER-REMOVAL. 4. Disconnect the rod end of the brake rod from the brake lever arm by removing the capscrew, flat washer and nylon locknut.

5. Loosen the jam nut on the brake rod end.

Sheet 11: Brake System

Figure 5-5 - Brake Pedal Height 6. Rotate the rod end to lengthen or shorten the brake rod. (Rotating the rod end counterclockwise will decrease the brake pedal height, rotating the rod end clockwise will increase the brake pedal height.)

7. Tighten the jam nut on the rod end.

8. Attach the rod end to the brake lever arm with a capscrew, flat washer, spacer and nylon locknut.

9. Check the height of the brake pedal and adjust if necessary.

10. Install the control cover and the top cover. See Section 2-TOP COVER and CONTROL COVER-INSTALLATION. 11. Connect the battery.

Brake Switch

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Check that the key switch is in the off "O" position.

2. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 3. Remove the top cover and control cover. See Section 2-TOP COVER-REMOVAL and CONTROL COVER-REMOVAL. 4. With the brake pedal released, loosen the screws securing the brake switch. Move the brake switch toward the brake lever arm until it actuates.

5. Slowly press the brake pedal while watching the brake lever arm. The brake switch must deactuate after the pedal moves about 25 mm (1 in). Readjust as needed.

6. Install the control cover and the top cover. See Section 2-TOP COVER-INSTALLATION and CONTROL COVER- INSTALLATION. 7. Connect the battery.

8. Test the brake operation of the lift truck.

Brake Push Rod Length

Sheet 11: Brake System WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Check that the key switch is in the off "O" position.

2. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 3. Remove the top cover and control cover. See Section 2-TOP COVER-INSTALLATION and CONTROL COVER- INSTALLATION. NOTE: Verify that the stop bolt is locked in place and adjusted so that the distance from the bracket to the bolt head is 25 mm (1 in).

4. Check for 1.6 mm (0.0625 in) free play between the push rod and the master cylinder piston, with the brake lever arm against the stop bolt.

NOTE: Insufficient free play will prevent the brakes from releasing. Excessive free play can cause the brakes to drag.

5. If the brake push rod play is either insufficient or excessive, adjust the length of the push rod.

6. To adjust the length of the push rod, loosen the jam nut on the spherical rod end and rotate the threaded rod to the proper length. Rotating the hexagonal portion of the push rod clockwise will increase the length of the push rod, reducing free play. Rotating the hexagonal portion of the push rod counterclockwise will reduce the length of the push rod, increasing the free play.

Figure 5-6 - Push Rod Length 7. Once free play is adjusted properly, tighten the jam nuts on the push rod.

8. Install the control cover and the top cover. See Section 2-TOP COVER and CONTROL COVER-INSTALLATION. 9. Test the brake operation of the truck.

Disc Brake Clearance Refer to the DISC BRAKE UNIT-INSTALLATION procedure.

NOTE: Disc brake clearance adjustment should only be required when the drive motor or disc brake unit is replaced.

Sheet 11: Brake System Brake Pressure Specification: The brakes must stop a fully loaded lift truck on a dry, level floor in 0.3 metres (1.1 feet) for every mph of truck speed. For example a fully loaded truck traveling at 11.3 km/h (7 mph) must stop within 2.3 metres (7.7 feet).

Special Tools: Spanner Wrench P/N 5204248-76 NOTE: Stopping distance is regulated by the brake pressure adjustment. This should be checked on a regular schedule.

1. Tilt the mast to the full forward position. Make certain that the forks do not raise the carriage.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

2. Check that the key switch is in the off "O" position.

3. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 4. Remove the front cover. See Section 2-FRONT COVER-REMOVAL. 5. Using spanner wrench 5204248-76, rotate the torque plate on the brake assembly. Counterclockwise increases stopping distance, clockwise decreases stopping distance. See Figure 5-7.

NOTE: A dead-blow hammer may be required to move the torque plate on the brake assembly.

6. Connect the battery.

7. Test the stopping distance of the truck with a full rated load. If stopping distance is not within specification, repeat Steps 2 through 5.

NOTE: If brake pressure cannot be adjusted to attain specified stopping distance, the disc brake unit must be replaced. Refer to DISC BRAKE UNIT. 8. Install the front cover. See Section 2-FRONT COVER- INSTALLATION.

Figure 5-7 - Brake Pressure Adjustment

TROUBLESHOOTING PROBLEM

POSSIBLE CAUSE

CORRECTIVE

Sheet 11: Brake System One brake drags

Both brakes drag

Brake line restricted Air in system Damaged disc brake unit Improperly adjusted wheel bearing One brake line pinched or dented Mineral or other contaminants in system Damaged master cylinder

Brake linkage to master cylinder adjusted wrong Both disc brake units are damaged Pinched or dented brake line from master cylinder Master cylinder push rod too long Foreign material under brake pedal Brake pedal will not come up Return spring broken or disconnected Brake pedal raises too high Pedal stop out of adjustment or stop bolt missing Unequal braking Wheel brake spring broken or out of adjustment Water oil or brake fluid on linings

Brakes chatter Brakes do not hold Noisy or grabbing brakes

Brakes do not release

Damaged disc brake unit Not enough pressure being applied due to improperly adjusted brake spring Brake linkage not properly adjusted Broken brake spring Pinched or plugged brake line tubing Linings glazed or worn Oil grease or brake fluid on linings Improperly adjusted brake spring Air in brake line Damaged master cylinder Improperly adjusted push rod linkage

Flush brake system Bleed system Replace disc brake unit Remove, clean, inspect and adjust Replace damaged brake line Flush system Repair using master cylinder repair kit, or replace master cylinder Adjust master cylinder Replace disc brake units Replace damaged brake line Shorten push rod Remove foreign material Replace and/or reconnect Readjust or replace stop bolt Replace or readjust Replace disc brake unit - Take necessary steps to prevent future contamination Replace disc brake unit Adjust Adjust Replace and adjust Replace and bleed system Replace Replace disc brake unit - Take necessary steps to prevent future contamination Adjust Bleed brake lines Repair using master cylinder repair kit or replace cylinder Adjust

Sheet 12: Steering System

STEERING SYSTEM GENERAL This section contains the description and repair procedures for the complete steering assembly fitted to the ESC 030 ZA, ESC 035 ZA, ESC 040 ZA, and ESC 050 ZA lift trucks. See Section 7, Hydraulic System for additional information on the steering system. See Section 3, Electrical System for additional information on servicing the steer pump motor.

DESCRIPTION The steering systems of the ESC 030 ZA, ESC 035 ZA, ESC 040 ZA, and ESC 050 ZA lift trucks consist of the following components: the steer motor and pump, the steer control valve and tiller, the hydraulic motor, the steering gears and the steer fork assembly. A potentiometer, attached to the top of the steering fork, is used by the system controller to determine the position of the steer tire. An indicator is incorporated in the operator's display to show the angle of the steer wheel(s).

Hydraulic fluid from the reservoir is drawn into the steering system by the steer pump. This gear pump is driven by a DC electric motor and is controlled by the lift amplifier. A pressure relief valve is included in the pump assembly.

Pressurized fluid is directed to the steer control valve. The steer control valve meters the flow rate and direction of the oil flow to the hydraulic motor. Speed and direction of hydraulic motor rotation is dependent on the amount of oil the steer control valve passes and the direction of the flow.

The hydraulic motor converts the hydraulic flow into rotational movement. Fluid is directed to the motor in proportion to the amount of movement of the steering tiller. As the tiller is moved, a metered amount of hydraulic fluid is directed to the hydraulic motor. As this fluid enters the motor, the output shaft of the motor is rotated. A pinion gear attached to the output shaft of the motor rotates the spur gear, which is attached to the steer fork assembly.

STEER PUMP AND MOTOR ASSEMBLY-REPAIRS Removal NOTE: The steer pump can be removed from the motor without removing the steer pump and motor assembly from the truck. Refer to STEER PUMP-REMOVAL.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Check that the key switch is in the off "O" position.

2. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 3. Remove the battery. See Section 2-BATTERY-RE MOVAL. 4. Remove the left drive unit (the drive unit in front of the steer pump and motor assembly). See Section 4-DRIVE UNIT-REMOVAL. 5. Label and disconnect the electrical cables from the steer pump motor.

6. Clean the area around the hydraulic connections to the steer pump.

WARNING: Before disconnecting any hydraulic lines, relieve the pressure in the lines. To relieve pressure in any auxiliary lines, let the truck sit for approximately five minutes. When removing hydraulic hoses, use care to avoid contaminating electrical components with oil.

7. Disconnect and cap the hydraulic lines from the steer pump.

Sheet 12: Steering System 8. Attach a lifting device to the steer pump and motor assembly for support.

WARNING: The steer pump and motor assembly is heavy. Be sure that all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the steer pump and motor assembly.

9. Remove the four capscrews, flat washers and flange locknuts securing the steer pump and motor assembly to the front frame of the truck.

10. Remove the steer pump and motor assembly from the truck.

Installation 1. Align the steer pump and motor assembly with the mounting holes in the front frame of the truck.

2. Attach the steer pump and motor assembly to the front frame of the truck with four capscrews, flat washers and flange locknuts.

3. Attach the hydraulic lines to the steer pump.

4. Reattach the electrical cables on the steer pump motor. (Ensure the electrical cables are returned to the correct terminals.)

5. Replace the left drive unit. See Section 4-DRIVE UNIT-INSTALLATION. 6. Install and reconnect the battery.

Sheet 12: Steering System

Figure 6-1 Hydraulic Motor and Steering Gear Assembly* 1. STEER POSITION POTENTIOMETER 2. MOUNTING BRACKET 3. FLEXIBLE COUPLING 4. CAPSCREW 5. FLAT WASHER 6. FASTENER 7. UPPER PLATE 8. HYDRAULIC MOTOR 9. LOCKWASHER 10. WOODRUFF KEY 11. PINION GEAR 12. COTTER PIN 13. SLOTTED HEX. NUT 14. GEAR BOX 15. JAM NUT 16. BUSHING 17. SPUR GEAR *FOR HOSES, CONNECTIONS, AND STEER PUMP, REFER TO THE HYDRAULIC SYSTEM

Sheet 12: Steering System STEER PUMP Removal NOTE: If the steer pump and motor assembly has already been removed from the lift truck, proceed to Step 7.

1. Tilt the mast to the full forward position.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

2. Check that the key switch is in the off "O" position.

3. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 4. Remove the front cover. See Section 2-FRONT COVER-REMOVAL. 5. Clean the area around the hydraulic connections to the steer pump.

WARNING: Before disconnecting any hydraulic lines, relieve the pressure in the lines. To relieve pressure in any auxiliary lines, let the truck sit for approximately five minutes. When removing hydraulic hoses, use care to avoid contaminating electrical components with oil.

6. Disconnect and cap the hydraulic lines from the steer pump.

7. Remove the four capscrews and lockwashers securing the steer pump to the steer pump motor.

8. Separate the steer pump from the steer pump motor.

9. Remove the steer pump from the truck.

10. Disassemble the steer pump as necessary for repairs. See Section 7-HYDRAULIC GEAR PUMP-DISASSEMBLY. Installation 1. Position the steer pump on the steer pump motor shaft.

2. Attach the steer pump to the steer pump motor with four capscrews and lockwashers. Tighten the screws to 23 N m (17 lbf ft).

3. Attach the hydraulic lines to the steer pump in the correct locations.

4. Install the front cover. See Section 2-FRONT COVER- INSTALLATION. 5. Connect the battery.

STEER CONTROL VALVE Removal

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Check that the key switch is in the off "O" position.

Sheet 12: Steering System 2. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE.

WARNING: Before disconnecting any hydraulic lines, relieve the pressure in the lines. To relieve pressure in any auxiliary lines, let the truck sit for approximately five minutes. When removing hydraulic hoses, use care to avoid contaminating electrical components with oil.

3. Remove the top cover and the control cover. See Section 2-TOP COVER and CONTROL COVER-REMOVAL. 4. Remove the pad on the left side of the operator compartment. See Section 2-OPERATOR COMPARTMENT PADS-REMOVAL.

WARNING: The hydraulic hoses MUST be connected to the correct ports or the steering system will not operate as expected. This operation that is not expected can cause damage or personal injury. Make sure the hoses are correctly identified and connected correctly.

5. Place identifying tags on all of the hydraulic hoses. Note the orientation of the steer control valve to the mounting bracket.

6. Remove the hydraulic hoses from the steer control valve.

7. Remove four socket head screws, flat washers and nylon locknuts. Remove the steer control valve mounting bracket from the lift truck.

8. Place the steer control valve and bracket on a clean work surface. Remove the four capscrews, lockwashers and flat washers. The steering column will separate from the bracket and valve.

Installation 1. Attach the steer control valve and the steering column to the mounting bracket, in the same orientation noted in Step 7 of REMOVAL, with four capscrews, lockwashers and flat washers.

2. Connect the battery.

3. Install the steer control valve and mounting bracket assembly to the truck and secure them with four socket head screws, flat washers and nylon locknuts.

WARNING: The hydraulic hoses MUST be connected to the correct ports or the steering system will not operate as expected. This operation that is not expected can cause damage or personal injury. Make sure the hoses are identified and connected correctly.

4. Install the hydraulic hoses in the correct locations.

5. Install the steering tiller using the socket head shoulder bolt.

6. Connect the battery and check the operation of the steering system.

7. Check all hydraulic connections for leaks.

8. Install the left hip pad in the operator compartment. See Section 2-OPERATOR COMPARTMENT PADS-INSTALLA TION. 9. Install the control cover and the top cover. See Section 2-TOP COVER and CONTROL COVER-INSTALLATION.

Sheet 12: Steering System

Figure 6-2 - Steer Control Valve Assembly 1. STEER CONTROL VALVE 2. SOCKET HEAD SCREW 3. FLAT WASHER 4. LOCKNUT 5. STEER COLUMN BRACKET 6. CAPSCREW 7. LOCKWASHER 8. TILLER 9. KNOB 10. SHOULDER BOLT

HYDRAULIC MOTOR Removal

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Check that the key switch is in the off "O" position.

2. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 3. Remove the top cover and the control cover. See Section 2-TOP COVER and CONTROL COVER-REMOVAL. 4. Remove the steer position potentiometer. Refer to STEER POSITION POTENTIOMETER-REMOVAL.

WARNING: Before disconnecting any hydraulic lines, relieve the pressure in the lines. To relieve pressure in any auxiliary lines, let the truck sit for approximately five minutes. When removing hydraulic hoses, use care to avoid contaminating electrical components with oil.

Sheet 12: Steering System WARNING: The hydraulic hoses MUST be connected to the correct ports or the steering system will not operate as expected. This operation that is not expected can cause damage or personal injury. Make sure the hoses are correctly identified and connected correctly.

NOTE: The hydraulic lines must be removed before removing the mounting screws from the hydraulic motor.

Hoses should be labeled to help install them correctly.

5. Remove the four capscrews, lockwashers and flat washers securing the mounting bracket.

6. Remove the hydraulic motor mounting plate by threading two capscrews UNC 3/8-16*3 inches long through the threaded holes (Item 1 in Figure 6-3). Alternately tighten the screws until the mounting plate is free.

Figure 6-3 - Hydraulic Motor Removal 1. THREADED HOLES 7. Remove the cotter pin, then the castle locknut from the hydraulic motor shaft.

NOTE: There are four capscrews securing the hydraulic motor to the mount plate. Three are 25 mm (1 in) long, one is 16 mm (0.625 in) long. Note that the shorter screw fits in a counterbore in the bottom of the mount plate so it will clear the spur gear.

8. Remove the four capscrews securing the motor to the mounting bracket.

9. Using a brass drift and hammer, drive the motor shaft from the gear.

10. Remove the hydraulic motor.

Installation 1. Install the hydraulic motor onto the mounting bracket and secure it with four capscrews and lockwashers.

NOTE: There are four capscrews securing the hydraulic motor to the mount plate. Three are 25 mm (1 in) long, one is 16 mm (0.625 in) long. Note that the shorter screw fits in a counterbore in the bottom of the mount plate so it will clear the spur gear.

2. Install the hydraulic motor gear onto the hydraulic motor shaft with a woodruff key, cotter pin and castle locknut.

3. Lower the hydraulic motor and bracket into position and align the mounting holes with the studs.

4. Install the mounting capscrews until finger tight. Gradually tighten the mounting capscrews in an alternating pattern to 45 N m (33 lbf ft) torque.

Sheet 12: Steering System 5. Install the steer position potentiometer. Refer to STEER POSITION POTENTIOMETER INSTALLATION. 6. Install the hydraulic hoses in the correct locations.

7. Install the steering tiller and secure it using the socket head shoulder bolt.

8. Connect the battery and test the steering system for proper operation. Inspect all of the hydraulic hoses and fittings for leaks.

9. Disconnect the battery and separate the connector.

10. Remove the socket head shoulder bolt then remove the steering tiller.

11. Install the control cover and the top cover. See Section 2-TOP COVER and CONTROL COVER-INSTALLATION. 12. Connect the battery.

STEERING GEAR Removal

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Check that the key switch is in the off "O" position.

2. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 3. Remove the top cover and the control cover. See Section 2-TOP COVER and CONTROL COVER-REMOVAL. 4. Remove the steer control valve and bracket. Refer to STEER CONTROL VALVE-REMOVAL. It is not necessary to remove the hydraulic hoses.

5. Remove the hydraulic motor and steer position potentiometer. Refer to HYDRAULIC MOTOR-REMOVAL and STEER POSITION POTENTIOMETER-REMOVAL. It is not necessary to remove the hydraulic hoses.

CAUTION: If the lift truck is blocked up off the floor, removing the locknut on the steer fork will allow the steer fork to drop to the floor. Place blocks or supports under the steer fork assembly. See Section 1-HOW TO RAISE THE STEER TIRE. 6. Remove the locknut securing the steering gear to the steer fork assembly.

7. Lift the steering gear off the steer fork shaft.

Installation 1. Before installing the steering gear, make sure the steer fork is properly positioned.

2. Install the steering gear on the splined portion of the steer fork shaft.

3. Install the locknut on the steer fork. Tighten the locknut to 47 to 54 N m (35 to 40 lbf ft) torque.

4. Jack the rear of the truck up until the steer wheel is off the ground and put the truck on blocks. See Section 1-HOW TO RAISE THE LIFT TRUCK. As the nut on the steer fork shaft is tightened, the steer fork should be checked to make sure it can rotate freely. Over tightening or under tightening of this nut can cause excessive wear on the bearings and steer fork shaft.

5. Install the hydraulic motor and the steer position potentiometer. Refer to HYDRAULIC MOTOR-INSTALLA TION and STEER POSITION POTENTIOMETER-INSTALLA TION.

Sheet 12: Steering System 6. Install the steer control valve. Refer to STEER CONTROL VALVE-INSTALLATION. 7. Check all hydraulic lines on the steering components for tightness.

8. Install the control cover and top cover. See Section 2-TOP COVER and CONTROL COVER-INSTALLATION. 9. Connect the battery.

STEER FORK ASSEMBLY Removal NOTE: To allow for the removal of the steer fork from the lift truck, the unit must be at least 690 mm (27 in) off the floor. The steer fork assembly is 915 mm (36 in) in length. If the truck is not 690 mm (27 in) off the floor, there is not enough clearance to remove the steer fork from the truck.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Check that the key switch is in the off "O" position.

2. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE.

WARNING: The removal of the steer fork requires that the lift truck be raised at least 690 mm (27 in) off the floor. Make certain that the lift truck is securely blocked to keep it from tipping over causing damage to the lift truck or personal injury.

3. Place the lift truck on jack stands at least 690 mm (27 in) off the floor. See Section 1- HOW TO RAISE THE STEER TIRE.

WARNING: The steer fork assembly must be supported by a suitable lifting device prior to removing the steering gear. If the steer fork assembly is not supported, serious damage to the lift truck or the steer fork may occur. Personal injury is also possible.

WARNING: The steer fork assembly is heavy. Be sure that all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the steer fork assembly.

4. Remove the steering gear. Refer to STEERING GEAR-REMOVAL. NOTE: During the removal and installation of the steer fork, use care to avoid damaging the bearing seals or the threads and splines on the steer fork shaft.

5. Lower the steer fork assembly to the floor.

Installation NOTE: The steer fork must be installed with the stop pin toward the front of the truck.

WARNING: The steer fork assembly is heavy. Be sure that all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the steer fork assembly.

1. Raise the steer fork into position with a suitable lifting device.

2. Install the steering gear. Refer to STEERING GEAR- INSTALLATION.

Sheet 12: Steering System 3. Lower the lift truck from the blocks. See Section 1-HOW TO RAISE THE STEER TIRE. 4. Install and connect the battery.

STEER WHEEL ASSEMBLY Removal 1. Rotate the steer fork fully counterclockwise.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

2. Check that the key switch is in the off "O" position.

3. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 4. Place the rear of the truck on blocks 50 to 75 mm (2 to 3 in) high. See Section 1-HOW TO RAISE THE STEER TIRE. 5. Remove the cotter pin from the castle nut securing the steer wheel axle in place.

6. Remove the castle nut from the steer wheel axle.

CAUTION: Use either a jack or jack stand to support the steer wheel assembly as the axle is removed. Once the axle is removed, the steer wheel(s) is(are) released from the steer fork assembly.

7. Remove the steer axle from the steer fork assembly.

8. Remove the steer wheel assembly.

NOTE: Inspect the steering axle, bearings and seals for wear or damage. Replace all worn or damaged parts prior to replacing the steer wheel assembly into the steer fork.

Installation 1. Rotate the steer fork fully clockwise.

2. Position the steer wheel assembly in the steer fork. Align the center hole of the steer wheel assembly with the axle holes in the steer fork. Note the position of the grease fittings on the wheels. The fittings should face the outside of the assembly.

Sheet 12: Steering System

Figure 6-4 - Steer Wheel Assembly 1. STEER WHEEL 2. STEER FORK 3. DUAL WHEEL AXLE 4. SPACER 5. SEAL 6. CONE BEARING 7. NUT 8. COTTER PIN 9. GREASE FITTING 10. BEARING CUP 3. Install the steer axle into the steer fork and the steer wheel assembly.

4. If installing a single steer wheel, install the grease fitting and adapter into the end of the steer axle.

5. Rotate the steer fork fully counterclockwise.

6. Install the castle nut on the steer axle.

CAUTION: Do not over tighten the castle nut on the steering axle. This nut serves as a bearing tightening adjustment. The nut should be tightened enough to remove any lateral play yet allow the steer wheel assembly to turn freely. If the nut is either over tightened or under tightened, the bearings and the steer axle may be damaged.

7. Tighten the castle nut and install the cotter pin.

8. Using a grease gun, fill the cavity of the steer wheel with grease. On single steer wheel units, the grease fitting is in the end of the axle. On dual steer wheel units, each of the steer wheels have a grease fitting on the outside edge of the wheel. See Section 2-LUBRICATION CHARTS. 9. Remove the lift truck from the blocks.

10. Connect the battery.

Sheet 12: Steering System STEER POSITION POTENTIOMETER Removal

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

1. Check that the key switch is in the off "O" position.

2. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 3. Remove the top cover and the control cover. See Section 2-TOP COVER and CONTROL COVER-REMOVAL. 4. Disconnect the 3-pin connector between the steer position potentiometer and the wiring harness.

5. Loosen the set screw securing the flexible coupler to the steer potentiometer shaft.

6. Remove the two capscrews, flat washers and four interlocking fasteners holding the potentiometer mounting bracket to the hydraulic motor mounting bracket.

7. Remove the jam nut then the steer position potentiometer from the bracket.

Installation 1. Install the potentiometer into the steering potentiometer bracket and secure it with one jam nut.

2. Slide the flexible coupler over the steer position potentiometer and tighten the set screw.

3. Install the steer potentiometer mounting bracket on the hydraulic motor bracket and secure it with two capscrews and flat washers and four interlocking fasteners.

4. Connect the 3-pin connector from the potentiometer to the main harness.

5. Perform the steer position potentiometer voltage adjustment. Refer to STEER POTENTIOMETER-ADJUSTMENT. 6. Install the control cover and the top cover. See Section 2-CONTROL COVER and TOP COVER-INSTALLATION. 7. Connect the battery.

STEER POSITION POTENTIOMETER ADJUSTMENT 1. Manually center the steer tire(s) in the straight forward position. Visually inspect the position.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

2. Check that the key switch is in the off "O" position.

3. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 4. Remove the top cover. See Section 2-TOP COVER-RE MOVAL. 5. Loosen the setscrew securing the potentiometer coupling to the steering fork shaft.

6. Disconnect the 3-pin connector.

7. Using the 2K ohm scale of a digital multimeter, attach the leads to pin A and pin C of the female end of

Sheet 12: Steering System the 3-pin connector. (See Figure 6-5.) Note the reading obtained.

Figure 6-5 - Steer Potentiometer Wiring Diagram 8. The center value for the potentiometer is half of the value found in Step 7.

9. Connect the digital multimeter to pin A and pin B of the female end of the 3-pin connector.

10. Manually adjust the potentiometer until the value calculated in Step the setscrew.

is displayed on the meter. Tighten

11. Connect the 3-pin connector.

12. Install the top cover. See Section 2-TOP COVER- INSTALLATION. 13. Connect the battery.

CHANGING STEER TIRES 1. Remove the steer wheel assembly. See Section 2-STEER WHEEL ASSEMBLY-REMOVAL. NOTE: Many users have a special repair service remove and replace tires. The capacity of the press must be approximately 36,320 kg (80,000 lbs.).

2. Remove the seals, spacers and bearings.

3. Press the wheel from the rim and tire.

4. Press the new tire onto the wheel.

5. Install the bearings and seals (and spacers on dual steer wheels).

6. Install the steer wheel assembly. See Section 2-STEER WHEEL ASSEMBLY-INSTALLATION.

STEERING PRESSURE ADJUSTMENT

WARNING: DO NOT exceed the steering pressures recommended by the manufacturer.

NOTE: The pressure for the steering system is dependent on the model of truck. On the E30FR-24 models with the single steer tire, the steering system pressure should be 5.95 to 6.3 MPa (850 to 900 psi). On the models with the dual steer tires the steering system pressure should be 4.7 to 5.0 MPa (675 to 725 psi). The internal relief valve is located on the steer pump. A check valve is also located in the outlet port of the steer pump.

1. Tilt the mast to the full forward position

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

2. Check that the key switch is in the off "O" position.

Sheet 12: Steering System 3. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 4. Remove the front cover. See Section 2-FRONT COVER-REMOVAL. 5. Connect a pressure gauge to the check port on the outlet side of the steer pump.

6. Connect the battery and turn the key switch to the "I" position.

7. Enter the PERFDIAG with a high-level password. Refer to PROGRAMING AND DIAGNOSTIC, see the Electrical System chapter. Go to the DIAGNOSTIC MENU (DIAGNSTC) and select OUTPUTS. Set O 02 to closed. This will turn on the steer pump motor.

8. Turn the steering tiller all the way to either the left or right. Read the pressure gauge while holding the tiller against the stop. DO NOT hold the tiller against the stop for more than five seconds. The steering system pressure should be 4.7 to 5.0 MPa (675 to 725 psi). If necessary adjust the pressure setting.

9. Turn the steer pump off by setting O 02 to open.

10. To adjust the pressure, remove the cap from the adjustment screw located on the bottom of the steer pump. Turn the steer pump on as listed in Step 9.

Figure 6-6 - Steer Pump Adjustment Location 11. Use a standard screwdriver to turn the adjustment screw. Turn the adjustment screw until the proper pressure is obtained. Turning the adjustment screw clockwise will increase the pressure, while turning the adjustment screw counterclockwise will decrease the pressure.

12. After the proper pressure has been obtained, turn the steer pump off by setting O 02 to open. Turn the key switch to the off "O" position.

13. Install the cap on the adjustment screw.

14. Install the front cover. See Section 2-FRONT COVER- INSTALLATION. 15. Connect the battery.

STEER PUMP MOTOR Brush Removal and Installation The brushes and springs for the steer pump motor are furnished with the rear end bell head. To replace the steer motor rear end bell head, see Section 3-ELECTRICAL SYSTEM.

Sheet 14: Steer Pump and Motor Assembly STEER PUMP AND MOTOR ASSEMBLY To remove the steer pump and motor assembly, see Section 6-STEER PUMP-REMOVAL. To replace the steer motor rear end bell head, see Section 3-ELECTRICAL SYSTEM.

Figure 7-2 - Types of Gear Pumps 1.

2.

3.

4.

ONE SECTION PUMP DRIVE GEAR TWO SECTION PUMP DRIVEN GEAR

HYDRAULIC GEAR PUMPS DESCRIPTION (See Figure 7-2) Gear pumps are made in three or more sections. Each gear pump has two covers and a gear housing with the gears. Seals prevent leaks between the sections. The inlet and outlet ports are on the gear housing or rear cover.

The front cover contains the seal for the input shaft. The input shaft connects to a driven sprocket, coupling or gear by splines or a key.

All the gear pumps have devices that keep the thrust clearance at a minimum when the pressure increases. When the pressure is low, the clearance increases to prevent wear. To prevent leakage when the pressure is high, the oil from the outlet side of the pump is transferred to a wear plate. The oil pushes the wear plate against the gears.

Gear pumps are designed with the teeth of the gears engaged in the center of the pump. When the input shaft is turned, the drive gear turns the driven gear. The oil in the inlet chamber is moved out from the center by the teeth of the rotating gears. The oil between the teeth moves around the pumping chamber to the outlet chamber. When the gear teeth begin to engage, they push the oil from the outlet chamber. See Figure 7-3.

Sheet 14: Steer Pump and Motor Assembly

Figure 7-3 - Operation of Gear Pumps 1. INLET 2. OUTLET 3. SEAL MADE BY GEAR TEETH

Figure 7-4 - Check Ball & Spring 1. OIL ENTERS GROOVES IN BUSHINGS 2. OIL ENTERS INLET CHAMBER The gears and the bearings are lubricated by oil from the outlet side of the pump. A small amount of oil flows past the gears and into the bearings and to the front seal cavity. A check ball and spring are installed in some pumps to keep pressure on the oil in this passage.

The oil pressure prevents air leaks through the front seal and makes sure there is oil to the bearings. When the pressure increases to the spring setting, the ball moves from the seat and oil flows to the inlet chamber. See Figure 7-4.

Sheet 14: Steer Pump and Motor Assembly FLOW CONTROL VALVE Some of the pumps have a flow control valve in the rear cover. The flow control valve has either a piston and spring or a cartridge with a piston and spring. The piston has an orifice that permits a constant volume of oil to flow to the controlled flow port. When the pump speed increases, the piston moves to partly open the passage to the hydraulic manifold block. This action keeps the pressure difference across the orifice constant. A constant pressure difference between both sides of an orifice causes a constant flow through the orifice.

RELIEF VALVE Some pumps have a relief valve installed in a cartridge or in a bore in the rear cover. Relief valves in the pump prevent the pressure in the flow controlled system from increasing beyond the specifications. The relief valve in the cartridge has a poppet and spring, with the seat for the poppet in the cartridge. The relief valve and flow control valve on some pumps are installed in the same cartridge. Some of the relief valves that are installed in the pumps are adjustable only with shims. Replace the cartridge if the relief valve has a problem.

REPAIRS DISASSEMBLY (See Figure 7-6 and Figure 7-7) 1. Remove the gear, sprocket or coupling from the input shaft.

2. Before disassembling the pump, make alignment marks on all the housings. Some of the housings can be assembled in the wrong positions, causing failure or increased wear. Carefully clean the outside of the pump.

NOTE: The inlet ports in most gear pumps are larger than the outlet ports.

3. Remove the capscrews or nuts that hold the housing together. Use a plastic hammer to separate the housings. Do not damage the machined surfaces.

4. Remove the gears and thrust plates. Note the positions of the thrust plates, seals, and gaskets. Do not use a punch to mark the parts. Remove any springs and check valves.

5. Remove the front seal.

NOTE: The position of the seals is important. In some pumps the direction of pump rotation is reversed by changing the position of the seals and housings. The holes in the seals must be aligned with the oil passages in the housing sections. The oil passage for the thrust plates is in the outlet chamber.

CLEANING

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

WARNING: Compressed air can move particles so that they cause injury to the user or to other personnel.

Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

Clean all parts of the pump with solvent and thoroughly dry the pans. Pieces of the cloth can cause restrictions in the hydraulic system. Make sure the work area and tools are very clean.

CAUTION: Any dirt that enters the hydraulic system can cause damage to the parts.

Sheet 14: Steer Pump and Motor Assembly

Figure 7-5 - Basic Parts of a Gear Pump 1.

2.

3.

4.

5.

6.

7.

INPUT SHAFT BEARING BLOCKS REAR COVER DRIVE GEAR CARTRIDGE FLOW CONTROL AND RELIEF VALVE DRIVEN GEAR FRONT COVER

INSPECTION 1. Inspect the outside edges of the gear teeth for grooves or scratches. If the edges are sharp, use emery cloth to break the edges. Replace the gears if there are deep grooves on the gears.

2. If the gear shafts have grooves or are worn more than 0.05 mm (0.002 in), they must be replaced. Wear on the seal area of the shaft indicates dirt in the oil or a hard seal. Inspect the seal to see if it has been too hot. Look for small cracks in the sealing surface. If the seal was too hot or the wrong oil was used, the seal will be too hard or too soft. Inspect the splines or key groove for damage.

3. Inspect the gear housing for wear or grooves. Most wear occurs on the inlet side of the gear chamber. Put a straight edge across the inlet side of the gear chamber. If a 0.13 mm (0.005 in) thickness gauge fits between the straight edge and the housing, the gear housing must be replaced. If the gear housing is worn, inspect the bearings or bushings for wear. If the system pressure is too high, the gear housings will wear quickly.

Grooves in the gear chamber indicate dirt is in the oil. Small holes in the outlet side of the gear chamber indicate that cavitation has occurred. Make sure the inlet hose, fittings and tank have no restrictions. Cavitation can also occur when the motor speed is too high.

If the surfaces of the gear chamber or gear teeth have blue marks, the pump was too hot. Heat damage in the pump can be caused by hot oil or lack of oil. Check the front seal surface to see if air was entering the pump through the front seal. Make sure the oil is the correct viscosity. The wrong viscosity oil can increase leakage within the pump. Leakage inside the pump increases the oil temperature.

4. Check the thrust plates for wear or grooves. If the thrust plate is worn more than 0.05 mm (0.002 in), it must be replaced. Replace the thrust plate if it has grooves or holes. Dirty oil causes the thrust plate to wear near where the gears engage. Small holes on the outlet side of the thrust plate are caused by cavitation. Lack of oil can also cause small holes in the thrust plates. If the color of the thrust plates has changed, the pump was too hot.

5. Inspect all the machined surfaces for scratches or damage. Remove with emery cloth any metal that is

Sheet 14: Steer Pump and Motor Assembly above the flat surface. Check the surfaces with a straight edge. Inspect the seal grooves for dirt or scratches.

6. Inspect the bearings for wear or damage. Replace the bearings if there are any small holes on the bearing surface. Replace the bushing if it is not round.

7. Look for damaged seals. Replace all the seals and O-rings, even if they are in good condition. Look for cuts or changes in shape that can cause leaks. Find out what caused the pump to fail. A worn thrust plate seal can cause the shaft seal to leak. A worn shaft seal can cause air to enter the hydraulic system.

Figure 7-6 - Typical Single Hydraulic Pump 1. END COVER 2. SEAL 3. BEARING 4. GEARS AND SHAFT 5. BOLT 6. WASHER 7. END PLATE 8. SEAL 9. PUMP BODY 10. SEAL 11. BOLT 12. WASHERS 13. GASKET 14. BEARING 15. SNAP RING 8. If any pump parts have damage from dirt in the oil, inspect the hydraulic tank. Drain the tank, clean the screen and tank, and replace the filter. Use only Yale approved hydraulic oil, see Section 2-LUBRICATION CHARTS.

CAUTION: Do not permit dirty oil to enter the gear pump.

9. Inspect the inlet hose to the gear pump. Use a lamp to look inside the hose. Look for pieces of the rubber

Sheet 14: Steer Pump and Motor Assembly that are separating from the hose. Inspect the hose for restrictions at the bends. Check for loose fittings or damaged O-rings.

ASSEMBLY 1. Lubricate all parts with hydraulic oil before installing them into the pump.

CAUTION: Make sure no dirt enters the pump during assembly.

2. Install the seal on the front cover. Make sure the seal is installed correctly.

3. Assemble the gears, thrust plate, gaskets, seals, O-rings and other parts of the pump according to the diagrams.

See Figure 7-6 and Figure 7-7.

CAUTION: Make sure the holes in the gaskets and seals are aligned with the holes in the output side of the pump. The pump will not operate correctly if the oil from the outlet chamber cannot flow to the thrust plate.

4. Align the marks on the gear housing with the marks on the covers. Use a plastic hammer to join the sections.

5. Install the capscrews or studs and tighten with your fingers. Rotate the driveshaft to make sure the pump is assembled correctly. Tighten the capscrews or nuts to the recommended specifications using an "X" sequence.

Figure 7-7 - Power Steering Pump 1.

2.

3.

4.

5.

6.

PUMP COUPLING SPRING COUPLING GREASE SEAL COVER-FRONT SPRING AND BALL ADJUSTMENT SCREW

Sheet 14: Steer Pump and Motor Assembly 7. HEX. CAP ASSEMBLY 8. NEEDLE BEARING 9. SNAP RING 10. SHAFT-DRIVE 11. SHAFT-IDLER 12. BALL 13. PIN, DRIVE SHAFT 14. GASKET 15. GEAR AND HOUSING SET 16. O-RING, SEAL 17. DOWEL PIN 18. COVER-BACK 19. PLASTIC PLUG 20. PLASTIC PLUG 21. WELCH PLUG 22. WASHER HD. SCREW 23. WASHER HD. SCREW

Sheet 15: Checks and Adjustments CHECKS AND ADJUSTMENTS NOTE: Always install a new filter when repairs are made to the hydraulic system. Drain and replace the hydraulic oil if the oil is dirty or burned.

CAUTION: Do not operate any valve until the pump has run for three minutes at low pressure and low speed. Do not permit hot oil to enter a cold pump.

CHECKING THE OUTPUT OF THE PUMP (See FIGURE 7-8 and FIGURE 7-9) Two methods are given for checking the volume of flow from the pump. The first method uses a flow meter, a pressure gauge, and a needle valve. The second method uses a needle valve, pressure gauge, container and timer.

1. If a flow meter is available, install the flow meter between a needle valve and the outlet port of the pump. The pressure gauge must be between the needle valve and the pump. When the hydraulic oil is at operating temperature, run the motor with no load on the hydraulic system. Note the reading of the flow meter. Compare the output rate of the pump with the specifications.

Figure 7-8 - Checking the Pump Output with a Flow Meter 1.

2.

3.

4.

5.

6.

7.

8.

PUMP INLET PORT OUTLET PORT HYDRAULIC TANK PRESSURE GAUGE TEE FITTING FLOW METER NEEDLE VALVE

Sheet 15: Checks and Adjustments

Figure 7-9 - Checking the Pump Output 1.

2.

3.

4.

5.

6.

7.

8.

9.

PUMP INLET PORT OUTLET PORT HYDRAULIC TANK PRESSURE GAUGE TEE FITTING NEEDLE VALVE CONTAINER TIMER

2. Run the motor at the maximum speed. Slowly close the needle valve until the gauge indicates a pressure just below the specification for the relief valve setting. The pump output at the high pressure point must be within 25% of the output with no load. If the output at high pressure is less than 75% of the low pressure output, the pump is damaged.

WARNING: Hydraulic oil may be hot.

Do not touch the oil during the tests.

3. Another method of checking the pump output is to measure the amount of oil moved in a given amount of time. Run the motor until the oil is between 54°C to 65°C (130°to 150° F). Disconnect the line from the outlet port of the pump. Install the needle valve on the end of the hose. Connect another hose to the needle valve. Put the other end of the hose in a container with an 18 litre (5 gallon) capacity and a cover. Make sure the truck hydraulic tank is full.

CAUTION: This test must be done quickly to prevent the hydraulic tank from becoming empty. Do not operate the motor when there is no oil in the hydraulic tank.

4. The needle valve must be fully open. Run the motor at the maximum speed for 5 seconds. Stop the motor.

Measure the volume of oil that entered the container in 5 seconds. Multiply the quantity in the container by 12 to find the output per minute. Compare the pump output rate with the specifications. The pump output and rate

Sheet 15: Checks and Adjustments must be within 20% of the specifications.

5. Run the motor. Close the needle valve until the pressure increases to just below the relief valve setting. Measure the volume of fluid the pump moves in 5 seconds. Compare this quantity with the results from the test of the pump output at low pressure. The output of the pump at high pressure must be within 25% of the volume of oil moved at low pressure.

CHECKING FOR AIR IN THE HYDRAULIC SYSTEM If the pump makes noise or does not move the correct amount of oil, check for air in the system. Run the motor until the oil is warm. Remove the filter cap and look into the tank. If there are bubbles in the oil, air is in the hydraulic system. The most common place of air entry is in the inlet hose to the pump. Check for air leaks by pouring oil over the fittings and hose when the motor is running. If the noise decreases, the leak is in that area. See the section TROUBLESHOOTING for other causes of air in the hydraulic system.

SPECIFICATIONS Hydraulic pump 36 N m (26 lbf ft) Steering pump 18 N m (13 lbf ft)

HYDRAULIC VALVE SOLENOID CARTRIDGE NOTE: There are five hydraulic valve solenoid cartridges on the manifold. See Figure 7-10. Three are double-solenoid valves controlling tilt, side shift, and auxiliaries. Two are single-solenoid valves for lift and lower.

Removal

WARNING: Unintentional lowering of the forks or movement of the mast may cause damage or injury.

Before removing any component on the manifold, lower or block the forks and allow the truck to sit for approximately five minutes to relieve the pressure in the lines.

1. Lower the forks completely and move the mast to the full forward position.

2. Turn the key switch to the off "O" position and allow the truck to sit for five minutes before doing any maintenance or repair on the hydraulic system.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

3. Turn the key switch to the off "O" position.

4. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 5. Remove the front cover and top cover. See Section 2-FRONT COVER and TOP COVER-REMOVAL. 6. Mark the wires to the solenoid(s) attached to the valve.

7. Remove the wires from the solenoid(s).

8. Remove the nut securing the solenoid(s) to the valve cartridge.

9. Remove the solenoid(s).

10. Place a shop towel over the top of the valve cartridge and loosen the cartridge 1/4 turn. Allow any internal pressure to escape. Remove the valve cartridge.

Installation

Sheet 15: Checks and Adjustments 1. Insert the cartridge into the opening and hand tighten.

2. Using a 25 mm (1 in) wrench, tighten the cartridge to 34 N m (25 lbf ft) torque.

3. Install the solenoid(s) and install the attachment nut. Tighten to 7 N m (5 lbf ft) torque.

4. Attach the control wires to the solenoid(s) in the locations from which they were removed.

5. Check the hydraulic oil level using the dipstick under the breather cap and fill to the proper level.

6. Connect the battery.

7. Operate the hydraulic system and check for leaks.

8. Disconnect the battery and separate the connector.

9. Install the top cover and front cover. See Section 2-FRONT COVER and TOP COVER-INSTALLATION. 10. Connect the battery.

Figure 7-10 - Hydraulic Manifold Block

Sheet 15: Checks and Adjustments 1. MANIFOLD 2. TILT VALVE 3. SIDE SHIFT VALVE 4. AUXILIARY VALVE 5. MANUAL LOWER VALVE 6. PRESSURE RELIEF VALVE 7. LIFT/LOWER VALVE 8. FLOW REGULATOR 9. LOWER VALVE 10. LIFT VALVE 11. CHECK VALVE 12. PRESSURE TRANSDUCER

PRESSURE RELIEF VALVE NOTE: The pressure relief valve is set to open at 21 MPa (3000 psi). Do not set relief pressure to a value other than factory specifications.

Removal

WARNING: Unintentional lowering of the forks or movement of the mast may cause damage or injury.

Before removing any component on the manifold, allow the truck to sit for approximately five minutes to relieve the pressure in the lines.

1. Lower the forks completely.

2. Move the mast to the full forward position.

3. Turn the key switch to the off "O" position and allow the truck to sit for five minutes before doing any maintenance or repair on the hydraulic system.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

4. Turn the key switch to the off "O" position.

5. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 6. Remove the front cover and top cover. See Section 2-FRONT COVER and TOP COVER-REMOVAL. 7. Place a shop towel over the relief valve. Using a 25 mm (1 in) wrench, loosen the relief valve 1/4 turn to relieve the internal pressure. Remove the relief valve cartridge.

Installation 1. Insert the relief valve cartridge into the opening and hand tighten.

2. Using a 25 mm (1 in) wrench, tighten the cartridge to 34 N m (25 lbf ft) torque. Adjust the pressure relief valve to the recommended setting. Refer to CHECKS AND ADJUST MENTS-RELIEF VALVE. 3. Connect the battery.

4. Operate the hydraulic system and check for leaks.

5. Disconnect the battery and separate the connector.

6. Check the hydraulic oil level using the dipstick under the breather cap and fill to the proper level.

Sheet 15: Checks and Adjustments 7. Install the top cover and front cover. See Section 2-FRONT COVER and TOP COVER-INSTALLATION. 8. Connect the battery.

MANUAL LOWERING VALVE Removal

WARNING: Unintentional lowering of the forks or movement of the mast may cause damage or injury.

Before removing any component on the manifold, lower or block the forks and allow the truck to sit for approximately five minutes to relieve the pressure in the lines.

1. Lower the forks completely.

2. Move the mast to the full forward position.

3. Turn the key switch to the off "O" position and allow the truck to sit for five minutes before doing any maintenance or repair on the hydraulic system.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

4. Turn the key switch to the off "O" position.

5. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 6. Remove the front cover and top cover. See Section 2-FRONT COVER and TOP COVER-REMOVAL. 7. Place a shop towel over the top of the manual lowering valve and loosen the valve 1/4 turn. Allow any internal pressure to escape. Remove the valve.

Installation 1. Insert the valve into the opening and hand tighten.

2. Using a 25 mm (1 in) wrench, tighten the valve to 34 N m (25 lbf ft) torque.

3. Connect the battery.

4. Operate the hydraulic system and check for leaks.

5. Disconnect the battery and separate the connector.

6. Check the hydraulic oil level using the dipstick under the breather cap and fill to the proper level.

7. Install the top cover and front cover. See Section 2-FRONT COVER and TOP COVER-INSTALLATION. 8. Connect the battery.

FLOW REGULATOR NOTE: There are two flow regulators on the manifold. See Figure 7-10.

Removal

WARNING: Unintentional lowering of the forks or movement of the mast may cause damage or injury.

Sheet 15: Checks and Adjustments Before removing any component on the manifold, lower or block the forks and allow the truck to sit for approximately five minutes to relieve the pressure in the lines.

1. Lower the forks completely.

2. Move the mast to the full forward position.

3. Turn the key switch to the off "O" position and allow the truck to sit for five minutes before doing any maintenance or repair on the hydraulic system.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

4. Turn the key switch to the off "O" position.

5. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 6. Remove the front cover and top cover. See Section 2-FRONT COVER and TOP COVER-REMOVAL. 7. Place a shop towel over the top of the flow regulator and loosen 1/4 turn. Allow any internal pressure to escape.

Remove the flow regulator.

Installation 1. Insert the flow regulator into the opening and hand tighten.

2. Using a 25 mm (1 in) wrench, tighten the cartridge to 47 N m (35 lbf ft) torque.

3. Connect the battery.

4. Operate the hydraulic system and check for leaks.

5. Disconnect the battery and separate the connector.

6. Check the hydraulic oil level using the dipstick under the breather cap and fill to the proper level.

7. Install the top cover and front cover. See the FRONT COVER and TOP COVER-INSTALLATION, Section 2.

8. Connect the battery.

Sheet 16: Proportional Valve Cartridge PROPORTIONAL VALVE CARTRIDGE Removal

WARNING: Unintentional lowering of the forks or movement of the mast may cause damage or injury.

Before removing any component on the manifold, lower or block the forks and allow the truck to sit for approximately five minutes to relieve the pressure in the lines.

1. Lower the forks completely.

2. Move the mast to the full forward position.

3. Turn the key switch to the off "O" position and allow the truck to sit for five minutes before doing any maintenance or repair on the hydraulic system.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

4. Turn the key switch to the off "O" position.

5. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 6. Remove the front cover and top cover. See Section 2-FRONT COVER and TOP COVER-REMOVAL. 7. Mark the wires to the solenoid attached to the valve.

8. Mark the wires to the solenoid attached to the valve.

9. Remove the wires from the solenoid.

10. Remove the nut securing the solenoid to the valve cartridge.

11. Remove the solenoid.

12. Place a shop towel over the top of the valve cartridge and loosen the cartridge 1/4 turn. Allow any internal pressure to escape. Remove the valve cartridge.

Installation 1. Insert the cartridge into the opening and hand tighten.

2. Using a 25 mm (1 in) wrench, tighten the cartridge to 47 N m (35 lbf ft) torque.

3. Install the solenoid and the attachment nut. Tighten the attachment nut to 23 N m (17 lbf ft) torque.

4. Attach the control wires to the solenoid in the locations from which they were removed.

5. Connect the battery.

6. Operate the hydraulic system and check for leaks.

7. Disconnect the battery and separate the connector.

8. Check the hydraulic oil level using the dipstick under the breather cap and fill to the proper level.

9. Install the top cover and front cover. See Section 2-FRONT COVER and TOP COVER-INSTALLATION. 10. Connect the battery.

HYDRAULIC OIL FILTER

Sheet 16: Proportional Valve Cartridge Removal

WARNING: Unintentional lowering of the forks or movement of the mast may cause damage or injury.

Before removing any component on the manifold, lower or block the forks and allow the truck to sit for approximately five minutes to relieve the pressure in the lines.

1. Lower the forks completely.

2. Move the mast to the full forward position.

3. Turn the key switch to the off "O" position and allow the truck to sit for five minutes before doing any maintenance or repair on the hydraulic system.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

4. Turn the key switch to the off "O" position.

5. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 6. Remove the front cover. See Section 2-FRONT COVER-REMOVAL. 7. Using an oil filter wrench, remove the oil filter canister.

8. Drain the oil into a suitable container and remove the filter element.

Installation 1. Install the new oil filter element into the oil filter canister.

2. Align the filter canister with the threaded base and hand tighten.

3. Connect the battery.

4. Check the hydraulic oil level using the dipstick under the breather cap and fill to the proper level.

5. Operate the hydraulic system and check for leaks.

6. Disconnect the battery and separate the connector.

7. Install the front cover. See Section 2-FRONT COVER- INSTALLATION. 8. Connect the battery.

HYDRAULIC OIL Removal 1. Lower the forks completely.

2. Move the mast to the full forward position.

3. Turn the key switch to the off "O" position and allow the truck to sit for five minutes before doing any maintenance or repair on the hydraulic system.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the

Sheet 16: Proportional Valve Cartridge frame or ground.

4. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 5. Remove the front cover. See Section 2-FRONT COVER-REMOVAL. 6. Place the lift truck on blocks to access the drain plug in the bottom of the hydraulic oil tank. See Section 2-LUBRICATION CHARTS. 7. Remove the breather cap and dipstick from the filler tube of the hydraulic reservoir.

8. Place a pan of adequate size, minimum 38 litres (10 gallons) capacity, underneath the drain plug.

9. Remove the drain plug from the bottom of the hydraulic reservoir.

10. Allow the oil to completely drain from the reservoir.

11. Remove the hydraulic oil filter. Refer to HYDRAULIC OIL FILTER-REMOVAL. Installation 1. Replace the hydraulic oil filter. Refer to HYDRAULIC OIL FILTER-REMOVAL. 2. Replace the drain plug in the opening of the hydraulic reservoir and tighten.

3. Insert a funnel into the filler neck of the hydraulic reservoir and pour the new hydraulic oil into the reservoir.

4. Using the dipstick in the filler cap, check the level of the hydraulic oil. Add oil until the proper level is reached.

5. Install the front cover. See Section 2-FRONT COVER- INSTALLATION. 6. Connect the battery.

TILT CYLINDERS Removal

WARNING: Unintentional lowering of the forks or movement of the mast may cause damage or injury.

Before removing any component on the lift cylinder, lower or block the forks and allow the truck to sit for approximately five minutes to relieve the pressure in the lines.

1. Lower the forks completely.

2. Move the mast to the full forward position.

3. Turn the key switch to the off "O" position and allow the truck to sit for five minutes before doing any maintenance or repair on the hydraulic system.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

4. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 5. Wrap a chain around the top cross members of the mast and attach it to a lifting device.

WARNING: The mast is heavy. Be sure that all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the mast.

Sheet 16: Proportional Valve Cartridge 6. Remove the slack from the chain so the lifting device will support the weight of the mast. DO NOT lift the front of the truck off the floor.

7. Remove the front cover. See Section 2-FRONT COVER-REMOVAL.

WARNING: Unintentional lowering of the forks or movement of the mast may cause damage or injury.

Before removing any component on the lift cylinder, lower or block the forks and allow the truck to sit for approximately five minutes to relieve the pressure in the lines.

8. Loosen the hydraulic connections to the tilt cylinders and remove the hoses.

9. Remove the cotter pins at the ends of the pins connecting the tilt cylinder to the mast.

10. WARNING: DO NOT use fingers to remove the tilt cylinder pins. Support the weight of the tilt cylinder when removing the pin so that it does not drop and damage the truck or the tilt cylinder.

11. Thread the end of a slide hammer into the hole in the end of the pin connecting the tilt cylinder to the mast.

Remove the pin from the mount.

12. Remove the plastic plug from the hole in the side frame of the truck.

13. Remove the cotter pins from the tilt cylinder pin. 13. Using a 12 mm*300 mm (1/2 in*12 in) drift pin, drive the tilt cylinder pin from the mount and remove the tilt cylinder from the truck.

Installation NOTE: When replacing the pins in the tilt cylinders, make sure to install the pins with threaded holes in the ends into the mast end of the tilt cylinder. If standard pins are installed, future removal will be difficult.

1. Align the spherical bearing in the housing of the tilt cylinder to accept the tilt cylinder pin.

2. Insert the base into the tilt cylinder mount in the frame of the truck.

3. Insert the tilt cylinder pin into the mount from the side closest to the side frame of the truck.

4. Using a 12 mm*300 mm (1/2 in*12 in) drift pin, drive the pin into the mount and the spherical bearing of the tilt cylinder.

5. Install the cotter pins into the ends of the tilt cylinder pin.

6. Attach the hydraulic hoses to the tilt cylinder and tighten all fittings.

7. Align the rod end of the tilt cylinder with the mounting bracket on the mast.

8. Insert the tilt cylinder pin into the mount.

9. Using a brass drift, drive the pin into place, securing the tilt cylinder to the mast assembly.

10. Install the cotter pins into the tilt cylinder pin.

11. Remove the lifting device supporting the mast assembly.

12. Connect the battery.

13. Operate the tilt function to test for proper function and to check for leaks.

14. Disconnect the battery and separate the connector.

15. Check the hydraulic oil level using the dipstick under the breather cap and fill to the proper level.

16. Install the front cover. See Section 2-FRONT COVER- INSTALLATION. 17. Connect the battery.

Sheet 17: Hydraulic Tank Repairs HYDRAULIC TANK REPAIRS The hydraulic tank is located on the front of the electric lift truck. Various methods of cleaning the hydraulic tank can be done while the tank is attached to the frame. Repairs for small leaks can also be done with the hydraulic tank attached to the frame, but will require special procedures described in the following paragraphs. For repairing large leaks, remove the hydraulic tank and replace or follow the special procedures as described under LARGE LEAKS. Inspection Make a visual inspection of all sides of the tank. Inspect the welds for cracks and leakage. Check for wet areas, accumulation of dirt, and loose or missing paint caused by leakage. Areas of the tank that are not easily seen can be checked with an inspection mirror and a light that is approved for locations with flammable vapors.

Small Leaks Small leaks can be sealed as follows: 1. Use steam to clean the area around the leak. Remove all paint and dirt around the leak.

WARNING: Do not use tools that can make sparks, heat or static electricity. The vapors in the tank can cause an explosion.

2. Apply Loctite * 290 to the leak. Follow the instructions of the manufacturer.

Large Leaks

WARNING: Special procedures must be followed when large leaks or other repairs need welding or cutting. "Safe Practices for Welding and Cutting Containers that Have Held Combustibles" by the American Welding Society, A6.0-65. "Safety in Welding and Cutting," American National Standard, ANSI Z 49.1-1973. All work must be done by authorized personnel. If the tank is cleaned inside of a building, make sure there is enough ventilation.

See the following manuals for additional information: •

"Safe Practices For Welding And Cutting Containers That Have Held Combustibles" by the American Welding Society, A6.0-65.

•

"Safety In Welding And Cutting", American National Standard, ANSI Z 49.1 - 1973.

When cleaning the tank, do not use solutions that make dangerous gases at normal temperatures or when heated. Wear a device for the protection of the eyes. Protect the body from burns.

When cleaning with steam, use a hose with a minimum diameter of 19 mm (0.75 in). Control the pressure of the steam by a valve installed in the front of the hose. If a metal nozzle is used; it must be made of a material that does not make sparks. Make an electrical connection between the nozzle and the tank. To prevent static electricity, connect a ground wire to the tank.

CLEANING THE HYDRAULIC TANK Steam Method of Cleaning Clean the tank as follows: 1. Remove all the parts from the tank. Install the drain plug.

2. Fill the tank 1/4 full with a solution of water and sodium bicarbonate or sodium carbonate. Mix 0.5 kg (1 lb) per 4 litres (1 gal) of water.

3. Mix the solution in the tank using air pressure. Make sure all the surfaces on the inside of the tank are flushed.

Drain the tank.

4. Put steam into the tank until the tank does not have odors and the metal is hot. Steam vapors must come out of

Sheet 17: Hydraulic Tank Repairs all the openings.

5. Flush the inside of the tank with boiling water. Make sure all the loose material is removed from the inside of the tank.

6. Make an inspection of the inside of the tank. If it is not clean, repeat Steps 4 and 5 and make another inspection.

When making inspections, use a light that is approved for locations with flammable vapors.

7. Put plugs in all openings in the tank. Wait 15 minutes, then remove the inlet and outlet plugs. Test a sample of the vapor with a special indicator for gas vapors. If the amount of flammable vapors is above the lower flammable limit, repeat the cleaning procedures.

Chemical Solution Method of Cleaning If the tank cannot be cleaned with steam, use the following procedure: 1. Mix a solution of water and trioxide phosphate or a cleaning compound with an alkali base. Follow the instructions given by the manufacturer.

2. Fill the tank with the cleaning solution. Use compressed air to mix the solution in the tank.

3. Drain the tank. Flush the inside of the tank with hot (boiling) water. Make sure all the cleaning compound is removed.

4. Make an inspection of the inside of the tank. If the tank is not clean, repeat Steps 1, 2 and 3.

5. Make another inspection of the tank. When making inspections, use a light that is approved for locations with flammable vapors.

6. Check the tank for flammable vapors using special indicator for gas vapors. If the amount of flammable vapors is not below the lower flammable limit, repeat the cleaning procedures.

Other Methods If nitrogen gas or carbon dioxide gas is available, prepare the tank for welding using these gases. See the manual "Safe Practices for Welding and Cutting Containers that Have Held Combustibles" by the American Welding Society, A6.0-65. If these gases are not available, another method using water can be used as follows: 1. Fill the tank with water to just below the point where the work will be done. Make sure the space above the level of the water has a vent.

2. Use acceptable welding practices to repair the tank. See the American National Standard "Safety in Welding and Cutting" ANSI Z 49.1-1973.

RELIEF VALVE-CHECKS AND ADJUSTMENTS (See FIGURE 7-11) 1. Locate the pressure check port for the lift system. The pressure check port is located in the manifold mounted on the mast. On the two stage limited free lift mast, three stage full free lift and the four stage full free lift masts the manifold is located on the middle crossbar of the outer mast. On the two stage full free lift the manifold is located on top of the crossbar of the outer rail.

Figure 7-11 - Pressure Check Port-(Triplex Mast)

Sheet 17: Hydraulic Tank Repairs 2. Connect the pressure gauge to the port.

3. Start the truck and lift the carriage to its maximum height. Read the pressure gauge while attempting to lift against the stops. DO NOT lift against the stops for more than five seconds. The pressure should be approximately 21 MPa (3000 psi).

4. Lift pressure may be adjusted at the pressure relief valve on the hydraulic manifold block. See Figure 7-10.

Loosen the locknut and turn the internal screw clockwise to increase the pressure and counterclockwise to reduce the pressure. When the proper pressure has been obtained, tighten the locknut.

Figure 7-13 - Hydraulic Schematic

Sheet 17: Hydraulic Tank Repairs

TROUBLESHOOTING

Sheet 17: Hydraulic Tank Repairs

Sheet 17: Hydraulic Tank Repairs

Sheet 17: Hydraulic Tank Repairs

Sheet 23: Battery and Charging Systems

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 23: Battery and Charging Systems

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 inter-cell 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.

Sheet 23: Battery and Charging Systems Why-A loose connection may mean sparking or even arcing with attendant danger of gas explosion.

13. Allow only authorized personnel (qualified by training and experience) in the battery room.

Why-An untrained or inexperienced person may unknowingly break normal rules for proper handling, causing injury to themselves and damage to batteries and equipment.

14. Enclose all bare wires and buss bars in the battery room by wire guards, guard rails or other means of isolation from general plant traffic.

Why-Any open high current transmission equipment is a possible hazard to you, other workers and equipment.

15. Never lay metal tools such as wrenches or other material on top of an open battery.

Why-Sparking and short circuiting will occur and the battery will quickly be discharged or may explode.

16. Check batteries for cracks or leaks. Repair at once.

Why-Electrolyte will spill on floor or equipment, causing corrosion of the steel tray and related equipment.

Continuous flow of leaking electrolyte can cause a ground bath that reduces battery life and capacity.

17. When batteries are disposed of as scrap at the end of useful life, they should be sent to a authorized recycling center or salvage dealer.

Why-Even an old battery no longer capable of useful life may have enough residual voltage left to cause a spark if filled with electrolyte.

18. Familiarize yourself as completely as possible with batteries and the proper rules for their charging, handling and maintenance.

Why-Full knowledge of batteries and the dangers of improper handling will pay dividends in the elimination of injuries and damage.

CAUTION: Keep vent plugs in the cells at all times, except when taking hydrometer readings, adjusting specific gravity and electrolyte levels, troubleshooting or assembling a repaired cell.

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

NOTE: If batteries are not in use, keep them charged. Check specific gravities monthly and give a freshening charge (3 to 4 hours at the finish rate) if the gravities have fallen 30 points (.030) or more, otherwise, give freshening charge every three months.

BATTERY TROUBLESHOOTING PROBLEM Battery overheats on discharge

POSSIBLE CAUSE Over discharge

CORRECTION Limit discharge to 1.110 specific gravity.

Put more batteries into service Set up more frequent charging schedule.

Excessive load Determine cause of overload and correct.

Put more batteries into service if equipment requirements exceed battery capacity.

Not fully charged prior to work Needs more frequent and complete assignment resulting in over discharge charging.

Electrolyte levels low Add water as required. Do not assign battery to work if levels are below top of plates.

When overheating is confined to few Install heat insulating material between cells, nearby operating equipment may equipment cells with air circulating space be source between.

Operating in high ambient temperatures Provide cool location for charging and good ventilation.

Sheet 23: Battery and Charging Systems Low electrolyte level

Broken or cracked jar Replace jar.

Water additions neglected or cell missed Better maintenance supervision. Add water in previous water addition. as required to all cells.

Overcharging Adjust charging equipment. a. Voltage relay set for many cells a. Connect relay for proper number of b. Timer set for too many hours cells. c. Voltage change rate relay operating b. Reduce time. c. Reduce voltage value at which voltage relay operates.

Specific gravity between cells Overfilled with water Do not fill above high level - give equalizing not uniform charge and adjust acid.

Operating cell with cracked jar Replace jar and adjust acid.

Acid not adjusted properly after jar Adjust acid specific gravity. change Vent caps removed during operation Keep vent caps securely in place. Give equalizing charge and adjust acid.

Electrolyte leaking through sealing Reseal and adjust acid compound Operating battery with broken coil cover Replace cover and adjust acid Neutralizing agent in cell Keep vent caps in place at all times except when adding water. keep battery clean.

Unequal cell voltages Refer to Unequal Cell Voltages Unequal cell voltages Over discharge. Also more than .020 Give an equalizing charge and do not points spread in specific gravity from discharge below 1.110. average Lack of equalizing charges Give an equalizing charge periodically.

Internal shunt Make internal inspection of low voltage cell and correct cause. Check for split separator and moss short.

Dirty battery top Neutralize and clean top of battery.

Cells operated with low electrolyte level Add water as required. Give equalizing charge.

Low specific gravity of fully charged cell Adjust acid after equalizing charge.

Sediment space filled Replace battery.

Half tap on cells for lower voltage circuit Remove tap and connect load to battery terminals through resistance.

External source heating certain cells Install heat insulating material between heat source and battery.

Impurities in cell Add only distilled or approved water to electrolyte.

Variation in charge rate Take readings when charge rate is constant.

Battery will not work full shift Uneven cell voltages Give an equalizing charge.

Low electrolyte levels Refer to Low Electrolyte Level.

Battery not charged before work cycle Check charging schedules. Do not assign discharged battery to work.

One or more jars leaking electrolyte Replace broken jars.

Incorrect battery (number of cells) Install battery with correct voltage and assigned to equipment capacity to equipment.

Fully charged specific gravity below Adjust specific gravity to normal. normal Impurities in electrolyte Add only distilled or approved water to electrolyte.

Operator "riding the brake" Discourage practice.

Using reverse in place of braking Discourage practice.

Inexperienced operator Instruct him on power conservation.

Load excessive Use larger battery or reduce load Wheels, axles and bearings need grease Plan lubrication schedule.

Tires under inflated or wrong type Plan periodic check of air pressure Brakes dragging Adjust brakes properly.

Series field in motor shorted or grounded Replace field and remove ground Armature needs repair Replace or repair armature.

Ground on equipment Find ground and insulate.

Excessive grades Use larger battery or revise battery charge schedule.

Capacity or equipment assigned to job is Reassign equipment inadequate

Sheet 23: Battery and Charging Systems LEAD-ACID BATTERIES A lead-acid battery converts chemical energy into electrical energy. The battery is discharged when the chemical reaction has occurred and the battery will not supply its rated voltage and current. A reverse chemical action must occur so that the battery can be used again. The batteries can be charged by an electric voltage and current from an outside source to provide the reverse chemical action. The lead-acid chemicals store the electrical energy until needed.

A lead-acid battery is made from several lead-acid batteries called cells. Each cell has positive and negative plates with dielectric spacers between each plate. All of the plates are in a solution of electrolyte.

Specific Gravity The strength of the electrolyte is measured in points of specific gravity. For example, a solution of sulfuric acid has a specific gravity of 1.835. Water has a specific gravity of 1.000. Electrolyte is 27% acid and 73% water and has a specific gravity of 1.275.

CAUTION: NEVER pour water into acid. The quick production of heat can cause the acid to boil and splash out of the container. ALWAYS pour acid into water when making a dilute solution of acid.

Figure 9-2 - Fully Charged Cell Chemical Reaction The cell generates a voltage (potential difference) when two different types of metal are in the electrolyte. The two metals in a lead-acid cell are lead peroxide (Pb03) for positive plates, and sponge lead (Pb) for negative plates. A potential difference of approximately two volts per cell is generated. The potential difference does not vary according to the size of the cell.

During the discharging of the cell, lead peroxide and sponge lead mix with sulfuric acid to make lead sulfate (PbS04) on both plates. This action decreases the voltage in the cell. When the sulfuric acid is removed from the electrolyte, the specific gravity of the electrolyte decreases. The potential difference of a discharged cell is approximately 1.75 volts.

Sheet 23: Battery and Charging Systems

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 23: Battery and Charging Systems

Figure 9-5 - Cell Charging

HOW TO SELECT THE BATTERY The battery needed to operate a period of eight hours depends on many conditions. Operations that require the lift truck to go up ramps or require the use of additional attachments increases the use of power from the battery. Some work conditions require that more than one battery must be used during a work period. The number of eight hour work periods per day is normally equal to the number of batteries needed. The capacity of the battery you need is found as follows: •

The size of the lift truck and the attachments.

•

The type of work. Heavy duty operation or normal operation for one eight hour work period.

The battery voltage you need is found as follows: •

Will your lift truck operate on more than one voltage?

•

If you have more than one lift truck in operation, do the battery voltages need to be the same?

Lift trucks are available in various voltage ranges. The small "Motorized Hand" trucks are normally 12 to 24 volts.

Larger "Sit-down Rider" lift trucks are normally 24 to 48 volts.

Voltage of a Battery To reach the necessary battery voltage, the cells are connected in series. For example: •

24 volts 12 cell battery

•

36 volts 18 cell battery

•

48 volts 24 cell battery

Sheet 23: Battery and Charging Systems

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 ) / 1,000 = kilowatt hours of KWH 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 / 1,000 = 28.8 KWH (Power available from a fully charged battery.)

All the electrical operations figure a specific watt-hours in electric energy. These operations include distances, loads, ramps, lifting heights, attachments, etc. The watt-hours can be converted to kilowatt-hours to indicate the battery needed for the operation. Always select the correct type of battery. Remember, a battery that has a rating of 300 ampere-hours will not do the same job as a battery that has a rating of 600 ampere-hours. Do not permit the specific gravity to go below the limits shown in the manual.

THE BATTERY AS A COUNTERWEIGHT On electric lift trucks that use the battery as part of the counterweight, the battery is part of the capacity of the lift truck to lift loads. The minimum weight of the battery is shown on the nameplate. If the battery is not the minimum weight, the capacity of the lift truck is reduced. If the battery used in the lift truck is less than the size of the battery compartment, blocks and spacers must be installed to hold the battery in position. The maximum allowable movement of a battery is 12.7 mm (0.5 in) from side to side and 12.7 mm (0.5 in) fore and aft. (Reference ANSI B-56.1.)

Sheet 23: Battery and Charging Systems 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.

1. Keep batteries clean and free of acid spills.

2. Do not over-discharge. Excessive discharge shortens battery life.

3. Do not overcharge. Overcharging produces corrosion of positive grids and excessive gassing, which loosens the active material of the plates.

4. Charge batteries in a well ventilated area to remove the explosive gases and acid fumes.

5. Maintain electrolyte at the proper level. If low, add water. Before charging, make sure tops of plates are covered; after charge, fill to recommended level. Do not add acid.

6. Keep batteries from freezing.

Sheet 23: Battery and Charging Systems 7. Keep batteries in a charged state.

8. Do not charge a battery with a charger that has an ampere-hour rating higher than that of the battery. This will give too high a charging current and excessive heating. Charging with a lower ampere-hour charger will cause no harm, but may require longer than 8 hours to fully charge.

Maintenance Records Always complete the Battery Inspection Report and the Daily Battery Report.

NOTE: Follow the same sequence when you record the cell number. Always begin the record with a positive cell.

Follow a sequence so that the last cell is always the cell for the negative cable.

Record the beginning ampere reading of the charger each time the battery is charged. Any difference in the daily ampere reading can indicate a problem with the battery or the charger.

Figure 9-8 - Battery Inspection Report

Figure 9-9 - Daily Battery Record Cleaning the Battery Keep the battery compartment clean and dry. Use a clean cloth to wash the battery with water. Dry with compressed air.

CAUTION: Do not clean the battery with steam or hot water. Do not use a high pressure hose.

Sheet 23: Battery and Charging Systems 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.

NOTE: Keeping the electrolyte level within the correct limits is the most important item of battery maintenance.

Always use distilled water. If you add distilled water, wait five minutes before measuring the specific gravity with a hydrometer. Do not add distilled water to a cell during the charging cycle. The electrolyte can flow out of the cell through the fill hole. Figure 9-10 shows a general rule for the incorrect electrolyte level. See the instructions from the manufacturer of your battery for the operating level of the electrolyte.

CELL HEIGHT Less than 38cm (15 in) 38-61 cm (15-24 in) Greater than 61 cm (24 in)

DIMENSION "A" 3 mm (1/8 in) 6 mm (1/4 in) 12 mm (1/2 in)

Table 9-1 - Electrolyte Level

Figure 9-10 - Electrolyte Level Hydrometer 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 23: Battery and Charging Systems

Figure 9-11 - Hydrometer Battery Temperature The temperature of the electrolyte will change the reading of the specific gravity. When the temperature increases approximately 6°C (10° F), the specific gravity will decrease by 0.003 points. Refer to Figure 9-12 for making specific gravity corrections.

SPECIFIC GRAVITY READING 1.210 1.210 1.210 1.210

ELECTROLYTE CORRECTION TEMP. POINTS 31ºC (87ºF) +0.003 27ºC (80ºF) +0.001 25ºC (77ºF) +0.000 18ºC (64ºF) -0.004 +0.001 for each 1.7ºC (3º F) from the 25ºC (77ºF) Base Value Degrees C + 17.8 x 1.8 = Degrees F.

Table 9-2 - Specific Gravity Corrections

Figure 9-12 - Battery Thermometer

CORRECT VALUE 1.213 1.211 1.210 1.206

Sheet 23: Battery and Charging Systems Never charge or discharge a battery at a rate that will raise the temperature of the electrolyte above 50o* C (120o* 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 25o C (77o 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 gas when charging. Always open the battery cover or hood and provide good ventilation when charging.

To charge the battery, a direct current must pass through the cells in the opposite direction to the discharging current. The ampere-hours must be equal to the discharging ampere-hours plus the energy lost as heat. This additional amount of charge will vary according to the battery and the temperature, but the average additional charge is 12%. When the battery is nearly charged, the final charging must be at a low rate. A charging rate that is too high will cause heating in the battery and a high loss of water from the electrolyte. The charging of the battery must be done correctly or the service life of the battery will be decreased.

NEVER discharge a battery below 1.130 to 1.110. Discharging a battery beyond the design limits will decrease the service life of the battery.

If lift truck operation results in only partial discharges (50% or less) and specific gravities are 1.210 to 1.220 or more at the end of the shift, recharging may be deferred and the battery used for another shift providing the work load is not expected to increase. Hydrometer readings and experience will disclose the frequency of charge intervals under 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: •

The battery is too small for the job.

•

The battery is not fully charged.

•

The battery charger is not operating correctly.

•

The battery is near the end of its service life.

Methods of Charging There are three methods of charging a battery.

1. GRADUAL CHARGE-This method uses a solid state automatic battery charger. The charging rate begins at 20-25 amps/100 amp-hours and decreases to less than 5 amps/100 amp-hours when the battery is 80% charged. The charging current decreases when the voltage across the cell increases during the charging cycle.

Sheet 23: Battery and Charging Systems 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 14o C (25o 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 and damage.

WARNING: Always charge the battery at the end of the work period (shift). Never let the specific gravity reach a level less than the limits shown in the manual.

WARNING: Always de-energize 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.

Sheet 23: Battery and Charging Systems 5. Type of lift truck.

6. Distances that the lift trucks must travel for service.

7. Safety regulations and instructions.

Equipment Needed •

A lifting device to remove the battery from the lift truck.

•

Racks to hold the batteries during charging and storage. These racks must be made of wood and must not be metal unless the metal racks are covered with an insulating material.

•

A battery charger that will charge your batteries.

•

Tools for maintenance.

•

An area with a drain for cleaning batteries and battery compartments.

•

Distilled water.

•

Air and water supplies for cleaning.

•

Maintenance records.

•

A work bench.

•

Spare parts and repair equipment.

•

Protective clothing and safety equipment for handling batteries.

•

Water sources for washing eyes and preventing acid burns.

•

Install a NO SMOKING sign in the service area.

•

Keep the charger in a clean, dry area with good ventilation.

Sheet 2: User Support Information

USER SUPPORT INFORMATION Your investment in a Yale industrial truck is important to you and to your Yale industrial truck dealer. You measure the return on your investment through the drivers who operate the trucks and the mechanics who service them safely and efficiently.

A "Guide to Lift Truck Use and Maintenance", which addresses lift truck safety in the workplace, good maintenance practices and training programs, is available from your Yale industrial truck dealer. Order manual #2020.

The following information and programs are intended to help you to achieve your investment objectives.

SERVICE PARTS ORDERING INSTRUCTIONS In order to avoid delay, unnecessary correspondence and to have your orders filled correctly, promptly and at the least possible expense, the following is the recommended procedure to use when ordering replacement parts.

Contact your authorized Yale Industrial Truck Dealer and give him the following information: 1. Your Purchase order number.

2. Complete invoicing and shipping address.

3. Specify the method of shipment, otherwise the least expensive method will be used.

4. Correct part number(s) and description(s). Use your parts manual as a reference.

5. Model and serial number of the truck.

TECHNICAL PUBLICATIONS Technical literature, with detailed information, is available at a nominal fee to assist users to effectively maintain Yale industrial trucks in a safe, useful condition. Parts Manuals with complete replacement parts identification, Service Maintenance Manuals which provide service and overhaul procedures and additional copies of this Operating Manual, can be obtained from your Yale industrial truck dealer.

PARTS MANUAL-520371644 OPERATING MANUAL-5189768-22 (ITD 1635) To provide instructions for safely operating and servicing Yale Industrial Trucks, each truck is equipped with an Operating Manual.

The Operating Manual describes various operating techniques and safety warnings for the operator. The Operating Manual also contains a guide to safe maintenance practices and recommended schedules for maintenance.

If the Operating Manual is missing from any Yale industrial truck, it should be replaced. Replacement copies are available for a nominal fee from your Yale industrial truck dealer.

OPERATOR TRAINING Yale "Basic Operator Training" program helps industrial truck users increase materials handling productivity and safety through proper lift truck operation training and motivation. The Yale program is based upon real life experience - not theoretical concepts. We developed a "complete" program that is totally self-contained incorporating the most modern instructional techniques, including elements of self-study, audio-visual support (both video and slides) and classroom study.

SERVICE TRAINING COURSES User and Yale Industrial Truck Dealer service technicians can improve their technical ability for maintaining and repairing Yale industrial trucks and reduce down-time and cost by participating in Yale sponsored Service

Sheet 2: User Support Information Training courses. A variety of mechanical, electrical and electronic subjects are offered at published tuition rates.

Courses are available at user and dealer facilities in addition to regularly scheduled courses which are conducted at Yale Corporate Headquarters in Flemington, New Jersey.

SERVICE TRAINING MATERIALS Your own service training efforts are supported through a complete line of Yale Service Training materials. An index is available from your Yale industrial truck dealer which lists textbooks, audio-visual programs, films and their cost which will provide your trainer with everything necessary to conduct service training for your organization.

For additional information or assistance in obtaining these user support publications and programs, contact your Yale industrial truck dealer or the Yale Materials Handling Corporation, 15 Junction Road, Flemington, New Jersey 08822-9499.

Sheet 13: General

HYDRAULIC SYSTEM GENERAL This section contains the description of the hydraulic system. Information about the repair of the hydraulic tank and a section describing the repair of hydraulic gear pumps are also included.

DESCRIPTION (See Figure 7-1) The hydraulic pump and motor assembly is located on the front frame bulkhead above the tilt cylinders. The hydraulic pump is a single gear pump that receives its supply directly from the hydraulic tank. The outlet port of the pump is connected to the hydraulic manifold block.

The hydraulic manifold block controls the operation of the lift and tilt cylinders. Lift trucks equipped with optional functions will have additional hydraulic valve solenoid cartridges installed on the hydraulic manifold block. A lift truck can be equipped with a control valve having two, three or four hydraulic valve solenoid cartridges.

The power steering system is a separate hydraulic system that gets its supply from the hydraulic tank. See Section 6-STEERING SYSTEM. The hydraulic oil from both systems is filtered through a return filter before returning to the tank.

OPERATION The hydraulic pump produces oil flow from the tank to the hydraulic manifold block. The hydraulic manifold block controls the flow of oil to the lift cylinders, tilt cylinders, side shift cylinders and auxiliary functions. A primary relief valve on the hydraulic manifold block keeps pressure within the design limits of the hydraulic system.

Figure 7-1 - Pumps and Motors

Sheet 13: General 1.

2.

3.

4.

POWER STEERING MOTOR POWER STEERING PUMP HYDRAULIC PUMP HYDRAULIC PUMP MOTOR

Hydraulic fluid from the reservoir is drawn into the steering system by the steer pump. This gear pump is driven by a DC electric motor. Power to the steering motor is controlled by a lift amplifier. See the Electrical System section for additional information. The pump assembly includes a pressure relief valve. This valve prevents the buildup of excessive pressure in the steering system. It is designed to limit the pressure in this system to 6200 kPa (900 psi).

For further explanation of the steering system, see Section 6-STEERING SYSTEM.

MULTI-FUNCTION CONTROL HANDLE The multi-function control handle is a molded plastic handle that controls travel, lift, tilt, side shift and auxiliary functions (if so equipped) and the horn. Forward travel is controlled by tilting the multi-function control handle toward the forks. Reverse travel is controlled by tilting the multi-function control handle away from the forks. Moving the multi-function control handle toward the right raises the forks. Moving the multi-function control handle toward the left lowers the forks. Travel and lift are proportionally controlled; the more the handle is tilted, the faster the truck or forks move. Tilt and side shift are single speed functions controlled by a four way switch on the top of the handle. Any auxiliary functions are controlled by two buttons on the shaft of the multi-function control handle.

The horn switch is located on the lower edge of the top of the multi-function control handle.

The multi-function control handle is mounted to a dual axle mechanism with a potentiometer on each axis for the travel and lift proportional controls. Return springs keep the handle centered and stop blocks limit the movement of the multi-function control handle.

REPAIRS This section describes the removal of the hydraulic pump, the power steering pump and the hydraulic manifold block. The procedure for the hydraulic tank is included in this section.

LIFT PUMP AND MOTOR ASSEMBLY Removal NOTE: The lift pump can be removed from the lift pump motor without removing the lift pump and motor assembly from the truck. Refer to LIFT PUMP-REMOVAL.

WARNING: Unintentional lowering of the forks or movement of the mast may cause damage or injury.

Before disconnecting any hydraulic lines, lower or block the forks and allow the truck to sit for approximately five minutes to relieve the pressure in the lines.

1. Lower the forks completely.

2. Move the mast to the full forward position.

3. Turn the key switch to the off "O" position and allow the truck to sit for five minutes before doing any maintenance or repair on the hydraulic system.

WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

4. Check that the key switch is in the off "O" position.

5. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE.

Sheet 13: General 6. Remove the overhead guard. See Section 2-OVERHEAD GUARD-REMOVAL. 7. Label and disconnect the electrical connections to the lift pump motor.

8. Clean the area around the hydraulic connections to the lift pump.

9. Disconnect the hydraulic lines from the lift pump and cap them.

10. Attach a lifting device to the lift pump and motor assembly for support.

WARNING: The lift pump and motor assembly is heavy. Be sure that all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the lift pump and motor assembly.

11. Remove the four capscrews, flat washers and flange locknuts securing the lift pump and motor assembly to the frame of the truck.

12. Remove the lift pump and motor assembly from the truck.

Installation 1. Align the lift pump and motor assembly with the holes in the front frame of the truck.

2. Attach the lift pump and motor assembly to the frame of the truck with four capscrews, flat washers and flange locknuts.

3. Attach the hydraulic lines to the lift pump in the correct locations.

4. Install the electrical cables on the lift pump motor in the same positions from which they were removed.

5. Connect the battery.

6. Operate the hydraulic system and check for leaks.

7. Disconnect the battery and separate the connector.

8. Check the hydraulic oil level using the dipstick under the breather cap and fill to the proper level.

9. Install the top cover and front cover. See the General Truck and Lubrication section.

10. Install the overhead guard. See Section 2-OVERHEAD GUARD-INSTALLATION. 11. Connect the battery.

LIFT PUMP Removal NOTE: If the lift pump and motor assembly has been removed from the truck, proceed to Step 13.

WARNING: Unintentional lowering of the forks or movement of the mast may cause damage or injury.

Before disconnecting any hydraulic lines, lower or block the forks and allow the truck to sit for approximately five minutes to relieve the pressure in the lines.

1. Lower the forks completely.

2. Move the mast to the full forward position.

3. Turn the key switch to the off "O" position and allow the truck to sit for five minutes before doing any maintenance or repair on the hydraulic system.

Sheet 13: General WARNING: To prevent electrical shock and injury, disconnect the battery, separate the connector and discharge the capacitor bank before inspecting or repairing any component. DO NOT short the capacitor bank to the frame or ground.

4. Turn the key switch to the off "O" position.

5. Disconnect the battery and discharge the capacitors. See Section 3-CAPACITOR DISCHARGE PROCEDURE. 6. Remove the front cover and top cover. See Section 2-FRONT COVER and TOP COVER-REMOVAL. 7. Clean the area around the hydraulic connections to the lift pump.

8. Disconnect the hydraulic lines from the lift pump and cap them.

9. Remove the two capscrews securing the lift pump to the lift pump motor.

10. Separate the lift pump from the lift pump motor.

11. Remove the lift pump from the truck and disassemble as necessary for repairs. See HYDRAULIC GEAR PUMPS for repair information.

Installation 1. Position the lift pump on the lift pump motor shaft.

2. Attach the lift pump to the lift pump motor with two capscrews and tighten the screws to 40 N m (30 lbf ft).

3. Attach the hydraulic lines to the lift pump.

4. Connect the battery.

5. Operate the hydraulic system and check for leaks.

6. Disconnect the battery and separate the connector.

7. Check the hydraulic oil level using the dipstick under the breather cap and fill to the proper level.

8. Install the top cover and front cover. See Section 2-FRONT COVER and TOP COVER-INSTALLATION. 9. Connect the battery.

LIFT PUMP MOTOR Brush Removal and Installation For brush removal and installation procedures, see Section 3-ELECTRICAL SYSTEM.