PDF DOWNLOAD: Yale MT60UX (A7S7) Sit-Drive Electric Tow Tractor Service Manual

MT60UX (A7S7) Sit-drive electric tow tractor Service and maintenance manual

PART NO. 550234251

REVISION 00 (03/2020)

Contents Description of symbols .......................................................................................................... 4 Maintenance ........................................................................................................................... 5 Precautions during maintenance ............................................................................................ 5 Places for maintenance ...................................................................................................... 5 Precautions before repair and maintenance ......................................................................... 5 Setting up a new truck.......................................................................................................... 6 Initial charge .................................................................................................................... 6 Battery use and maintenance ................................................................................................ 7 Common charge ............................................................................................................... 7 Balancing charge .............................................................................................................. 7 Equalizing charge .............................................................................................................. 8 Battery storage ................................................................................................................. 8 Maintenance of electrolyte ................................................................................................. 8 Operation of storage batteries during the final stage of their lifetime...................................... 8 Emergency treatment ........................................................................................................ 9 Charger............................................................................................................................ 9 Daily inspection .................................................................................................................... 9 Periodic inspection and maintenance .................................................................................... 10 Inspection and maintenance every day (8 hours) ............................................................... 10 Inspection and maintenance every 350 hours .................................................................... 10 Inspection and maintenance every 1000 hours .................................................................. 11 Recommended fluids ....................................................................................................... 11 Repair .................................................................................................................................. 12 Driving system ................................................................................................................... 12 Principles of operation ..................................................................................................... 12 Driving axle structure ...................................................................................................... 12 Wheel hub structure ........................................................................................................ 13 Drive axle description ...................................................................................................... 14 Installation, adjustment, and maintenance ........................................................................ 15 Steering system ................................................................................................................. 24 Principles of operation ..................................................................................................... 24 Steering system structure ................................................................................................ 24 Steer wheel structure ...................................................................................................... 25 Steer wheel description ................................................................................................... 25 Installation, adjustment, and maintenance ........................................................................ 25 Brake system ..................................................................................................................... 40 Principles of operation ..................................................................................................... 40 Service brake system structure ......................................................................................... 40 Service brake description ................................................................................................. 41 2

Park brake description ..................................................................................................... 41 Brake maintenance ......................................................................................................... 41 Electrical system ................................................................................................................ 42 Principles of operation ..................................................................................................... 42 Electrical schematic – manual steering trucks..................................................................... 43 Electrical schematic – power assist steering trucks ............................................................. 44 Electrical component identification .................................................................................... 45 Electrical controller panel access ....................................................................................... 46 Controller panel identification ........................................................................................... 47 Traction controller 1236E – description.............................................................................. 48 Steer controller 1222 (power assist steering only) – description ........................................... 50 Troubleshooting .................................................................................................................... 52 Mechanical breakdowns ...................................................................................................... 52 Fault codes ........................................................................................................................ 53 Fault codes for traction controller 1236E ........................................................................... 53 Fault codes for steer controller 1222 (power assist steering only) ........................................ 61 Truck storage and transportation ............................................................................................ 67 Loading and unloading........................................................................................................ 67 Transportation of truck ....................................................................................................... 68 Storing the truck ................................................................................................................ 68

3

Foreword  

 

Please read the manual carefully before servicing.

This manual is a common manual. We reserve the right to modify technology of the electric truck. If there is anything in the manual that is not consistent with the actual truck, the actual truck should be considered correct and the manual is only for reference.

The instruction manual shall accompany the truck in case of truck leasing or transfer.

Please contact our sales department in case of any problem.

Warning Operator of the truck must strictly follow ISO 3691 “Safety Specification for Industrial Vehicles” and it is prohibited for untrained people to operate the truck.

Description of symbols The following symbols are of great importance to your safety and others.

Danger

Indicates an impending danger. Deaths or severe injuries will result without any precaution or avoidance. You must observe those requirements.

Warning

Indicates a potential danger. Deaths or severe injuries may result without any precaution or avoidance. You must observe those requirements.

Caution

Indicates a potential danger. Moderate injuries may result without any precaution or avoidance. You must observe those requirements.

Notice

You shall pay attention to statements that are in direct or indirect relation with personal security and truck maintenance.

4

Maintenance Comprehensive checks of the truck can avoid malfunction and ensure the service life. The hours listed in maintenance procedures assume that the truck works for 8 hours per day and 200 hours per month. For the sake of safety, maintenance shall be carried out according to maintenance procedure.

Notice All the repair work shall be carried out by professional personnel.

Please contact the sales department of our company if you need to adjust or replace the components.

Precautions during maintenance Notice The components for replacement shall be produced completely by our company. When replacing components of the truck, the components with the same safety requirement with the original design shall be used.

The lubricating oil and hydraulic oil in use shall be recommended by our company.

Places for maintenance Notice Designated places for maintenance shall be appointed that can provide other services such as hoisting and safety protection facility.

The places shall have level ground and good ventilation.

The places shall be equipped with fire-extinguishing devices.

Precautions before repair and maintenance Notice

No smoking.

Use all required safety gear.

Clean up leaks or spilled fluids quickly.

Before adding lubricating oil, clean up the dirty oil or dust on the joint with brush or cloth.

Unless otherwise instructed, turn off the key switch and pull off the power socket.

Ensure no goods are on the truck during service or maintenance.

Discharge capacitors before performing any electrical work.

Clean the electric section with compressed air. Never flush with water.

When the truck requires working at height, fall protection must be provided for the repairing and maintenance personnel.

5

Setting up a new truck In order to follow the industry related regulations and ensure the absolute security to the truck in the transportation, a new lift truck may arrive onsite with no electrolyte in the battery.

The electrolyte of storage battery is prepared before the truck leave the factory, and must be poured into the storage battery by the professional personnel before the first use.

1. Place the truck to the site with good ventilation.

2. Open the lid of storage battery box.

3. Open all the top plastic lids of storage battery.

4. Use a plastic funnel and pour electrolyte into storage battery slowly and carefully.

5. Add electrolyte until it can be seen through the fill ports in the plastic lids of storage battery.

6. After all the storage battery is filled, conduct initial charge.

Initial charge There are some special tasks that must be completed when charging a new battery for the first time.

The initial charging and supplementary charging of the battery group must be conducted strictly according to the regulations stipulated in the battery specification manual.

1. Clean up the surface of the battery before the initial charge, and then check for damage to ensure reliable connection.

2. Open gas cap.

3. When the charging equipment is able to operate normally, pour the sulfuric acid electrolyte with a density of 1.260±0.005 (25℃) at a temperature below 30℃ (86°F) into the batteries.

The electrolyte level should be 15-25mm (.5-1 in) higher than the protective board. In order to reduce the temperature rise caused by chemical reaction of the electrolyte and to let the electrolyte fully penetrate into the pores of the polar plates and the baffles, let the batteries sit still for 3-4 hours but not exceeding 8 hours. The initial charging can only be conducted when the electrolyte temperature reduces to below 35℃ (95°F). When necessary, the batteries can be put into cold water for temperature reduction. After this cooling period, if the electrolyte level reduces, electrolyte should be added.

4. The sulfuric acid electrolyte is prepared with battery sulfuric acid complying with the state standard GB4554-84 and distilled water. Never use industrial sulfuric acid and running water.

The standard temperature of 25℃ (77°F) and density of the electrolytic solution can be converted as follows: D25 = Dt+ 0.0007 (t-25) Where: D25: the density of the electrolytic solution at 25℃ (77°F) Dt: the actual density of the electrolytic solution at t ℃. t: temperature of the electrolytic solution when testing the density.

5. Dry up the electrolyte spilled on the surface of battery.

6. Connect the positive and negative poles of batteries with those of the charger and then turn on the charger power. Charge with the current of 30A (the current of the first stage). After the charge voltage achieves 28.8V (12×2.4V=28.8V), switch to the 15A current of the second stage. When charging, the temperature of electrolyte shall never exceed 45℃ (113°F). When the temperature raising up nearly to 45℃ (113°F), reduce the current by half 6

or stop charging temporarily. After the electrolyte temperature reduce below 35℃ (95°F), continue charging. The charge time needs to be extended in this case.

7. Fully charged basis: When the voltage during the second stage charging reaches 31.2V (12 ×2.6V = 31.2V), the variation of the voltage is no greater than 0.005 (V). The density of the electrolytic solution reaches 1.280 ±0.005 (25℃). If there are no apparent density changes in 2 hours and fine air bubbles appear violently, it can be deemed that the batteries are fully charged. The charged power capacity is 4-5 times of the rated capacity and the charging time is about 70 hours 8. In order to accurately control the sulfuric acid content of the electrolytic solution, the electrolytic solution density of the batteries should be examined during the last period of charging. If needed, adjust with distilled water or sulfuric acid with a density of 1.40. The electrolytic solution density and the liquid surface should be adjusted to the stipulated value within two hours in the charging state.

9. After the initial charging is completed, the surface of the batteries should be cleaned. Close the gas cap and then the batteries can be used.

Battery use and maintenance In order to guarantee the service life of the batteries, the batteries in use should be fully charged.

Insufficiently charged batteries must not be used. During the process of use, close attention should be paid to the discharge extent. Over-discharge is prohibited; do not continue to use the battery if the voltage reduces to 1.7V per cell (when the total voltage reduces to 1.7V×12 = 20.4V ). When the density of the electrolytic solution reduces to 1.17, discharging should be stopped and charging should be conducted at once. The batteries should not be placed idle for a long period of time.

Common charge Common charge describes charging of batteries during normal working conditions. The first stage current of common charge is 30A and that of the second stage is 15A. The charging method is the same as that of initial charge. The charged volume is 130-140 % of the discharged volume and the charging time is about 12 hours.

Balancing charge Do not over-charge batteries in normal use, but conduct a balancing charge as described below when required.

1. “Lag-behind” cells: Cells with a voltage lower than that of the other batteries in the discharging process, and cells having been repaired for failure may require a balancing charge.

2. When balance charge is conducted, the positive and negative poles of the “lag-behind” cells should be connected with the positive and negative ends of the charger (the DC power supply) and the charge should be conducted independently.

3. Balancing charge should be conducted for the batteries in normal use every 2-3 months.

4. Balancing charge should be conducted for the batteries that have not been used for a long period of time before use.

7

Equalizing charge 1. Charge with a 4A current.

2. When the charge voltage reaches 31.2V (12 ×2.6V = 31.2V) and air bubbles occur in the electrolyte, the current should be reduced by 50% (2A) and continue to charge.

3. When the batteries are fully charged, stop charging for 0.5 hour and charge again with a 1A current for one more hour.

4. Stop charging for another 0.5 hour and charge with a 1A current for another one hour.

5. Repeat step 4 until air bubbles occur violently in the batteries when the charger is switched on.

Battery storage The storage battery shall be kept in clean, dry and ventilated warehouse within the temperature range of 5 to 40℃ (41 to 104°F). The valid storage period is 2 years. Safekeeping shall be made within storage period according to the following requirements:  Avoid direct sunlight. The distance from heat source shall not less than 2m (6.5 ft).  Avoid contact with any harmful substance. No metal impurity shall fall inside the battery.  No inversion, mechanical collision, or heavy weight on top of the battery is permitted.  Storage with electrolyte is forbidden. Under special cases that the storage with electrolyte is necessary, the density and solution level of electrolyte shall be adjusted to the specified value.  Every month, perform a common charge.

Maintenance of electrolyte Density check The suction-type densimeter shall be used to check density. During operation, avoid spilling out the electrolyte, and wear protective gear.

Operation besides check Consult professional personnel (a service technician), especially when complementing electrolyte (dilute sulfuric acid).

Electrolyte leakage As for the electrolyte leakage resulting from storage battery tilting and damage, emergency treatment shall be made at once. See Emergency treatment.

Operation of storage batteries during the final stage of their lifetime When the lifetime of storage battery is about to terminate, the electrolyte in single battery reduces very fast. If electrolyte has to be added very often, even every day, the battery is at the end of its useful life.

8

Treatment of waste battery As for the waste battery, draw out the electrolyte. Recycle the battery as recommended by the battery manufacturer. The waste electrolyte can be disposed according to relevant local rules and regulations.

Emergency treatment 1. If the electrolyte spills on skin, wash with large amount of water 2. If the electrolyte spills into eyes, wash with large amount of water, and then seek help from specialized doctor.

3. If the electrolyte spills on clothes, take off clothes right away, wash with water, and then flush with weak basic soap solution.

4. If the electrolyte spills or leaks from the battery neutralize it with lime or strong carbonic acid, and then flush with large amount of water.

Charger If the charger you use is full automatic type, it must meet the following 2 requirements:  The output voltage of charger: 24V  The output current of charger: 20-30A If the charger you use is semi-automatic or manually adjustable, please charge the battery pack according to the requirements of use and maintenance in Battery use and maintenance.

Daily inspection 1. Check that all the connecting points and plugs of the electric system are in good condition.

2. Clean the surface of the battery.

3. Check whether the voltage of the battery, the proportion of electrolyte and the electrolyte level is appropriate.

4. Release the parking brake. Turn the steering wheel to check that the steering system is in normal condition. Drive the tractor truck slowly and step down the brake pedal to check that the brake system is in normal condition.

5. Check that the tire is in good condition and that the wheel bolts are fastened tightly.

9

Periodic inspection and maintenance Inspection and maintenance every day (8 hours) Clean dust and grease from exterior of the truck.

Whole truck

Ensure all hardware is tight and undamaged.

Make sure the tow pin is undamaged.

Braking system

Check brake fluid level and fill if required.

Make sure all lights are working properly.

Electrical system

Make sure the horn works properly.

Make sure all operation switches work properly.

Inspection and maintenance every 350 hours Every 350 hours, in addition to the daily inspections, the following maintenance should be carried out. When the parts must be adjusted and replaced, please contact with maintenance personnel.

Keep a monthly maintenance record.

Thoroughly clean the truck, including inside the battery compartment and the Whole truck undercarriage.

Check all switches for wear.

Electrical system

Make sure the battery box has no excessive corrosion, and that the battery posts are properly connected and undamaged.

Check all wiring to make sure the wires, connectors, and insulations are all in good condition.

Tighten the hardware fastening the electrical components.

Check the clearance between the brake drum and brake shoe and adjust if necessary.

Brake system

Check the brake pedal movement and adjust if necessary.

Check the brake shoes for wear and replace if necessary.

10

Inspection and maintenance every 1000 hours Every three months, in addition to the 350-hour maintenance, the following maintenance should be carried out. When the parts must be adjusted and replaced, please contact with maintenance personnel.

Drive motor

Clean and inspect internal components of the motor.

Electrical system

Check the main electrical contactor for damage and tighten the fastening hardware.

Drive axle

Check the gearing inside the drive axle and adjust gear clearance if necessary.

Brake system

Check all internal components of the brake for wear and damage.

Replace the brake seals.

Drain and release the brake fluid.

Steering system

Clean and inspect internal components of the steering system.

Adjust the clearance between the steering gear and the steer column.

Whole truck

Grease the chassis.

Recommended fluids Name Gear oil Lubricant grease Brake fluid

Specification China Rest of world GL-5 85W/90 gear oil 2# lithium lubricating JISK2220/2＃ grease DOT3 synthetic brake fluid

Notice Always recycle or dispose of all fluids according to local regulations.

11

Quantity 2L 1L

Repair Driving system Principles of operation The running of the tractor relies on the storage battery as its power source and the DC motor as its driving force to drive the truck through the two-speed transmission. The travel direction (forward or backward) is achieved through changing the rotation direction of the driving motor. When the truck turns , this driving axle controls the rotating speed of the right and left drive wheels by symmetrical taper planetary gear differential to achieve the coordinated turning of the two wheels so as to meet the requirements of driving kinematics.

Driving axle structure 27

26

28

29

30

31 32 33

34, 35 36 37 38 39 40 41 42 43 44

1 2,3 4 5

25

24 23 22 2120 19 18

1 2 3 4 5 6 7 8 9 10 11 12

Wheel Wheel bolt Wheel nut Brake drum Nut Rolling bearing Bearing 6011 Shaft sleeve Framework oil seal FB70x90x10 Brake Shaft tube Minor semi-axis

23 24 25 26 27 28 29 30 31 32 33 34

16, 17

15 14 13 12 11

Major semi-axis Shaft bush Motor bracket Mechanical brake Motor hoop Motor 3KW Motor flange O-type ring 47x2.65 Gear box housing Coupling band Bearing 6204 Seal screw M10 12

6 7 8 9 10

13 14 15 16 17 18 19 20 21 22

Bearing 6208 Hoop 1 Differential 462 Seal screw M16 Combined washer 16 Gear 83 Oil tank cover Hoop 2 Framework oil seal FB28x47x7 Circlip for hole

35 36 37 38 39 40 41 42 43 44

Combined washer 10 Gear 17 Washer 20x30x3 Bearing gland Thin flat key 5x8x20 Washer 20x30x5.5 Gear 18 Gear 46 End cap Nut sleeve

Wheel hub structure

1 2

Brake branch pump assembly Hand brake push rod

8 9

3

Spring

10

4 5 6 7

Brake shoe with friction plate assembly (rear) Spring 2 Return spring Pawl

13

Pin Clearance adjuster assembly Brake shoe with friction plate assembly (rear)

11

Brake base plate assembly

12 13

Pressing spring Hand brake pull rod

Drive axle description Motor 3KW (item 28) is connected to gear box housing (item 31) through motor flange (item 29) with bolts.

The male spline at the output shaft of motor is linked to male spline at gear 17 (item 36) shaft through female spline of coupling band (item 32).

When motor 3KW (item 28) turns, it rotates gear 17 (item 36). Gear 17 (item 36) and gear 46 (item 42) makes up high speed gear transmission. Gear 46 (item 42) is connected to gear 18 (item 41) shaft through flat keys.

When the gear 17 (item 36) shaft turns, it rotates gear 46 (item 42) through small gears. Because gear 46 (item 42) is connected to gear 18 (item 41) shaft by a flat key, when the gear 46 (item 42) rotates, it rotates gear 18 (item 41) shaft to achieve the first deceleration of the high speed gear transmission.

The small gears at gear 18 (item 41) shaft and gear 83 (item 18) make up the second gear transmission. Because the gear 83 (item 18) is connected together with differential 462 (item 15) through bolts, the gear 18 (item 41) shaft turns, it rotates gear 83 (item 18) through small gear.

Because gear 83 (item 18) is connected to differential housing (item 15) through bolts, it rotates differential 462 (item 15) when gear 83 (item 18) turns to achieve the second gear deceleration.

The rotation of gear 83 (item 18) passes to wheels through differential 462 (item 15), the minor semi-axis (item 12) and the major semi-axis (item 23). Differential 462 (item 15) is connected to the semi-axis through splines, while the semi-axis is linked to brake drum (item 4) with bolts. When gear 83 (item 18) turns with differential 462 (item 15), it rotates the semi-axis and brake drum (item 4). The wheel (item 1) is connected to brake drum (item 4) through wheel bolts (item 2) so as to realize the rotation of wheel.

The differential 462 (item 15) of the driving axle is the symmetrical taper planetary differential. The differential is installed on the reduction gearbox through the bearings on the two ends. The differential housing is divided into the right and left parts and has two differential gears and four planetary gears.

The drive axle includes reduction gearbox and two shaft tubes which are connected through flange.

The hub brake drum at the wheel is supported by two tapered roller bearings on the axle. The power is transmitted onto the half shaft through differential. The hub brake drum is driven by the half shaft and takes the rotation of driving wheel. The half shaft only bears the torque transmitted to the hub. There is an oil seal inside the hub to prevent water and dust entering or oil leakage.

This drive axle is installed with double shoe brake at two sides of the wheel.

The wheel brake is a double shoe brake which is composed of two groups of brake shoes with friction plate, brake branch pump, clearance adjuster assembly, hand brake pull rod, spring, base plate and other components. When the brake oil flows into the brake branch pump, the push rods on two sides open the brake shoe with equal pressure to press the friction plate of the brake shoe onto the brake drum so that the brake drum stops rotation. Because the brake drum and wheel shell are fixed together, wheel braking is realized when the wheel stops running.

14

Installation, adjustment, and maintenance Installation  The drive axle has the functions of driving the truck as well as supporting weight of the truck. The drive axle and truck body are fixed together with bolts.

1 2 3

4 1 2

Chassis Screw

3 4

Washer Drive axle

Adjustment of bearing clearance on transmission shaft  Bearing glands (item 38) are installed at the ends of gear 17 (item 36) shaft and gear 18 (item 41) shaft which are mounted with end cap (item 43) and which are used to press the bearing gland. Two adjusting screws are mounted at the end cap against bearing gland (item 38). Axial internal clearance of deep groove ball bearings is adjusted through adjusting the tightness of the adjusting screws. After the axial internal clearance is adjusted, fix the screws with locknuts.  When the taper roller bearings at the driving axle wheel wear out, the axial internal clearance becomes large and the truck wheel will swing. Then the axial internal clearance can be eliminated through adjusting the nut (item 5) to make the internal ring of tapered roller bearing contact with rollers.

Maintenance  When driving the truck, try to avoid pits and depressions on the road surface as far as possible, and also try to avoid sharp objects stabbing the tires.  Conduct regular checks for tightness of wheel nuts. If they are not tight, screw them down.  Check if the wheel brake is in proper working condition and if not, adjust it or repair.

15

Drive axle – remove 1. Support the rear part of the chassis with a block or stand (item1) rated to hold the weight of the truck.

1

2. Remove 6 M14x1.5 hub nuts (item 2) from each wheel and remove the drive wheels (item 3).

2 3 3. Remove 24 M8x30 hex screws (item 4) that fasten the semi-shaft and remove the semi shaft (item 5).

4 5

16

4. Remove 2 M5x12 screws (item 6), and remove check ring (item 7) and nut (item 8).

8 7 6

5. Remove the hub (item 9).

9

6. Remove the bearing 32011 (item 10) and bearing 32910 (item 11).

10

11

17

7. Remove the seal ring (item 12) and bearing check ring (item 13).

13 12

8. Remove 4 M8×18 screws (item 14) and take out the brake (item 15).

Remove the left brake in same way.

15 14

9. Remove 4 M14×45 screws, then take out the drive axle.

18

Drive axle – disassemble 1. Remove 2 M14×1.5 nuts (item 1), then remove the brake and the brake wire.

1

2. Remove the traction motor from the gear box.

3. Remove 6 M12×30 screw (item 2) from the long shaft on the reduction gear box, and remove long shaft assembly. Remove the left short shaft (item 3) in same way.

3 2

19

4. Remove 12 M6×20 screws (item 4) from the gearbox cover and remove the cover.

4

5. Remove 8 M10×50 screws (item 5) from the inner cover.

5

20

6. Remove the differential device and gear assembly.

7. Remove the gear assembly.

21

8. Remove 1 M12 nut (item 6) and 8 M8x25 screws (item 7) from the end cover.

6

7

9. Remove the gear shaft assembly from the gearbox.

22

10. Remove the nuts (item 8), circlip for hole 20 (item 9) and seal ring (item 10) from the long shaft assembly.

11. Remove the circlip for hole 20 and seal ring in the short shaft assembly in same way.

8

9

10

23

Steering system Principles of operation The steering system consists of the steering device, transmission gear device, front wheel and other components.

The steering device consists of the steering wheel, steering column assembly, universal joints and other components. Its role is to control the tractor driving direction.

The transmission gear device consists of large gears, pinions, bearings, slewing bracket, bolts and other components. Its role is to reduce the steering force.

The steering wheel not only has the function of steering, but also supports the weight of the truck.

The steering of the wheel slows down through the two-stage gear transmission, which increases the steering torque to the steering wheel to achieve the steering of the truck.

Steering system structure

1

2

3

1 2 3

Steering device Transmission gear device Front (steer) wheel

24

Steer wheel structure 1

2 3 4

5 7

6

1 2 3 4

Tire Rim Screw and nut Steer wheel housing

5 6 7

Hub cap Bearing Front axle

Steer wheel description One steer tire (item 1) is installed in the middle of the two steel rings by the screw and nuts (item 3) to form the steer tire wheel assembly.

The steering wheel housing is supported by two bearings 32206 (item 6), and mounted on the front axle (item 7).

During the assembly of steering wheel housing, add lubricant grease at the bearing. The quantity of lubricant grease should be enough to fill the bearing raceway.

Installation, adjustment, and maintenance Maintenance Check the tightness of hub and wheel tire daily.

25

Mechanical steer wheel – remove 1. Remove 16 M6×12 screws from the three covers (item 1) in the operator compartment, and remove the 3 covers.

1

2. Remove 4 M12×25 screws (item 2) that fix the steer wheel to the steer column. Secure the steer wheel, then lift the truck chassis with hoisting equipment and take out the steer wheel from the bottom of the truck.

2

26

Mechanical steer wheel – disassemble 1. Unthread and remove bearing 6004 gland (item 1), then remove 4 M5×16 screws (item 2) and remove bearing 6004 cover (item 3).

1 2

3

2. Remove circlip for shaft 20 (item 4), ball bearing 6004 (item 5) and circlip for hole 40 (item 6).

4 5 6

27

3. Remove the circlip for shaft 20 (item 7), then remove ball bearing 6004 (item 8).

7

8

4. Remove 8 M6×20 screws (item 9) from the gearbox cover and remove the gear box cover.

9

28

5. Remove the bearing spacer bushing (item 10), ball bearing 6004 (item 11), bearing spacer bushing (item 12), gear (item 13) and steering gear shaft (item 14).

10 11 12 13 14

6. Remove 4 M6×16 screws (item 15), bearing 6008 gland (item 16) and ball bearing 6008 (item 17).

15 16 17

29

7. Remove gear (item 18).

18

8. Remove steering wheel housing (item 19).

19

30

9. Remove the bearing (item 20).

20

10. Remove the ball bearing 51208 (item 21), gear (item 22) and ball bearing 61912 (item 23).

21 22 23

31

Power assist steer wheel – remove 1. Remove 5 M6 x 12 screws (item 1) from the steer wheel cover plate.

1

2. Remove 6 M8×25 screws (item 2) that fix the steer wheel. Secure the steer wheel, then lift the truck chassis with hoisting equipment and take out the steer wheel from the bottom of the truck.

2

32

Power assist steer wheel – disassemble 3. Remove 4 M6×12 screws (item 3) on the steer wheel closing plate.

3

4. Remove closing plate (item 4), bearing (item 5), collar (item 6), bearing (item 7), O-ring (item 8) and bearing (item 9) from the steer wheel.

4 5

6 7 8 9

33

5. Remove 8 M8×30 screws (10) that fix the steer wheel fluted gear, and remove the steer wheel gear.

10

6. Remove 6 M14×1.5 hub nuts (11) that fix the steer tire.

11

34

7. Release the air from the steer tire (item 12), then remove the steer tire.

12

8. Remove the steer wheel hub cover (item 13).

13

35

9. Remove the cotter pin (item 14) from the steer wheel shaft.

14

10. Remove the M24 x 2 nut (item 15) from the steer wheel shaft.

15

36

11. Remove the steer wheel hub assembly (item 16).

16

12. Remove the bearings (items 17 and 18) from each side of the steer wheel hub.

17

18

37

Power assist steer motor – remove 1. Lift the truck and remove the gear (item 1) under the steer motor from the bottom of the truck.

1

2. Remove 4 screws (item 2) that hold the steer motor.

2

38

3. Remove the steer motor from the truck.

39

Brake system Principles of operation The brake system consists of the service brake assembly, the foot pedal assembly, the park brake assembly, brake lines, hand brake shaft, brake oil reservoir, and other components.

Service brake system structure Service brake structure

5 4

1

1 2 3

2

3

Electromagnetic (park) brake Brake line Brake line

4 5

Foot pedal assembly Brake oil reservoir

Foot pedal structure

1 2 3 4 5

Foot pedal Spring Foot pedal support Pin Brake support

6 7 8 9

40

Brake pump Cotter pin Pin Adjustment screw

Service brake description When braking, step on brake pedal (item 1) to make the brake pedal rotate around pin (item 4).

The sway arm together with the brake pedal will turn together.

The rod pushes on the brake pump (item 6) and the sway arm on the brake pedal is connected together with pin (part 8). The push rod passes the pressure to the piston in the brake pump. The piston passes the pressure to the brake oil which is fed into brake pump from brake oil reservoir.

The brake pedal changes the mechanical force into brake oil pressure through the push rod and brake general. The pressurized oil is transmitted to the cylinder on each side of the wheel through the two outlets on the brake pump so that the brake pump presses the brake shoe with friction pad presses on the brake drum to actuate the brake. When brake is released, the tension spring (item 2) will make the brake pedal and push rod on brake pump return to position.

Park brake description The electromagnetic brake is used as a park brake, to prevent movement of the truck when parked.

Brake maintenance Every day before driving, check if the braking system stops the truck as expected and the return spring on the foot pedal assembly returns the brake to neutral position. If the brake does not stop the truck properly or if the foot pedal does not return to position, they must be adjusted.

It is also necessary to check these items:  Connection of the hand brake lever and brake hoop at the driving motor  Tightness of rivets and other hardware of brake components  Flexibility of hand brake lever protection sleeve and steel wire rope  Smooth movement of the foot pedal  Park brake hold Only operate the truck when the brake system is in good working condition.

Brake pedal adjustment To adjust the position of brake pedal up or down, adjust the adjustment screw (item 9) while moving the push rod.

Park brake adjustment When the park brake is set, the struck should hold on a 6% slope without moving.

To adjust hand brake turn the adjusting screws on the electromagnetic brake, then adjust the position of the cable. Pull out the cable to increase braking force.

41

Electrical system Principles of operation Start-up The truck is energized when both the emergency power disconnect SA1 and the keyswitch are turned on.

Travelling  When the seat is occupied and the seat belt is work, seat switch T9 is energized.  When the hand brake is released, the hand brake switch T10 is energized.  When the directional switch is pushed forward, forward switch T22 is energized, or when the direction switch is pulled back, reverse switch T33 is energized.  When the accelerator pedal is pressed, a variable signal of 0-5V will be on T16. Lower accelerator voltage means a slower traction speed, and higher accelerator voltage means a faster traction speed.

Acousto-optic  When the turn signal lever is pulled back, left steering switch 131 is energized with 12V voltage and the left turn signal turns on.  When the turn signal lever is pushed forward, the right steering switch 132 is energized with 12V and the right turn signal turns on.  When the width light switch 141 is turned on, the width light receives 12V power and turns on.  When the headlight switch 142 is turned on, the headlight receives 12V power and turns on.  The headlight switch and width light are on at the same time.

Steering controller – power assist steering only The steering controller 1222 (T13) is energized with 48V after the drive controller 1236E is energized. The controller will adjust the position of the steer wheel back and forth to find the zero position.

When the steering wheel is rotated, two sets AB-phase steering encoders output a square wave.

The high speed counter in the steering controller 1222 sends signal to the steer motor according to the number of square waves.

42

Electrical schematic – manual steering trucks

43

Electrical schematic – power assist steering trucks

44

Electrical component identification

1 3 4 5 6 7 8 9 10 11 12 13 14

Controller panel Washer 8 Washer 8 AC motor Micro switch TM-1308 (solenoid brake) Rear light Nut M5 Main circuit chart Control circuit chart Lead-acid battery Brake light switch JK231 Accelerator Screw M8 x 30

15 16 17 18 19 20 21 22 23 24 26 27

45

Nut M8 Horn Combined switch JK804 Blue light Turn signal Headlight Screw M5 x 12 DC power switch ZDK31/250A Warning ring yellow Mushroom head JD12-01C Instrument panel Strobe light LTD152/12V-24V

Electrical controller panel access

1

2

1

Rear cover plate

2

46

Controller panel

Controller panel identification

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Base plate Fixed seat THD-AD18.5 Black Screw M4 x 8 Screw M8 x 16 Washer 8 Washer 8 Reverse buzzer DC converter Screw M6 x 10 Washer 6 Washer 6 Screw M6 x 16 DC/DC support plate Reverse relay DCJ-01/48V Electronic flasher SG152-12V AC controller

47

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Screw M6 x 30 Screw M4 x 12 Fuse seat Buzzer Washer 5 Washer 5 Screw M5 x 12 Mounting plate 1 (SW180) Contactor Connecting stripe Fuse Screw M5 x 20 Fuse seat Screw M5 x 8 Screw M3 x 12

Traction controller 1236E – description

Terminal B+ BU V W

Description Battery positive to controller Battery negative to controller Motor phase U Motor phase V Motor phase W

Battery cables These two cables should be routed near each other between the controller and the battery. Use high quality copper lugs and observe any specified torque ratings. For the best electrical noise reduction, do not rout cables across the center of the controller. When using multiple high-current controllers, use a star ground from the B- terminal.

Motor wiring The three phase cables should be close to the same length and routed together between the controller and motor. Keep the cable lengths as short as possible. Use high quality copper lugs and observe any specified torque ratings. F or the best electrical noise reduction, do not rout cables across the center of the controller. Do not rout low current signal wires parallel to motor cables.

48

Traction controller connector pinout All low power connections are made through a single 35-pin AMPSEAL connector. The mated plug housing is AMP part number 776164-1, and the contact pins are AMP part number 770520-3. The connector will accept 20 to 16 AWG wire with 1.7-2.7mm (.067-106 in) thin wall insulation.

49

Steer controller 1222 (power assist steering only) – description

Terminal B+ BU V W

Description Battery positive to controller Battery negative to controller Motor phase U Motor phase V Motor phase W

Battery cables These two cables should be routed near each other between the controller and the battery. Use high quality copper lugs and observe any specified torque ratings. For the best electrical noise reduction, do not rout cables across the center of the controller. When using multiple high-current controllers, use a star ground from the B- terminal.

Motor wiring The three phase cables should be close to the same length and routed together between the controller and motor. Keep the cable lengths as short as possible. Use high quality copper lugs and observe any specified torque ratings. F or the best electrical noise reduction, do not rout cables across the center of the controller. Do not rout low current signal wires parallel to motor cables.

50

Steer controller connector pinout All low power connections are made through a single 35-pin AMPSEAL connector. The mated plug housing is AMP part number 776164-1, and the contact pins are AMP part number 770520-3. The connector will accept 20 to 16 AWG wire with 1.7-2.7mm (.067-106 in) thin wall insulation.

Pin number 1

Name

Description

Keyswitch

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Contactor driver [reserved] [reserved] [reserved] [reserved] Ground Command analog 1 Interlock input 1 Home input 2 Interlock input 3 Home input 4 Coil return Command encoder 1A +10V Position analog 5 Position analog 6 Ground Command analog 3 Command encoder 2B +5V Motor temperature sensor CAN high Fault output Command encoder 1B Steer motor encoder 4A Steer motor encoder 4B TX RX Ground Steer motor encoder 3A Steer motor encoder 3B Command encoder 2A +5V CAN low

Provides logic power for the controller and power to the coil drivers Driver for steer connector Not used Not used Not used Not used Ground Primary steer command pot Primary interlock switch pot Primary home switch input Redundant interlock switch input Redundant home switch input Coil return pin for all contactor coils Steer command encoder 1 input phase A Regulated low power +10V output Primary position feedback pot Redundant position feedback pot Ground Redundant steer command pot Steer command encoder 2 input phase B Regulated low power +5V output Motor temperature sensor CANbus high Steer fault output Steer command encoder 1 input phase B Steer motor encoder 4 input phase A Steer motor encoder 4 input phase B Serial transmit line Serial receive line Ground Steer motor encoder 3 input phase A Steer motor encoder 3 input phase B Steer command encoder 2 input phase A Regulated low power +5V output CANbus low 51

Troubleshooting Mechanical breakdowns Fault

Improper braking

Noise in brake

Uneven brake

Improper brake

Possible cause

Possible repair

1. Leaking in brake system 2. Clearance between brake shoe is not well adjusted 3. Brake is overheated 4. Improper contact between brake drum and friction pad 5. Impurity on friction plate 6. Impurity in brake liquid 7. Micro adjust valve on brake pedal is not well adjusted 1. Friction plate surface is hardened or has impurity 2. Base plate is deformed or screws are loosened 3. Brake shoe is deformed or is not mounted correctly 4. Friction plate is worn out 5. Wheel bearing is loosened 1. Oil stain on the friction plate surface 2. Clearance between brake shoe is not well adjusted 3. Branch pump doesn’t work 4. Return spring on the brake shoe is damaged 5. Brake drum is slanting 1. Oil leaking in brake system 2. Clearance between brake shoe is not well adjusted 3. Air in brake system 4. Brake pedal is not well adjusted

52

1. Repair 2. Adjust the adjuster 3. Check the return spring 4. Readjust 5. Repair or change 6. Check the brake liquid 7. Adjust

1. Repair or change 2. Repair or change 3. Repair or change 4. Change 5. Repair 1. Repair or change 2. Adjust the adjuster 3. Repair or change 4. Change 5. Repair or change 1. Repair or change 2. Adjust the adjuster 3. Release the air 4. Readjust

Fault codes Fault codes for traction controller 1236E The traction controller detects a wide variety of faults or error conditions. Faults can be detected by the operating system or by the VCL code.

Faults detected by VCL code (51-67) vary from application to application.

Diagnostics Diagnostics information can be obtained in either of two ways.

If a 1313 handheld device or a 1314 PC Programmer is available, the fault log in these devices displays faults that are currently set and faults that have been set since the fault log was last cleared. Faults are displayed by name in these devices.

Without a handheld device or a PC Programmer, the fault codes are communicated by the status LEDs on the controller itself.

The controller has one red LED and one yellow LED. The patterns of these LEDs communicate the status of the controller (including a fault code number if there are faults present).

LED illumination Controller status Neither LED is illuminated Controller is not powered on, battery is dead, or truck is severely damaged Yellow LED is flashing continuously Controller is operating normally Yellow and red LEDs are both on and solid Controller is in programming mode Red LED is on and solid No software is loaded to the controller or an internal hardware fault is detected; cycle the keyswitch, reload software, or replace the controller to resolve Red LED and yellow LED flash alternately in The controller has detected a fault; see Fault different patterns code identification with LEDs Fault code identification with LEDs The red LED will flash once to indicate that the first digit of the code will follow, and the yellow LED will then flash to indicate the value of that digit. Then, the red LED will flash twice to indicate the second digit of the code will follow, and again the yellow LED flashes to indicate the value of that digit.

For example, if the fault code 23 (B+ Battery Undervoltage Cutback) is set, the red LED will flash once to indicate the first digit of the fault code is coming. Then, the yellow LED will flash twice to indicate that the first digit of the fault code is 2. The red LED will then flash twice to indicate that the second digit of the code is coming, and the yellow LED will flash three times to indicate the second digit of the fault code is 3.

53

Troubleshooting chart – traction controller 1236E Use this chart to identify fault names, potential causes, and conditions to set and clear the fault.

Before troubleshooting, cycle the keyswitch to see if the fault clears. If the fault does not clear, turn off the keyswitch and disconnect the 35 pin connector from the controller, inspect the connector for damage or corrosion, clean and replace if necessary, and reconnect. If the fault persists, use the troubleshooting chart.

Code 12

Name Controller Overcurrent

13

Current Sensor Fault

14

Precharge Failed

15

Controller Severe Undertemp

16

Controller Severe Overtemp

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

2. Motor parameters are mistuned 3. Controller defective.

4. Speed encoder noise problems.

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

2. Controller defective.

1. See Monitor menu>>Battery: Capacitor Voltage.

2. External load on capacitor bank (B+ connection terminal) that prevents capacitor bank from charging.

1. See Monitor menu>>Controller: Temperature.

2. Controller is operating in an extreme environment.

1.

2.

17

Severe B+ Undervoltage

3.

1.

2.

3.

4.

5.

6.

17

Severe KSI Undervoltage

1.

2.

3.

4.

5.

See Monitor menu>>Controller: Temperature.

Controller is operating in an extreme environment.

Excessive load on vehicle.

Battery Menu parameters misadjusted.

Non-controller system drain on battery.

Battery resistance too high.

Battery disconnected while driving.

See Monitor menu>>Battery: Capacitor Voltage.

Blown B+ fuse or main contactor did not close.

See Monitor menu>>Battery: Keyswitch Voltage.

Non-controller system drain on battery.

Resistance in low power circuit too high.

Low power circuit power source disconnected while driving.

Blown fuse.

54

Set/clear conditions Set: Phase current exceeded the current measurement limit.

Clear: Cycle keyswitch.

Set: Controller current sensors have invalid offset reading.

Clear: Cycle keyswitch.

Set: Precharge failed to charge the

capacitor bank to the keyswitch voltage.

Clear: Cycle Interlock input or use VCL function Enable_Precharge().

Set: Heatsink temperature below 40°C (-40°F).

Clear: Bring heatsink temperature above -40°C (-40°F) and cycle interlock or keyswitch.

Set: Heatsink temperature above 95°C (203°F).

Clear: Bring heatsink temperature below 95°C (203°F) and cycle interlock or keyswitch.

Set: Capacitor band dropped below the Severe Undervoltage limit with FET bridge enabled.

Clear: Bring capacitor voltage above Severe Undervoltage limit.

Set: Keyswitch voltage dropped

below 8.4V (Brownout voltage is 8.0V).

Clear: Bring keyswitch voltage above 8.4V.

Code 18

Name Severe B+ Overvoltage

22

Controller Overtemp Cutback

23

B+ Undervoltage Cutback

24

B+ Overvoltage Cutback

25

+5V Supply Failure

26

27

Digital Out 6 Open/Short

Digital Out 7 Open/Short

Possible cause 1. See Monitor menu>>Battery: Capacitor Voltage.

2. Battery menu parameters are misadjusted.

3. Battery resistance too high for given regen current.

4. Battery disconnected while regen braking.

1. See Monitor menu>>Controller: Temperature.

2. Controller is performance-limited at this temperature.

3. Controller is operating in an extreme environment.

4. Excessive load on vehicle.

5. Improper mounting of controller.

1. Normal operation; fault shows that batteries need recharging (controller is performance-limited at this voltage).

2. Battery parameters are misadjusted.

3. Non-controller system drain on battery.

4. Battery resistance too high.

5. Battery disconnected while driving.

6. See monitor menu>>Battery: Capacitor Voltage.

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

1. Normal operation; fault shows that regen braking currents elevated the battery voltage during regen braking (controller is performance-limited at this voltage).

2. Battery parameters are misadjusted.

3. Battery resistance too high for given regen current.

4. Battery disconnected while regen braking.

5. See Monitor menu>>Battery: Capacitor Voltage.

1. External load impedance on the +5V supply (pin 26) is too low.

2. See Monitor menu>>Outputs: 5 Volts and Ext Supply Circuit.

1. External load impedance on digital output 6 driver (pin 19) is too low.

1.

External load impedance on digital output 7 driver (pin 20) is too low.

55

Set/clear conditions Set: Capacitor bank voltage exceeded the Severe Overvoltage Limit with FET bridge enabled.

Clear: Bring capacitor voltage below Severe Overvoltage Limit.

Set: Heatsink temperature

exceeded by 85°C (153°F).

Clear: Bring heatsink temperature below 85°C (153°F).

Set: Capacitor bank voltage

dropped below the Undervoltage limit with the FET bridge enabled.

Clear: Bring capacitor voltage above the Undervoltage limit.

Set: Capacitor bank voltage

exceeded the Overvoltage limit with the FET bridge enabled.

Clear: Bring the capacitor voltage below the Overvoltage limit.

Set: +5V supply (pin 26) outside

the +5V+/-10% range.

Clear: Bring voltage within range.

Set: Digital Output 6 (pin 19)

current exceeded 15 mA. Clear: Remedy the overcurrent cause and use the VCL function Set_DigOut() to turn the driver on again.

Set: Digital Output 7 (pin 20) current exceeded 15 mA. Clear: Remedy the overcurrent cause and use the VCL function Set_DigOut() to turn the driver on again.

Code 28

Name Motor Temp Hot Cutback

29

Motor Temp Sensor Fault

Possible cause 1. Motor temperature is at or above the programmed temperature hot setting and current is being cut back.

2. Motor temperature control menu parameters are mistuned.

3. See Monitor menu>> Motor: Temperature and Inputs: Analog 2.

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

2. If the application does not use a motor thermistor, Motor Temp sensor Enable should be programmed Off. 3. See Monitor menu>> Motor: Temperature and Inputs: Analog 2.

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

31

Coil1 Driver Open/Short

31

Main Open/Short

1.

2.

3.

Open or short on driver load.

Dirty connector pins.

Bad crimps or faulty wiring.

32

Coil2 Driver Open/Short

1.

2.

3.

Open or short on driver load.

Dirty connector pins.

Bad crimps or faulty wiring.

32

EMBrake Open/Short

1.

2.

3.

Open or short on driver load.

Dirty connector pins.

Bad crimps or faulty wiring.

33

Coil3 Driver Open/Short

1.

2.

3.

Open or short on driver load.

Dirty connector pins.

Bad crimps or faulty wiring.

34

Coil4 Driver Open/Short

1.

2.

3.

Open or short on driver load.

Dirty connector pins.

Bad crimps or faulty wiring.

35

PD Open/Short

1.

2.

3.

Open or short on driver load.

Dirty connector pins.

Bad crimps or faulty wiring.

36

Encoder Fault

1.

2.

3.

Motor encoder failure.

Bad crimps or faulty wiring.

See Monitor menu>>Motor: Motor RPM.

56

Set/clear conditions Set: Motor temperature is at or above the Temperature Hot parameter setting.

Clear: Bering the motor temperature within range.

Set: Motor thermistor input (pin 8) is at the voltage rail (0 or 10V).

Clear: Bring the motor thermistor input within range.

Set: Driver 1 (pin 6) is either open

or shorted. This fault can be set only when Main Enable = Off. Clear: Correct open or short, and cycle driver.

Set: Main contactor driver (pin 6) is either open or shorted. This fault can be set only when Main Enable = On. Clear: Correct open or short, and cycle driver.

Set: Driver 2 (pin 5) is either open or shorted. This fault can be set only when EM Brake Type = 0.

Clear: Correct open or short, and cycle driver.

Set: Electromagnetic brake driver (pin 5) is either open or shorted.

This fault can be set only when EM Brake Type > 0.

Clear: Correct open or short, and cycle driver.

Set: Driver 3 (pin 4) is either open or shorted.

Clear: Correct open or short, and cycle driver.

Set: Driver 4 (pin 3) is either open or shorted.

Clear: Correct open or short, and cycle driver.

Set: Proportional driver (pin 2) is either open or shorted.

Clear: Correct open or short, and cycle driver.

Set: Motor encoder phase failure detected.

Clear: Cycle keyswitch.

Code 36

Name Sin/Cos Sensor Fault

37

Motor Open

38

Main Contactor Welded

Possible cause 1. Sin/cos sensor failure.

2. Bad crimps or faulty wiring.

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

2. Bad crimps or faulty wiring.

1.

2.

3.

39

Main Contactor Did Not Close

1.

2.

3.

41

Throttle Wiper High

4.

1.

2.

42

Throttle Wiper Low

1.

2.

43

Pot2 Wiper High

1.

2.

44

Pot2 Wiper Low

1.

2.

45

Pot Low OverCurrent

1.

2.

46

EEPROM Failure

1.

Main contactor tips are welded closed.

Motor phase U or V is disconnected or open.

An alternate voltage path (such as an external precharge resistor) is providing current to the capacitor bank (B+ connection terminal).

Main contactor did not close.

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

Eternal load on capacitor bank (B+ connection terminal) that prevents capacitor bank from charging.

Blown B+ fuse.

See Monitor menu>>Inputs: Throttle Pot. Throttle pot wiper voltage too high.

See Monitor menu>>Inputs: Throttle Pot. Throttle pot wiper voltage too low.

See Monitor menu>>Inputs: Pot2 Raw. Pot2 wiper voltage too high.

See Monitor menu>>Inputs: Pot2 Raw. Pot2 wiper voltage too low.

See Monitor menu>>Outputs: Pot Low. Combined pot resistance connected to pot low is too low.

Failure to write to EEPROM memory.

This can be caused by EEPROM memory writes initiated by VCL, by the CAN bus, by adjusting parameters with the programmer, or by loading software into the controller.

57

Set/clear conditions Set: Motor Sin/Cos sensor failure detected.

Clear: Cycle keyswitch.

Set: Motor phase U, V, or W

detected open.

Clear: Cycle keyswitch.

Set: Just prior to the main contactor closing, the capacitor bank voltage (B+ connection terminal) was loaded for a short time and the voltage did not discharge.

Clear: Cycle keyswitch.

Set: With the main contactor

commanded closed, the capacitor bank voltage (B+ connection terminal) did not change to B+.

Clear: Cycle keyswitch.

Set: Throttle pot wiper (pin 16)

volage is higher than the high fault threshold (can be changed with the VCL function Setup_Pot_Faults()).

Clear: Bring the throttle pot wiper voltage below the fault threshold.

Set: Throttle pot wiper (pin 16) volage is lower than the low fault threshold (can be changed with the VCL function Setup_Pot_Faults()).

Clear: Bring the throttle pot wiper voltage above the fault threshold.

Set: Pot2 wiper (pin 17) volage is higher than the high fault threshold (can be changed with the VCL function Setup_Pot_Faults()).

Clear: Bring the Pot2 wiper voltage below the fault threshold.

Set: Pot2 wiper (pin 17) volage is lower than the low fault threshold (can be changed with the VCL function Setup_Pot_Faults()).

Clear: Bring the Pot2 wiper voltage above the fault threshold.

Set: Pot low (pin 18) current exceeds 10mA. Clear: Clear pot low overcurrent condition and cycle keyswitch.

Set: Controller operating system tried to write to EEPROM memory and failed.

Clear: Download the correct software 9OS) and matching parameter default settings into the controller and cycle keyswitch.

Code 47

Name HPD/Sequencing Fault

47

Emer Rev HPD

48

Following Error Fault

Possible cause 1. Keyswitch, interlock, direction, and throttle inputs applied in incorrect sequence.

2. Faulty wiring, crimps, or switches at keyswitch, interlock, direction, or throttle inputs.

3. See Monitor menu>>Inputs.

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

1.

2.

3.

49

68

Parameter Change Fault

VCL Runtime Error

1.

1.

2.

69

External Supply Out of Range

1.

2.

71

OS General

1.

The Following Error Limit has been exceeded for the Following Error Time.

Incorrect or overly restrictive Following Error Limit and Following Error Time parameter settings.

Motor or drivetrain rotation obstruction or degradation.

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

VCL code encountered a runtime VCL error.

See Monitor menu>>Controller: VCL Error Module and VCL Error. This error can then be compared to the runtime VCL module ID and error code definitions found in the specific OS system information file.

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

Fault checking menu Ext Supply Max and Ext Supply Min parameters are mistuned.

Internal controller fault.

58

Set/clear conditions Set: HPD (High Pedal Disable) or sequencing fault caused by incorrect sequence of keyswitch, direction, and throttle inputs.

Clear: Reapply inputs in the correct sequence.

Set: At the conclusion of

Emergency Reverse, the fault was set because various inputs were not returned to normal.

Clear: If EMR_Interlock = On, clear the interlock, throttle, and direction inputs. If EMR_Interlock = Off, clear the throttle and direction inputs.

Set: The Following Error Limit has been exceeded for the Following Error Time.

Clear: Cycle keyswitch.

Set: Adjustment of a parameter setting requires cycling of keyswitch.

Clear: Cycle keyswitch.

Set: Runtime VCL code error

condition.

Clear: Edit VCL application software to fix this error condition; flash the new compiled software and matching parameter defaults; cycle keyswitch.

Set: The external supply current

(combined current used by the 5V supply [pin 26] and 12V supply [pin 25]) is either greater than the upper current threshold or lower than the lower current threshold.

The two thresholds are defined by the External Supply Max and External Supply Min parameter settings.

Clear: Bring the external supply current within range.

Set: Internal controller fault detected.

Clear: Cycle keyswitch.

Code 72

Name PDO Timeout

Possible cause 1. Time between CAN PDO messages exceeded the PDO Timeout Period.

73

Stall Detected

1.

2.

3.

4.

5.

77

Supervisor Fault

1.

2.

3.

78

Supervisor Incompatible

1.

Stalled motor.

Motor encoder failure.

Bad crimps or faulty wiring.

Problems with power supply for the motor encoder.

See Monitor menu>>Motor: Motor RPM. The Supervisor has detected a mismatch in redundant readings.

Internal damage to Supervisor microprocessor.

Switch inputs allowed to be within upper and lower thresholds for over 100 milliseconds.

The main OS is not compatible with the Supervisor OS.

82

Bad Calibrations

1.

Internal controller fault.

83

Driver Supply

1.

Internal controller fault in the voltage supply for the driver circuits.

87

Motor Characterization Fault

1.

88

Encoder Pulse Count Fault

1.

Motor characterization failed during characterization process. See Monitor menu>>Controller Motor Characterization Error for cause: 0=none 1=encoder signal seen, but step size not determined; set Encoder Step Size manually 2=motor temp sensor fault 3=motor temp hot cutback fault 4=controller overtemp cutback fault 5=controller undertemp cutback fault 6=undervoltage cutback fault 7=severe overvoltage fault 8=encoder signal not seen, or one or both channels missing 9=motor parameters out of characterization range Encoder Steps parameter does not match the actual motor encoder.

Motor type fault

1.

89

The Motor_Type parameter value is out of range.

59

Set/clear conditions Set: Time between CAN PDO messages received exceeded the PDO Timeout Period.

Clear: Cycle keyswitch or receive CAN NMT message.

Set: No motor encoder movement detected.

Clear: Either cycle keyswitch, or detect valid motor signals while operating in LOS mode and return Throttle Command = 0 and Motor RPM = 0.

Set: Mismatched redundant readings; damaged Supervisor; illegal switch inputs.

Clear: Check for noise or voltage drift in all switch inputs; check connections; cycle keyswitch.

Set: Incompatible software.

Clear: Load properly matched OS

code or update the Supervisor code; cycle keyswitch.

Set: Internal controller fault detection.

Clear: Cycle keyswitch.

Set: Internal controller fault detection.

Clear: Cycle keyswitch.

Set: Motor characterization failed during the motor characterization process.

Clear: Correct fault, cycle keyswitch.

Set: Motor lost IFO control and

accelerated without throttle command.

Clear: Ensure the Encoder Steps parameter matches the actual encoder, cycle keyswitch.

Set: Motor_Type parameter is set to an illegal value.

Clear: Set Motor_Type to correct value and cycle keyswitch.

Code 91

Name VCL/OS Mismatch

Possible cause 1. The VCL software in the controller does not match the OS software in the controller.

92

EM Brake Failed to Set

1.

2.

93

Encoder LOS (Limited Operating Strategy)

1.

2.

3.

4.

94

EMR Rev Timeout

1.

2.

98

Illegal Model Number

1.

2.

3.

99

Parameter Mismatch

1.

2.

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

EM Brake will not hold the motor from rotating.

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

Motor encoder failure.

Bad crimps of faulty wiring.

Vehicle is stalled.

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

The emergency reverse input is stuck On. Model_Number variable contains illegal value.

Software and hardware do not match.

Controller defective.

Dual Motor Enable parameter is set On and Control Mode Select parameter not set to 1 (Speed Mode Express) or 2 (Speed Mode) Motor Technology and Feedback Type parameters do not match.

60

Set/clear conditions Set: VCL and OS software do not match; when keyswitch cycles, a check is made to verify that they match and a fault is issued when they do not.

Clear: Download the correct VCL and OS software into the controller.

Set: After the EM Brake was commanded to set and time has elapsed to allow the brake to fully engage, vehicle movement has been sensed.

Clear: Activate the throttle.

Set: Encoder Fault (Code 36) or Stall Detect Fault (Code 73) was activated, and Brake or Interlock has been applied to activate LOS control mode, allowing limited motor control.

Clear: Cycle keyswitch or, if LOS mode was activated by Stall Fault, clear by ensuring encoder senses proper operation, Motor RPM = 0, and Throttle Command = 0.

Set: Emergency Reverse was activated and ran until the EMR Timeout timer expired.

Clear: Turn the emergency reverse input Off. Set: Illegal Model_Number variable; when keyswitch cycles, a check is made to confirm a legal Model_Number, and a fault is issued if one is not found.

Clear: Download appropriate software for your controller model.

Set: When the Dual Drive software is enabled, the controller must be set to either Speed Mode Express or Speed Mode; otherwise fault is set. Motor Technology=0 must be paired with Feedback Type=1, and Motor Technology=1 must be paired with Feedback Type=2; otherwise this fault is set.

Clear: Adjust parameters to appropriate values and cycle keyswitch.

Fault codes for steer controller 1222 (power assist steering only) The steer controller detects a wide variety of faults or error conditions. Faults can be detected by the operating system or by the VCL code.

Diagnostics Diagnostics information can be obtained in either of two ways.

If a 1313 handheld device is available, the fault log in these devices displays faults that are currently set and faults that have been set since the fault log was last cleared. Faults are displayed by name in these devices.

Without a handheld device, the fault codes are communicated by the status LEDs on the controller itself.

The controller has one red LED and one yellow LED. The patterns of these LEDs communicate the status of the controller (including a fault code number if there are faults present).

LED illumination Controller status Neither LED is illuminated Controller is not powered on, battery is dead, or truck is severely damaged Yellow LED is flashing continuously Controller is operating normally Yellow and red LEDs are both on and solid Controller is in programming mode Red LED is on and solid No software is loaded to the controller or an internal hardware fault is detected; cycle the keyswitch, reload software, or replace the controller to resolve Red LED and yellow LED flash alternately in The controller has detected a fault; see Fault different patterns code identification with LEDs Fault code identification with LEDs The red LED will flash once to indicate that the first digit of the code will follow, and the yellow LED will then flash to indicate the value of that digit. Then, the red LED will flash twice to indicate the second digit of the code will follow, and again the yellow LED flashes to indicate the value of that digit.

For example, if the fault code 25 (5V Supply Failure) is set, the red LED will flash once to indicate the first digit of the fault code is coming. Then, the yellow LED will flash twice to indicate that the first digit of the fault code is 2. The red LED will then flash twice to indicate that the second digit of the code is coming, and the yellow LED will flash five times to indicate the second digit of the fault code is 5.

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Troubleshooting chart – steer controller 1222 (power assist steering only) Use this chart to identify fault names, potential causes, and conditions to set and clear the fault.

Before troubleshooting, cycle the keyswitch to see if the fault clears. If the fault does not clear, turn off the keyswitch and disconnect the 35 pin connector from the controller, inspect the connector for damage or corrosion, clean and replace if necessary, and reconnect. If the fault persists, use the troubleshooting chart.

Unless indicated as a Warning in the Name column, all faults in this table cause the truck to shut down.

Code 11

12

Sub Code 1

1

Name

Possible cause

Set/clear conditions

Hardware Fault

1.

Set: a)System starting with an indication

Controller Overcurrent 1

1.

2.

12

2

Controller Overcurrent 2

13

1

Current

3.

1.

1.

2.

14

1

Precharge

1.

2.

15

1

Controller Severe Undertemp (Warning)

1.

2.

16

1

Controller Severe Overtemp

1.

2.

3.

4.

Hardware error: an unexpected HW Reset, one of the internal supply voltages is out of range, or one of the RAM tests failed.

External short of phase U, V, or W motor connection.

Motor parameters are mistuned.

Controller defective.

Rail check or calibrated current greater than 120% of base current.

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

See Monitor menu>>Battery & Supply>>Capacitor Voltage.

External load on capacitor bank (B+ connection terminal) that prevents the capacitor bank from charging.

See Monitor menu>>Controller>>Tempera ture.

Controller is operating in an extreme environment.

See Monitor menu>>Controller>>Tempera ture.

Controller is operating in an extreme environment.

Excessive load on vehicle.

Improper mounting of controller.

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of HW Reset, b) CORE supply voltage is not within +/-5% of 3.75V on main or within +/-5% of 2.5V on supervisor, or c) a RAM test failed.

Clear: Cycle keyswitch.

Set: BridgeEnabled and TrapBar = Off for twenty consecutive samples in the interrupt.

Clear: Cycle keyswitch.

Set: a) Irms > 120% max base current

for 1.2 msec, b) I-U or I-V (current sensor raw ADC) or I-W (-((I-U – UOffset) + (I-V – VOffset) + 2.5 V)) is greater than 950 (4.65V) or less than 41 (0.2V) for five consecutive samples at 240 μs.

Clear: Cycle keyswitch.

Set: a) UOffset or VOffset is outside the ADC range of 450 92.2V) to 573 (2.8V) or, b) UOffset or VOffset functions did not compute.

Clear: Cycle keyswitch.

Set: Capacitor Voltage does not reach ¾ Keyswitch Voltage or 2/3 Nominal Voltage within 3 sec.

Clear: Cycle keyswitch.

Set: Controller heatsink Temperature

equal to or below -40°C (-40°F).

Clear: Bring heatsink temp above -35°C (-31°F).

Set: Controller heatsink Temperature

equal to or above 95°C (203°F).

Clear: Bring heatsink temp below 95°C (203°F) and cycle keyswitch.

Code 17

Sub Code 1

Name

Possible cause

Set/clear conditions

Severe Undervoltage

1.

Set: a) Capacitor Voltage < 12V and

2.

3.

4.

5.

6.

18

22

1

1

Severe Overvoltage

Controller Overtemp (Warning)

1.

2.

1.

2.

25

1

5V Supply Failure

1.

2.

26

1

10V Supply Failure

1.

2.

27

1

Severe Motor Overtemp

1.

2.

3.

28

1

Severe Motor Hot Cutback

1.

2.

3.

29

1

Motor Temp Sensor Fault (Warning)

1.

2.

3.

Battery parameters are misadjusted.

Non-controller system drain on battery.

Battery resistance too high.

Battery disconnected while driving.

See Monitor menu>>Battery & Supply>>Capacitor Voltage.

Blown B+ fuse or main contactor did not close.

See Monitor menu>>Battery & Supply>>Capacitor Voltage.

Battery parameters are misadjusted.

See Monitor menu>>Controller>>Tempera ture.

Controller is performancelimited at this temperature.

External load impedance on the +5V supply (pin 21 or 34) is too low.

See Monitor menu>>Battery & Supply>>5V Out External load impedance on the +10V supply (pin 15) is too low.

See Monitor menu>>Battery & Supply>>10V Out. Motor temperature is at or above the programmed Temperature Max setting.

Motor Temperature Control parameters are mistuned.

See Monitor menu>>Steer Motor>>Temperature.

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

Motor Temperature control parameers are mistuned.

See Monitor menu>>Steer Motor>>Temperature.

Motor thermistor is not connected properly.

If the application does not use a motor thermistor, parameter Motor>>Temperature Control>>Sensor Enable should be programmed Off. See Monitor menu>>Steer Motor>>Temperature Sensor Voltage.

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Interlock = On and (Contactor Control Type = 1 and Contactor State = 2), or b) Contactor Control Type <>1 for 60 msec.

Clear: Bring capacitor voltage above Severe Undervoltage limit and cycle keyswitch.

Set: a) Keyswitch Voltage > 65V, or b) Capacitor Voltage > 65V for 30 msec.

Clear: Bring capacitor voltage below

Severe Overvltage limit and cycle keyswitch.

Set: Controller heatsink Temperature > 85°C (185°F).

Clear: Brink heatsink temp below 85°C (185°F).

Set: a) 5v Out < 4.5V for 80 msec, or b) 5v Out >5.5V for 80 msec.

Clear: Bring voltage within range and cycle keyswitch.

Set: a) 10v Out < 9.0V for 80 msec, or b) 10v Out > 11.0V for 80 msec.

Clear: Bring voltage within range and cycle keyswitch.

Set: Sensor Enable = On and Steer Motor Temperature > programmed

Temperature Max. Clear: Bring voltage within range and cycle keyswitch.

Set: Sensor Enable = On and Steer Motor Temperature > programmed Temperature Hot. Clear: Bring temp within range.

Set: Sensor Enable = On and Motor-

Temp (raw A/D) is > 1003 (4.9V) or <20 (0.1V) for 80 msec.

Clear: Sensor Enable = On and MotorTemp (raw A/D) is < 1003 (4.9V) or <20 (0.1V) for 80 msec.

Code 31

Sub Code 1

Name

Possible cause

Set/clear conditions

Contactor Open/Short

1.

2.

3.

Set: Contactor Control Type = 1 and

Open or short on driver load.

Dirty connector pins.

Bad crimps or faulty wiring.

35

1

Fault Output Open/Short

-

37

1

Motor Open

1.

2.

Motor phase is open.

Bad crimps or faulty wiring.

38

1

Contactor Welded

1.

Main contactor tips are welded closed.

Motor phase U or V is disconnected or open.

An alternative voltage path (such as an external precharge resistor) is providing a current to the capacitor bank (B+ connection terminal).

1222 contactor was closed but is no longer closed.

2.

3.

39

1

Contactor Opened

1.

39

2

Contactor Did Not Close

1.

2.

3.

41

1

Command Analog1 Out of Range

4.

-

Main contactor did not close.

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

External load on capacitor bank (B+ connection terminal) that prevents capacitor bank from charging.

Blown B+ fuse.

Checks Enable = On and Contactor Driver = 0% and DrainOut1 = Off for 60 msec.

Clear: Correct open or short, and cycle keyswitch.

Set: Fault output = On and ABS (KSI – FaultOutputVoltage) < 2.0V for 80 msec, or b) Fault Output = On and FaultOutputVoltage < 4.0V for 80 msec.

Clear: Correct open or short, and cycle keyswitch.

Set: No current on phase V or phase W when 10A DC current is run out of phase U after the contactor is closed before operation begins.

Clear: Cycle keyswitch.

Set: Contactor Control Type = 1 and Checks Enable = On and Contactor State = 3 and Weld Check = On and ABD (Keyswitch Voltage – Capacitor Voltage) is 1.0V for 100 msec.

Clear: Cycle keyswitch.

Set: Contactor Control Type = 1 and Checks Enable = On and Contactor State = 2 and ABS (Keyswitch Voltage – Capacitor Voltage) is > 5.0V for 1 sec.

Clear: Cycle keyswitch.

Set: Contactor Control Type = 1 and Checks Enable = On and Contactor State = 1 and ABS (Keyswitch Voltage – Capacitor Voltage) is > 5.0V for 1 sec.

Clear: Cycle keyswitch.

Set: (Command Input Device = 0 or 2) and (Analog 1 > Analog 1 Fault Max or Analog 1 < Analog 1 Fault Min) for 60 msec.

42

43

1

1

Command Analog3 out of Range

-

Feedback Analog5 Out of Range

-

Clear: Cycle keyswitch.

Set: (Command Input Device = 0 or 2) and (Analog 3 > Analog 3 Fault Max or Analog 3 < Analog 3 Fault Min) for 60 msec.

Clear: Cycle keyswitch.

Set: (Command Input Device = 0 or 2) and (Analog 5 > Analog 5 Fault Max or Analog 5 < Analog 5 Fault Min) for 60 msec.

Clear: Cycle keyswitch.

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Code 44

Sub Code 1

Name

Possible cause

Set/clear conditions

Feedback Analog6 Out of Range

-

Set: (Command Input Device = 0 or 2) and (Analog 6 > Analog 6 Fault Max or Analog 6 < Analog 6 Fault Min) for 60 msec.

46

1

EEPROM Failure

1.

47

1

Sin/Cos Command Sensor

-

48

1

Sin/Cos Feedback Sensor

-

49

1

Parameter Change Fault

1.

2.

3.

51

1

52

1

53

1

Interlock Switch Supervision (Sets Interlock=Off) Home Switch Supervision

-

Home Position Not Found

-

Failure to write to EEPROM memory. This can be caused

by EEPROM memory writes initiated by the CAN bus, by adjusting parameters with the programmer, or by loading new software into the controller.

Clear: Cycle keyswitch.

Set: EEPROM CRC does not match after four attempts to read.

Clear: Cycle keyswitch.

Set: Analog 1 and Analog 3 inputs are

A parameter value was changed that requires a power cycle or must be changed prior to first interlock.

A new software application was loaded that does not match the existing parameters and the parameters were overwritten with the defaults from FLASH. A device (such as the 1313) using the serial interface is requesting a change to a parameter that is outside allowable range.

not within the parameter Command Device >>2 – Sin/Cos Sensor>>Fault Volts of the ideal waveform as defined by the Gain and Offset parameters.

Clear: Cycle keyswitch.

Set: Analog 5 and Analog 6 inputs are not within the parameter Command Device >>2 – Sin/Cos Sensor>>Fault Volts of the ideal waveform as defined by the Gain and Offset parameters.

Clear: Cycle keyswitch.

Set: a) A parameter is changed using CAN or ESP that requires a power cycle, b) an application is loaded and started that has a parameter interlock key different from the old application (an automatic reset of the parameters occurs when the keys do not match; the fault is set to indicate that the parameter settings need review), or c) a parameter change is requested when using ESP that is out of range.

Clear: Cycle keyswitch.

Set: Interlock Type = 2 and Switch1 = Switch3 for 60 msec.

Clear: Interlock Input 1 <> Interlock

Input 3 for 60 msec.

Set: a) Input Type = 1 and Switch2 = Switch4 and Wheel Position > 5° from last position where they did not match for more than 60 msec., or b) Input Type = 2 and Switch2 <> Switch4 and Wheel Position > 5° from last position where they matched for 60 msec.

Clear: Cycle keyswitch.

Set: Steer Command State = 2 and Wheel Position changes by more than 180° without a change in the monitor variable Home Reference>>Home.

Clear: Cycle keyswitch.

-

65

Code 54

55

56

Sub Code 1

1

1

Name

Possible cause

Set/clear conditions

Home Reference Tolerance Fault

1.

Set: Steer Command State = 4 and ABS (Encoder 3 Degrees from Home at the

Steer Command Supervision

1.

Wheel Position Supervision

1.

69

1

5V Current Out of Range

1.

71

1

Software Fault 1

-

71

2

Software Fault 2

-

71

3

Software Fault 3

-

71

4

Software Fault 4

-

71

5

Software Fault 5

-

72

1

PDO1 Timeout

-

73

1

Following Error

-

During steering (Steer Command State = 4), the wheel position at which the Home variable changes is farther than the allowed tolerance from the original position found during homing (Steer Command State = 2).

Steer Command differs from Steer Command 2 by more than the allowed tolerance.

Wheel Position differs from Wheel Position 2 by more than the allowed tolerance.

The monitor variable 5V Out is less than the programmed 5V Current Min or greater than the programmed 5V Current Max.

home transition) >Home Reference Tolerance for 60 msec.

Clear: Cycle keyswitch.

Set: Device State = 4 and ABS (Steer Command (deg) – Steer Command 2 (deg)) > Wheel Position Tolerance for 80 msec.

Clear: Cycle keyswitch.

Set: Device State = 4 and ABS (Steer

Command (deg) – Steer Command 2 (deg)) > Steer Command Tolerance for

80 msec.

Clear: Cycle keyswitch.

Set: a) 5v Out < 5V Current Min for 80 msec, or b) 5v Out > 5V Current Max for 80 msec.

Clear: Cycle keyswitch.

Set: a) Watchdog reset, or b)

unexpected re-entry from the Start Manager.

Clear: Cycle keyswitch.

Set: a) ENUM out of range, or b) an improperly calculated value (assert).

Clear: Cycle keyswitch.

Set: a) out of range calculated value or parameter, or b) common parameters CRC for main and supervisor do not match.

Clear: Cycle keyswitch.

Set: A fault occurred in the supervisor micro that can only occur in the main micro.

Clear: Cycle keyswitch.

Set: a) An internal CAN PDO was not received from the other micro within 100 msec, or b) the internal PDO sequence number is not in sequence.

Clear: Cycle keyswitch.

Set: CAN NMT State = 5, and time since the last PDO1 message is greater than PDO1 TimeoutTime.

Clear: Cycle keyswitch.

Set: Steer Command State = 4 and ABS (Steer Command 2 (deg) – Wheel Position 2 (deg)) > Following Error Tolerance for Following Error Time.

Clear: Cycle keyswitch.

66

Code 74

Sub Code 1

Name

Possible cause

Set/clear conditions

Hardware Software Mismatch

1.

Set: a) The hardware product code

2.

3.

75

1

Parameter Conflict

1.

Software not compatible with controller hardware configuration.

Application software loaded into one or both micro controllers is loaded into the wrong micro.

Different versions of the application software are loaded into the two micro controllers.

Using quadrature encoder 1 for steering command and for traction motor feedback.

(3300000x, where x = 1, 2, 3, 4, 5, 6) does not match the application product code, or b) the controller rated voltage (g_profile.controllerRatedVoltage) does not conform with the hardware product code.

Clear: Download appropriate software and cycle keyswitch.

Set: Command Device>>Command

Input Device =1 and Vehicle Configuration>> Traction Speed Input >>Input Type=1.

Clear: Resolve conflict and cycle keyswitch.

Truck storage and transportation Loading and unloading Before loading the truck, check the nameplate for the total weight of truck to choose appropriate hoisting handling equipment.

When hoisting the truck, connect the lifting gear to three points on the truck. Use the two lift points under the front of the truck, one on each side, and the tow pin.

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

67

Transportation of truck During transportation of the truck, please pay attention to the following items:  Set the parking brake of the tractor.  Fix the front wheel and rear driving axle with steel wire and block the front and back wheel.

Make sure that the tractor truck is tied down to the transport truck securely.  During hoisting of the tractor, lift the tractor truck only according to the “hoisting marks” on the covers.  Trucks used to load and transport the tractor should not run too fast and should avoid sharp turning and sudden braking to prevent damaging the tractor truck and avoid accidents.

Storing the truck    

Shut off the electric lock and unplug the battery.

Set the parking brake of the tractor truck.

Block the front and rear wheel.

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

68