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CAT NR3000 Service Manual

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100% found this document useful (4 votes)

3K views273 pages

CAT NR3000 Service Manual

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Kelli Brown

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Service Manual

Chassis, Mast & Options

NR3000-36V 2NR3300000
NR3500-36V 4NR3300000

NR4000-36V 5NR3300000

NR4000P-36V 6NR3300000
NR4500-36V 7NR3300000
NR4500P-36V 8NR3300000

ND2500-36V 1ND3300000

ND3000-36V 2ND3300000

ND3000P-36V 3ND3300000

NS3000-36V 2NS3300000

NS4000-36V 5NS3300000

SENB2900
SAFETY PRECAUTIONS

CAT® Lift Trucks Important Safety

Information ! CAUTION
Most accidents involving product operation, Indicates a potentially hazardous situation
maintenance and repair are caused by failure to which, if not avoided, may result in minor or
observe basic safety rules and precautions. An moderate injury, or damage to your machine.
accident can often be avoided by recognizing
potentially hazardous situations before an
accident occurs. A person must be alert to
potential hazards. This person should also have
! WARNING
the necessary training, skills and tools to perform Attention! Become Alert! Your Safety is involved.
these functions properly. The message that appears under the warning
Improper operation, lubrication, maintenance or explains the hazard and can be either written or
repair of this product can be dangerous and pictorially presented.
could result in injury or death. Operations that may cause product damage are
Do not operate or perform any lubrication, identified by NOTICE labels on the product and
maintenance or repair on this product, until you in this publication.
have read and understood the operation, Mitsubishi Caterpillar Forklift America Inc. cannot
lubrication, maintenance and repair information. anticipate every possible circumstance that might
Safety precautions and warnings are provided in involve a potential hazard. The warnings in this
this manual and on the product. If these hazard publication and on the product are therefore not
warnings are not heeded, bodily injury or death all-inclusive. If a tool, procedure, work method or
could occur to you or other persons. operating technique not specifically
The following safety signs and NOTICES are recommended by Mitsubishi Caterpillar Forklift
used in this manual to emphasize important and America Inc. is used, you must satisfy yourself
critical instructions. that it is safe for you and others. You should also
ensure that the product will not be damaged or
made unsafe by the operation, lubrication,
! maintenance or repair procedures you choose.
The above safety alert symbol is used to alert you The information, specifications, and illustrations
to potential personal injury hazards. Obey all safe- in this publication are on the basis of information
ty messages that follow this symbol to avoid pos- available at the time it was written. The
sible injury or death. specifications, torques, pressures,
measurements, adjustments, illustrations, and
other items can change at any time. These
! DANGER changes can affect the service given to the
Indicates a imminently hazardous situation product. Obtain the complete and most current
which, if not avoided, will result in death or seri- information before starting any job.
ous injury.
CAT Lift Trucks dealers have the most current
information available.

! WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in death or
serious injury.
TABLE OF CONTENTS

1. GENERAL INFORMATION & FEATURES

Glossary ............................................................................................................................... 1-1
General Overview................................................................................................................. 1-4
Operator's Display ................................................................................................................ 1-7

2. THEORY OF OPERATIONS
Plugging in the Battery ......................................................................................................... 2-1
B+ Feed to............................................................................................................................ 2-1
B- Feed to............................................................................................................................. 2-1
Additional Safety Circuit (Emergency Power Off) ................................................................ 2-1
Turning Key Switch (S2) ON ................................................................................................ 2-1
CAN Bus Communications .................................................................................................. 2-2
Stepping on the Operator Presence Pedal .......................................................................... 2-2
Steer Request....................................................................................................................... 2-3
Steer Motor Controller .......................................................................................................... 2-4
Travel Request ..................................................................................................................... 2-5
Plugging Request ................................................................................................................. 2-6
Regenerative Braking ........................................................................................................... 2-7
Lift/Lower Request................................................................................................................ 2-8
Lift Activation ........................................................................................................................ 2-8
Lower Activation ................................................................................................................... 2-8
Auxiliary Functions ............................................................................................................... 2-9
Tilt Request ......................................................................................................................... 2-9
Tilt Activation......................................................................................................................... 2-9
Reach/Retract Request ........................................................................................................ 2-9
Side Shift Request................................................................................................................2-10
Reach/Retract and Side Shift Activation ..............................................................................2-10
Reach/Retract Activation ......................................................................................................2-10
Side Shift Activation..............................................................................................................2-10
Solenoid Activation Chart .....................................................................................................2-11
Lift Pressure Adjustment ......................................................................................................2-12
Maximum Lowering Speed Adjustment (Mechanical) ..........................................................2-12
Emergency Lowering............................................................................................................2-12
Electrical Lowering Speed Adjustment .................................................................................2-13

Standard Performance Schematic - Hydraulic Control Circuits ........................................... 3-7

Standard Performance Schematic - Hydraulic Control Output Circuits ............................... 3-8
Standard Performance Schematic - Keypad Switches Hydraulic Sensing Circuits ............. 3-9
Standard Performance Schematic - Pump & Traction Encoders/Temp Sensing Ckts.........3-10
Standard Performance Schematic - Communications Connections ....................................3-11
Standard Performance Schematic - Horn, Lights and Travel Alarm ....................................3-12
Standard Performance Schematic - Fans ............................................................................3-13
Standard Performance Schematic - Cold Storage Use - Option .........................................3-14
High Performance Schematic - Power Supply 36 Volt.........................................................3-15
High Performance Schematic - Main Power Circuits ...........................................................3-16
High Performance Schematic - Drive Circuits......................................................................3-17
High Performance Schematic - Steering Circuits.................................................................3-18
High Performance Schematic - Hydraulic Control Circuits ..................................................3-19
High Performance Schematic - Hydraulic Control Output Circuits.......................................3-20
High Performance Schematic - Keypad Switches/Hydraulic Sensing Circuits ....................3-21
High Performance Schematic - Pump and Traction Encoders/Temp Sensing Circuits........3-22
High Performance Schematic - Communications Connections ...........................................3-23
High Performance Schematic - Horn, Lights and Travel......................................................3-24
High Performance Schematic - Fans ...................................................................................3-25
High Performance Schematic - Cold Storage Use - Option.................................................3-26
Standard Schematic 14.25 Optional - Power Supply 36 Volt...............................................3-27
Standard Schematic 14.25 Optional - Main Power Circuits .................................................3-28
Standard Schematic 14.25 Optional - Drive Circuits............................................................3-29
Standard Schematic 14.25 Optional - Steering Circuits.......................................................3-30
Standard Schematic 14.25 Optional - Hydraulic Control Circuits ........................................3-31
Standard Schematic 14.25 Optional - Hydraulic Control Output Circuits ............................3-32
Standard Schematic 14.25 Optional - Keypad Switches/Hydraulic Sensing Circuits ..........3-33
Standard Schematic 14.25 Optional - Pump & Traction Encoders/Temp Sensing Ckts ......3-34
Standard Schematic 14.25 Optional - Fans .........................................................................3-35
Standard Schematic 14.25 Optional - Horn, Lights and Travel Alarms................................3-36
Standard Schematic 14.25 Optional - Cold Storage Use - Option.......................................3-37
Standard Hydraulic Schematic/Diagram ..............................................................................3-39
High Performance Hydraulic Schematic/Diagram ................................................................3-40
High Performance Schematic - Description of Components on Electrical Schematic .........3-41

Tester: (Traction Controller).................................................................................................. 4-7

Alarms: (Traction Controller) ................................................................................................ 4-8
Default Settings for Traction Controller ................................................................................4-10
Pump Control Inverter Diagram............................................................................................4-11
Set Options: (Pump Controller) ............................................................................................4-12
Parameter Change: (Pump Controller).................................................................................4-14
Tester: (Pump Controller) .....................................................................................................4-15
Alarms: (Pump Controller) ....................................................................................................4-16
Default Settings for Pump Controllers ..................................................................................4-18
Reach Handset Settings.......................................................................................................4-19
Electric Steer Controller EPS Diagram ................................................................................4-20
Set Options: (Electric Steer Controller "EPS") .....................................................................4-21
Adjustments: (Electric Steer Controller "EPS") ....................................................................4-22
Parameter Change: (Electric Steer Controller "EPS")..........................................................4-24
Tester: (Electric Steer Controller "EPS") ..............................................................................4-25
Alarms: (Electric Steer Controller "EPS") .............................................................................4-26
Electric Steer Controller Default Settings .............................................................................4-29
General Information - Handset .............................................................................................4-30
Handset Tree Diagram .........................................................................................................4-31
Handset Menu Description ...................................................................................................4-32

5. CONSOLE PROGRAMMING
Programming and Set Up of Performance Values ............................................................... 5-1
Console Switches and Functions ......................................................................................... 5-1
Insert Password.................................................................................................................... 5-2
Program Password ............................................................................................................... 5-2
Parameters ........................................................................................................................... 5-3
Tester Master (Diagnostics).................................................................................................. 5-3
Tester Slave.......................................................................................................................... 5-3
To Access AutoTeaching (Option)......................................................................................... 5-4
To Access Alarms ................................................................................................................. 5-4
To Access Adjust Time and Date.......................................................................................... 5-4

6. SET UP AND OPTION INSTALLATION

Setting Hours for the Maintenance Alarm ............................................................................ 6-4

Metric or English Values Displayed ...................................................................................... 6-4
Height Detection Overview ................................................................................................... 6-5
Height Detection Installation................................................................................................. 6-6
Height Display Activation ......................................................................................................6-10
Pre-Height Selector Activation..............................................................................................6-10
Operation Instructions for Pre-Selected Shelf Height Selector ............................................6-11
Lift Limit Cutout with Bypass ................................................................................................6-12
Load Weight Installation .......................................................................................................6-13
Weight Function Installation .................................................................................................6-13
Maximum Weight Setting......................................................................................................6-14
Minimum Load Adjustment ...................................................................................................6-14
Maximum Load Adjustment ..................................................................................................6-14
Cooler/Freezer Condition Option..........................................................................................6-14

Cylinder Operation................................................................................................................7-16
Main Lift Cylinder Service.....................................................................................................7-17
Free Lift Cylinder Service .....................................................................................................7-19
Mast Uprights ......................................................................................................................7-21
Upright Description ...............................................................................................................7-21
Upright Chain Inspection ......................................................................................................7-22
Cracked Plates ....................................................................................................................7-23
Ultimate Strength Failure......................................................................................................7-23
Tight Joints ...........................................................................................................................7-23
Chain Length Adjustment .....................................................................................................7-24
Periodic Inspection - Triple-Stage Upright (TSU) Chain Length Adjustments......................7-25
Periodic Inspection - Chain Lubrication................................................................................7-27
Chain Removal and Replacement........................................................................................7-28
Lift Bracket............................................................................................................................7-29
Periodic Inspection Upright & Lift Bracket Removal & Replace Roller Shim Adjustments ..7-29
Lift Bracket Removal Preparation.........................................................................................7-29
Upright & Lift Bracket Removal ............................................................................................7-30
Upright Removal...................................................................................................................7-34
Upright Disassembly.............................................................................................................7-36
Shimming .............................................................................................................................7-42
Fork Removal .......................................................................................................................7-61
Lift Bracket Service ..............................................................................................................7-62
Fork Carriage Removal - Side Shift Only .............................................................................7-62
Fork Carriage Removal - Tilt Only........................................................................................7-63
Servicing Lift Bracket Arm Rollers Thrust Pads (Scissor Arm Roller "B" & "C" ...................7-64
Tilt Cylinder Overhaul - Cylinder Removal ...........................................................................7-66
ITA Lift Bracket with Side Shifter ..........................................................................................7-67
ITA Lift Bracket without Side Shifter .....................................................................................7-68
Cylinder Removal .................................................................................................................7-69
Preparation, Cleaning and Inspection ..................................................................................7-69
Disassembly .........................................................................................................................7-70
Retainer Assembly................................................................................................................7-70
Piston Rod and Piston..........................................................................................................7-70
Cleaning and Inspection .......................................................................................................7-71
Reassembly ..........................................................................................................................7-71
Reach Cylinder Overhaul .....................................................................................................7-72
Cylinder Removal .................................................................................................................7-72
Preparation, Cleaning and Inspection ..................................................................................7-74
Disassembly .........................................................................................................................7-75
Retainer Assembly................................................................................................................7-75
Piston Rod and Piston..........................................................................................................7-75
TABLE OF CONTENTS

Cleaning and Inspection .......................................................................................................7-76

Reassembly ..........................................................................................................................7-76
Retainer Assembly................................................................................................................7-76
Side Shift Cylinder Overhaul ................................................................................................7-78
Cylinder Removal .................................................................................................................7-78
Preparation, Cleaning and Inspection ..................................................................................7-79
Disassembly .........................................................................................................................7-79
Retainer Assembly................................................................................................................7-79
Cleaning and Inspection .......................................................................................................7-81
Reassembly ..........................................................................................................................7-81
Reach and Side Shift Selector Valve ...................................................................................7-82
Reach and Tilt Selector Valve ..............................................................................................7-86
Mounting Selector Valve.......................................................................................................7-88
Side Shifter Solenoid Control Valve .....................................................................................7-89
Servicing a Double Reach Bracket ......................................................................................7-93

8. TROUBLESHOOTING & PIN BY PIN VOLTAGES

Display Information Example................................................................................................ 8-1
Sicos Alarms and Warnings (Mod #1) .................................................................................. 8-1
Mhyrio Alarms and Warnings (Mod #9) ................................................................................ 8-1
Electric Steer Controller Alarms and Warnings (Mod #6)..................................................... 8-2
Lift Controller AC-3 (Mod #37) ............................................................................................. 8-2
AC-2, Traction (Mod #2), Pump (Mod #5) ............................................................................ 8-4
Pin by Pin Voltage Worksheet .............................................................................................. 8-6

9. PLANNED MAINTENANCE
Maintenance Locations......................................................................................................... 9-1
Maintenance Intervals .......................................................................................................... 9-2
Recommended Oils .............................................................................................................. 9-3
GENERAL INFORMATION & FEATURES

1. GENERAL INFORMATION & FEATURES

Glossary

Activate Contact Tips or Contacts

A word used with a component or circuit. To The portion of a switch, relay or contactor where
change from the normal condition to the “activated” the circuit can be opened or closed.
condition because of an application of force or
electricity. Contactor Assembly
An electrical component consisting of an
Auxiliary Function electromagnetic coil and a set of heavy contact
A vehicle function other than lift/lower or travel. tips.
These include reaching, retracting, tilting and side
shifting. Contactor Coil
An electromagnet used to close or open contact
Battery tips in a contactor assembly.
Two or more cells connected together for a supply
of electric current. Continuity
Having the ability to allow current flow.
BDI (Battery Discharge Indicator)
An electrically controlled display showing the Control Circuits
operator the state of battery charge. The wires and components carrying low current
used to signal the controllers, turn on main
Bus components, or support optional components.
A data path shared by many devices (e.g. ,
multipoint line) with one or more conductors for Controller
transmitting signals, data, or power. A device with multiple inputs and outputs used to
control a particular system or sub-system.
Bus Bar
A heavy electrical conductor that carries high Controller Area Network (CAN)
current from one point to another and to which A communication protocol developed for “noisy”
other smaller wires are connected. environments. It is used to establish an open
communication system for intelligent devices.
Circuit
A way for current to go from the positive (+) side of Current
an electrical power source to the negative (–) side The movement or flow of electricity through a
of an electrical power source. This can be through conductor. A circuit must be complete for current to
wires and electrical components. flow.

Closed Circuit Deactivate

Wiring or components in a circuit that have To change from the activated condition back to
continuity. the normal (deactivated) condition. It can be
caused by the application of force, the removal of
Coil force, or the removal of electricity.
A component made from many circles or turns of
wire used to concentrate a magnetic field. Digital Signal
A signal in which the elements may be either of
Conduct two distinct values. For example high voltage, low
To allow the flow of current. voltage.

Conductor Display
A material that provides a path for current flow. An electrical device that converts voltage inputs to
a visual output.
Connector
Part if a wire assembly or harness that connects Electric Motor
with another wire assembly or harness. Used for A device that changes electrical energy into
ease of assembly and disassembly. mechanical energy to do work.

1-1
GENERAL INFORMATION & FEATURES

Glossary (continued)

Electrical Braking Magnetic Field

Electrically trying to rotate the drive motor The area around a magnet where magnetic forces
opposite to the direction of truck movement. can be detected.

Electromagnet Microprocessor
A coil of wire, most often wound on an iron core, A small computer chip preprogrammed to control
which produces a strong magnetic filed when the various electrical functions on a lift truck.
current is sent through the coil.
Normal Condition
Electromotive Force (EMF) Words used with a switch or relay. Their normal
The force that causes an electric current to flow in condition is their condition when they are not
a circuit. This force is measured in volts. controlled by the application of force,
temperature, pressure, or electricity.
Encoder
Is a sensor of mechanical motion. It translates Normally Closed (N.C.)
motion (such as speed, direction, and shaft angle) A switch or relay whose contacts are closed in the
into electrical signals. normal condition.

Filter Normally Open (N.O.)

An electrical device or component for restriction A switch or relay whose contacts are open in the
or suppression of undesired voltage spikes. normal condition.

Fuse Ohm
A component in an electrical circuit that will open The unit of measurement of resistance. The
the circuit if too much current goes through it. amount of resistance that will let one volt push
only one ampere of current through it.
Harness
An assembly made of two or more wires that are Open Circuit
held together. Wiring or components of a circuit that have no
continuity.
Hour Meter
An electrically activated device used to record the Output
amount of usage a truck receives. The current flow from a component which initiated
from a voltage change at the component’s input.
Indicator
A lamp or LED that gives an indication of some Potentiometer
vehicle condition when it turns on or flashes. A device that converts mechanical movement into
a voltage pattern for a variable request.
Input
A voltage change at the incoming connection of a Power Circuits
component. The cables and components carrying high current
used to provide power to the motor controllers
Insulator and motors themselves.
A material that has a very large resistance so that
it will not let current flow through it. Resistance
Opposition to the flow of current in a circuit. The
Inverter unit of electrical resistance is the OHM. The lower
A circuit used to convert DC to AC and/or AC to DC the resistance, the greater the current flow for a
Lift/Lower given voltage.
The method in which the reach truck raises and Rotor
lowers the product to be removed or deposited The rotating component of a motor.
within the warehouse.

1-2
GENERAL INFORMATION & FEATURES

Glossary (continued)

Stator Volt
That part of an AC induction motor's magnetic The unit of measurement of electromotive force.
structure, which does not rotate. It usually contains One volt is the force needed to make one ampere
the primary winding. of current flow through one ohm of resistance in a
circuit.
Steering
The method in which the reach truck turns the Watt
vehicle while transporting product within the The unit of measurement of power. The amount of
warehouse power used when one volt pushes one ampere of
current through a resistance of one ohm. The
Terminal result of amperes (current) multiplied by volts
An electrical connection point on an electrical (voltage) is watts (power).
component.
Wire
Travel A conductor used to provide a path for current to
Method in which the reach truck transports product flow to and from electrical components.
within the warehouse.
Zener Diode
Varistor A special diode used to regulate voltage or as an
An electrical filter that is usually terminated across over voltage protector.
the horn connections of a mechanical horn to
eliminate voltage spikes when the horn is
activated.

1-3
GENERAL INFORMATION

General Overview The Sicos/Display Unit controller (Sicos) is the

interface between the control handle and the
The general overview section is designed to give
controllers responsible for carrying out the request
the technician a basic operational understanding of
(See Figure 1.1). The Sicos/Display Unit controller
the vehicle.
analyzes the information from the control handle
along with the operator presence switches to
The following information pertains to how the
determine if the request will be honored. Operating
operator requests a particular function and how the
limits may occur if the reach vehicle enters a low
vehicle reacts. There are many internal and
battery state, a lift cut out has been reached or if
external safety checks that take place during
the traction or lift motor has overheated. Other
vehicle operation. In the general overview section
optional equipment may also limit the operation of
we are assuming the vehicle is powered up and
the reach vehicle.
has passed all safety checks.

Over The Mast Cable

Valve Carriage
Controller Hydraulic
(MHYRIO) Tractor Manifold #1
Hydraulic
Manifold
Carriage
Hydraulic
Manifold #2
CAN Bus
Di splay Unit
(SICOS)

St eering Wheel
Operator
Pres ence
Swit ch 1 & 2

Electric Steer Tract ion Pump

Controller (EPS) Electric B rake Controller Controller Lift Pump
(AC2) (AC3)

UV W U VW

UVW Traction 3 Ph ase Power Cables

Mot or
Steer
Lift Motor
Mo tor

Figure 1.1 Control System Overview (Standard Performance Vehicle Shown)

1-4
GENERAL INFORMATION & FEATURES

Communications: the operator display section of this manual for a full

The vehicle has several “intelligent modules.” The description of information provided by the operators
modules are tied together with a means of commu- display. This process will continue until the operator
nicating. It is commonly referred to as a Controller releases the handle or an alarm occurs forcing the
Area Network or CAN. Because there are several traction controller to cease operation and apply the
devices in the system communicating to the main brakes. If while traveling the control handle is
module, the vehicle communications share a com- released to the neutral position the vehicle elec-
mon “Bus”. The communications for the vehicle will tronics will react accordingly. The traction controller
be referred to as the “CAN Bus” system. Several will reverse the phasing and retard or “plug” the
messages may travel over the CAN Bus system at motion of the motor. The brake is applied once the
any given moment. The vehicle’s internal software traction controller senses no movement from the
will determine the message priority and respond traction speed encoder.
accordingly.
Note: The operational characteristics of the traction
Travel: system can be modified. Refer to the “programming
A travel request begins with the battery plugged, through the handset” section of this manual for
emergency disconnect raised, the key switch on additional information.
and the operator depressing the operator presence
pedal prior to requesting travel from the control Lift:
handle. (See Figure 1.1). A lift begins with the battery plugged, emergency
disconnect raised, and the key switch on.
Note: If the control handle is engaged prior to the Depressing the operator presence pedal prior to
operator presence pedal becoming activated the requesting a lift or lower function is not required.
Sicos/Display Unit controller will indicate to the (See Figure 1.1).
operator incorrect start.
The SICOS/Display Unit controller will require the
If the sequence is correct the SICOS/Display Unit lift/lower potentiometer to be in the neutral position
controller will send a message over the CAN Bus upon key up or an alarm will occur. Rotating the
to the traction controller for travel including direc- lift/lower potentiometer within the control handle to
tion and desired speed. the lift position will indicate a request to lift. The
SICOS/Display Unit controller will then determine if
Once the traction controller receives the message there are constraints put on the vehicle such as a
from the SICOS/Display Unit controller indicating lift cut out or lift interrupt. If there are lift constraints,
travel direction and speed it will also verify the the operator display will indicate why the lift request
operator presence switch has been activated. (See is being ignored. If there are no lift constraints then
Figure 1.1) the SICOS/Display Unit controller will send the lift
request along with a percentage of the maximum
Before engaging the drive motor the traction con- lift speed to the pump controller. Additional informa-
troller will need to release the electric brake. The tion will be sent via the CAN Bus to the valve con-
traction controller through the electric steer controller (MHYRIO) to request the lift/lower solenoid
troller (internal relay) and operator presence switch be put in the lift position.
#2 powers the electric brake. Once the brake is
released the traction controller will begin to pulse Note: The CAN Bus is a noise immune two-wire
the traction motor. The duration of on time will communication line that allows the connection and
increase or decrease depending on the feedback communication of many controllers.
from the traction speed encoder. If the motor is
traveling too fast the on time will decrease and vice Note: The lift/lower solenoid is located on the trac-
versa if the motor is traveling too slow. This feed- tor manifold. (See Figure 1.1)
back allows for the control system to maintain an
exact speed regardless of whether the vehicle is The pump controller will then begin to pulse the lift
empty or loaded. Travel speed is indicated to the motor through the three phases (U, V & W).
operator through the SICOS/Display Unit. Refer to Velocity is related to the width and frequency of the

1-5
GENERAL INFORMATION & FEATURES

pulse being sent to the motor. The longer the on ence pedal has been depressed then the steer
time the longer the current will flow through the controller will not honor the steer request. Steer
motor. The duration of the on time will increase or direction is indicated to the operator through the
decrease depending on the feedback from the lift display. Refer to the operator display section of this
speed encoder. If the motor is traveling too fast the manual for a full description of information provided
on time will decrease and vice versa if the motor is by the operators display. The two proximity switch-
traveling too slow. This feedback allows for the cones located in the drive unit are used to determine
trol system to maintain an exact speed regardless the location of the drive unit wheel. When both
of whether the vehicle is empty or loaded. This switches are engaged the drive unit is centered.
process will continue until the operator releases the
handle or an error occurs forcing the pump con- Note: The operational characteristics of the steer
troller to cease operation. system can be modified. Refer to section 4 of this
manual for additional information.
Note: The CAN Bus is a noise immune two-wire
communication line that allows the connection and Auxiliary Function:
thus communication of many controllers. The request for an auxiliary function originates from
the control handle. The information is gathered
Lower: from the Sicos/Display Unit controller and is distrib-
A lower request begins with the battery plugged, uted via the CAN Bus to both the valve and pump
emergency disconnect raised, and the key switch controller.
on. Depressing the operator presence pedal prior
to requesting a lift or lower function is not required. Depressing the operator presence switch is not
(See Figure 1.1). required for auxiliary functions. Auxiliary functions
consisting of reaching, retracting, tilt up, tilt down,
The Sicos/Display Unit controller will require the sideshift left, and sideshift right require the dis-
lift/lower potentiometer to be in the neutral position placement of hydraulic fluid to the carriage. For
upon key up or an alarm will occur. The this reason a pair of manifolds are mounted on the
Sicos/Display Unit controller will gather this infor- carriage. (See Figure 1.1) Carriage hydraulic mani-
mation and send a request to the valve controller fold #1 directs the hydraulic fluid to the tilt cylin-
(MHYRIO) to engage the lowering and load holding ders. Carriage hydraulic manifold #2 directs the
solenoid. The amount of voltage across the propor- hydraulic fluid to either the reach or side shift cylin-
tional valve will vary with the lowering rate request- ders. The direction of the fluid used to tilt up or
ed and open the valve accordingly. The fluid flow down, side shift left or right, reach or retract is
through the proportional valve will control the lower- determined by the directional solenoids located on
ing speed. the tractor hydraulic manifold. A message from the
Sicos/Display Unit controller indicating an auxiliary
Note: The lift/lower, load holding and proportional request will engage the lift motor along with the
solenoids are located on the tractor manifold. required solenoids associated with the auxiliary
function. This system utilizes the lift motor and
Note: The operational characteristics of the lift and pump assembly to control lift and auxiliary require-
lower system can be modified. Refer to section 4 of ments.
this manual for additional information.
Note: The operational characteristics of the auxil-
Steering: iary system can be modified. Refer to section 4 of
The request to steer the vehicle originates from the this manual for additional information.
steering wheel. The steering wheel is attached to a
stepper motor. Manually rotating the steering wheel
will generate a signal from the motor. The steer
controller interprets this signal and determines the
rate and direction of the steering request. If the
Sicos/Display Unit controller has not sent a mes-
sage to the steer controller that the operator pres-

1-6
GENERAL INFORMATION & FEATURES

Operators Display extreme cold environments the vehicle should be

The operator’s display is the control systems equipped with the appropriate cold storage pack-
method of communicating to the operator. The age. Below is a picture of the operators display
display is an LCD (Liquid Crystal Display) and along with a description of the individual icons.
will not be easily visible under extreme cold 1. Travel Direction – If the operator should
environments or direct sunlight. In the case of request a travel function, a single arrow will

1 2 3 4 5 6 7 8

9 10

X L/B

11 12 13 14 15

Figure 1.2 Operators Display & Buttons

1-7
GENERAL INFORMATION

illuminate to indicate the direction of travel 6. Mode of Operation (Optional) – The

and approximate position of the steering vehicle has four traction modes of operation.
wheel. (I, II,III and IV) These traction modes are
programmable and allow four different
2. Steering Sensor Fault – If the steer modes of operation. The modes are cycled
controller senses a problem with the steer by depressing the and buttons below
sensors the S icon will illuminate. The the display. Refer to the programming
description of the error will be displayed at section of this manual for programming the
location 10 on the display. four modes.

3. Parking Brake – If the parking brake is 7. Battery Alarm – Should the battery drop
applied then the (P) icon will illuminate. This below the programmed level indicating a
option may or may not be available. fully discharged battery, the ! icon will
illuminate. Refer to the programming section
4. Traction Fault – If during start up or normal of this manual for programming the
operation the traction controller senses a discharge level.
fault within the traction system the T icon will
illuminate. The description of the error will be 8. Height Selector Levels (Optional) – If the
displayed at location 10 on the display. height selector option is installed the
operator has the ability to set up 50 different
5. Pump Fault – If during start up or normal levels in which the forks will cut out lifting or
operation the pump controller senses a fault lowering once the level is enabled. The icon
within the hydraulic pump system the P icon (See Figure 1.6) of the different levels has
will illuminate. The description of the error two heights for every level. Under a load the
will be displayed at location 10 on the forks may deflect thus having two different
display. heights will accommodate for the change in
fork height for loaded and unloaded
maneuvering.

Level #1 Loaded
Level #2 Loaded

Figure 1.3 Height Selector Display

Height Selection cease to move until the operator again requests

a lift or lower. If the same or different levels need
To access the height selector depress the X but- to be selected, the operator must once again
ton. The top number within the height selector enter the height selector display and enable that
display will become illuminated. To advance level.
through the levels use the and buttons.
When the level of choice is illuminated depress Refer to the autoteaching section of the pro-
the button to select that level. When the gramming section of this manual to set up the
level is selected a circle will be illuminated to the values for the different levels.
right of the level selected. The forks will cut out Note: In order for this option to be visible the
the lifting or lowering depending on whether the Pre-Height Sel option must be set to the “ON”
forks are above or below the selected level. position. Refer to the Controller Set Up section
Once the forks reach the level selected they will of this manual.

1-8
GENERAL INFORMATION & FEATURES

9. Vehicle Status Indicator – the vehicle status display the operator presence hour meter
indicator has five primary pieces of information. reading for a couple of seconds. (See Figure
After key up the vehicle status indicator will 1.8).

Figure 1.4 Operator Presence Hour Meter

Prior to engaging the operator presence pedal If the operator presence pedal is depressed and
the vehicle status indicator will display battery travel is requested the travel speed of the vehicle
percentage of charge. (See Figure 1.5) If the will be displayed. (See Figure 1.7) If the vehicle
vehicle has the height indicator option the height has the weight indicator option the weight of the
of the forks will be displayed, out of free lift, while forks will also be displayed within the vehicle
lifting or lowering is requested. (See Figure 1.6) status indicator.

Figure 1.5 Battery Percentage

Figure 1.6 Height Indication of the forks (Optional)

Figure 1.7 Travel Speed Indicator

1-9
GENERAL INFORMATION

10. Error Status Indicator – Should an error 13. – The down arrow button is used to move
occur within the system, the error number down through the menus or to decrease a
along with the hour meter will be displayed in selected value.
the error status field. The complete list of
errors along with their definitions is listed in
the troubleshooting section of this manual.
14. X – The X button is used to exit a selected
menu. It is also used to select the optional
height selector. The X button is also used as
11. – The enter button is used to select the a “No” answer when asked to “clear alarms?”
option or enter a changed value. The enter
button is also used as a “Yes” answer when 15. L/B – Lift Limit Bypass Button. This is an
asked to “clear alarms?” optional button provided with the lift Limit
option.
12. – The up arrow button is used to move
up through the menus or to increase a
selected value.

1-10
THEORY OF OPERATIONS

THEORY OF OPERATIONS Additional Safety Circuit (Emergency

Power Off)
The example given is for a high performance
model: for your particular vehicle, please use the If the emergency power off switch is in the
corresponding schematics as shown in the normally closed position B+ will continue to flow
Electrical Section. to the key switch (S2). B+ will also flow to the
main power contactor K1 (K1-1).
Every connection will not be addressed in the
theory of operation. To troubleshoot a particular Should at any time the operator need to remove
component you will need to locate the power to the system, the emergency power off
component on the associated page number of switch may be depressed. With the switch
the schematic, and check the circuitry associated depressed (down), the normally closed switch
with it. You will need to have the schematic will open and remove B+ from the main contactor
handy as a reference while reading the text. coil (K1).
With the switch in the vehicle operational (up)
Plugging In the Battery position, B+ will be present at the following
Upon plugging in the battery, B+ will flow through points
connector X12:1 To the contactor connections
and fuses listed. From the fuses it will feed
Page Zone
several areas of the vehicle. It will also go to the
emergency power off switch 3-17 12
3-17 13
B+ Feed to
3-25 18
Page Zone Component(s)
3-5 13 1F1 Fuse Turning Key Switch (S2) ON
3-5 14 2F1 Fuse Refer to Schematic in Electrical Section
3-5 15 K1 Contactor Upon turning on the key switch (S2) B+ will flow
to the Traction Motor Controller and to the B+
3-24 14 K11 Relay Pin 4 terminal of the K1 coil. This will cause the
3-17 12 S1 Emergency Disconnect energizing of the K1 contactor. B+ will now feed
to the K2 contactor tip. B+ will also flow to the
B- will connect to several fuses, several motor control fuses 10F1 and 11F1 which feed B+ to
controllers, the horn, the strobe light, the steering the other controllers.
feedback sensor, and to optional features such The individual controllers (Sicos/Display Unit-
as the fan as listed: Controller, Pump Controller, 2nd Pump
Controller, Electric Steer Controller, and
B-Feed to Hydraulic Controller will begin their internal
Page Zone Component(s) checks to verify all internal hardware is
functioning properly. After all internal checks
3-15 13 1F2
have passed the following controllers will engage
3-15 14 2F2 their respective safety circuits.
3-15 18 Connection (Reference The vehicle Controller Area Network (see CAN
Feed To Controllers) next page) will now be operational and the
3-15 23 Cold Storage Option controllers will communicate status and fault
3-15 24 Connection conditions.

3-15 25 Connection If everything checks out ok, the traction controller

will activate the K2 contactor coil and the K2
3-15 26 12F2 Fuse contactor tips will provide B+ to the power fuses
for the motor controllers. Should an error occur

2-1
THEORY OF OPERATIONS

causing the K2 contactor to become de- Stepping on the Operator Presence Pedal
energized, all power to the three AC motors Upon stepping on the operators presence pedal,
(Traction Motor, Pump Motor and Electric Steer two switches located underneath the pedal will
Motor) will be removed. be activated .
B+ will also go from the Traction Motor controller S11 (Page 3-17 Zone 18) will apply B+ to the
into the Electric Steer Controller at XA3B:7 (See electric brake coil. The brake coil activation will
page 3-17 Zone 18) . The Electric Steer now be controlled by the Traction Motor
Controller will allow B+ to exit the controller at Controller via pin XA1F:9.
XA3B:1 to feed B+ to the Brake Pedal
Switch(S11). The internal switch has been S12 (Page 3-17 Zone 20) will apply B+ to the
designed to remove or supply power to the Sicos/Display Unit which is used to determine
electric brake coil depending on the system the status of the Operator Presence Switch. It
status. will also supply B+ to the Traction Motor
Controller pin XA1F:4 (Page 3 Zone 15).
CAN Bus Communication
CAN stands for Controller Area Network. CAN is
a communication protocol developed for “noisy”
environments. A CAN uses two digital signal
lines referred to as Bus+ and Bus-. The CAN
Bus technology allows for easy expansion of
additional equipment so long as they are CAN
ready. The only method of determining the
functionality of the CAN Bus is with an
oscilloscope. Both the Bus+ and Bus- signals will
remain at 2.5v until a message is sent. The
message is very short in time duration therefore
making it very difficult to monitor utilizing a digital
voltmeter. All controllers or “nodes” connected to
the bus have the ability of communicating with
each other.
The communication connections are shown on
Page 3-23 of the schematic. The connections
used for communications are run as a twisted
pair to help reduce “noise”. There is also a
terminating resistor at the beginning and the end
of the communication loop.

2-2
THEORY OF OPERATIONS

Steer Request the Sicos/Display Unit controller will send a

Refer to Schematic in Electrical Section message on the CAN Bus notifying all controllers
attached to the bus that the operator presence
Prior to a steer request being accepted, the switch has been depressed. The Steer Motor
battery must be plugged into the truck, the Controller will then gather information from the
emergency power off switch must be raised, the steer wheel sensor. Electrical Schematic ( Page
key switch must be turned on and the control 3-18 Zone 14-17). As the steering wheel is
system must have passed self-test. rotated, the steering wheel motor will generate a
If all internal checks pass the electric steer sinusoidal wave through connector X11 pins 1,3,
controller will close the contacts of the internal 4 and 6. The signals from the steering wheel
relay. Refer to Schematic in Electrical Section motor will terminate at the steer controller
(Page 3-17 Zone 18). The contacts will exit the connector XA3B pins 3,4,7,9,10 and 20. The
Steer Motor Controller on connector XA3B pins 1 amplitude and frequency of these signals will
and 7. The internal relay is in series with the increase the faster the steering wheel is turned.
operator presence switch and will break power to See Figure 1.1 below.
the electric brake if an internal error occurs.
Once the operator presence switch is depressed

Steering Motor

Figure 1.1 Sinusoidal Output from Steering Wheel Motor

2-3
THEORY OF OPERATIONS

STEER MOTOR CONTROLLER The Steer Motor Controller will also determine
The Steer Motor Controller determines which position of the drive unit at all times through the
direction the operator wishes to steer by two proximity switches connected to XA4B pins 2
comparing the signals from the steering wheel and 13 on the Sicos/Display Unit controller. Refer
motor. The channels from the steering wheel to Appendix A: Electrical Schematic (Page 3-18
motor will be out of phase from each other. to Zone 26 and 29) With both proximity switches
Depending on which signal is leading or lagging engaged the drive tire is centered. The state of
will determine which direction the operator is these proximity switches is sent over the CAN
requesting. The aggressiveness of the steering bus to the Steer Motor Controller. B+ and B- are
will be determined through the amplitude and the supply for these proximity switches. The
frequency of the signal coming from the steering signal that enters the Sicos/Display Unit card at
wheel motor. XA4B pins 2 and 13 will be B+ when the LED on
the proximity switch is illuminated. The signal will
After the request for steering has been accepted, be 0 volts when the proximity switch leaves the
the Steer Motor Controller will begin to pulse the metal surface and the LED are turned off.
three separate inputs (U, V, W) of the AC steer
motor. Depending on the frequency and duty The extreme left or right of the drive unit is
cycle, the steer motor controller can vary the monitored through the use of a proximity switch
speed of the steer motor. (See Figure 1.6) The (S34) at XA3B: 12. When movement of the drive
outputs (U, V, W) from the steer motor controller unit has activated the switch, the Steer Motor
are pulsed with both a positive and negative Controller will stop pulsing the steer motor.
voltage. Figure 1.6 shows the varying duty cycle Position of the drive tire is indicated to the
along with the positive and negative values. The operator through the operator’s Sicos/Display
actual current passing through the motor will be Unit. The six arrows are normally not engaged
more sinusoidal than pulsed do to the until travel is requested. Once travel has been
characteristics of an inductor requested one of the six arrows will darken in
Note: The characteristics of the steering can be color to indicate travel direction and approximate
adjusted using the handset. Refer to the drive wheel position. See Figure 1.2 below.
programming section of this manual for
additional information.

Figure 1.5 Steer Indicator

2-4
THEORY OF OPERATIONS

Travel Request Before engaging the drive motor the Traction

Refer to Schematic in Electrical Section Motor Controller will need to release the electric
brake. The Traction Motor Controller through the
Prior to a travel request being accepted, the Electric Steer Controller and operator presence
battery must be plugged into the truck, the switch #2 powers the electric brake. Once the
emergency power off switch must be closed, the brake is released the Traction Motor Controller
key switch must be turned on and the control will begin to pulse the traction motor. through the
system must have passed self-test. three phases (U, V & W). Since the lift truck gets
The travel request comes from the traction its power from a DC battery the Traction Motor
potentiometer R12 (Page 3-17 Zone 22) within Controller must convert the DC to AC in order to
the control handle. The 5v supply for the traction satisfy the AC motor requirements. This is
potentiometer comes from the Sicos/Display Unit accomplished internal to the Traction Motor
controller at connector XA4D:4. The ground will Controller via a process known as inverting. By
be supplied through the Sicos/Display Unit applying three inputs out of phase a voltage drop
controller at connector XA4D:6. The wiper or is created between the three phases. Depending
varying voltage will be an input to the on which phase is leading or lagging will
Sicos/Display Unit controller at XA4D:5. In the determine which direction the motor will rotate.
neutral position, the voltage at the wiper of the Velocity is related to the width and frequency of
potentiometer will be nominally 2.5v. As the the pulse being sent to the motor. The longer the
control handle is moved in the tractor forward on time the longer the current will flow through
direction, the voltage on the traction the motor. The duration of on time will increase
potentiometer should gradually increase to or decrease depending on the feedback from the
nominal value of 4.5v. As the control handle is traction speed encoder (BM1). If the motor is
moved in the forks first direction, the voltage on traveling too fast the on time will decrease and
the traction potentiometer should gradually vice versa if the motor is traveling too slow. This
decrease to a nominal value of 0.5v. feedback allows for the control system to
Note: If the traction potentiometer requires maintain an exact speed regardless of whether
replacement, the values of the potentiometer the vehicle is empty or loaded. Travel speed is
must be learned through the handset. Refer to indicated to the operator through the
the programming section of this manual for Sicos/Display Unit. Refer to the operator display
additional information. section of this manual for a full description of
The Sicos/Display Unit controller will gather the information provided by the operators display.
information from the wiper of traction This process will continue until the operator
potentiometer many times per second. As the releases the handle or an alarm occurs forcing
voltage from the wiper of the traction the Traction Motor Controller to cease operation
potentiometer increases or decreases in voltage and apply the brakes. If there are no alarms then
above the nominal neutral value of 2.5v, the the Traction Motor Controller will reverse the
Sicos/Display Unit controller will distribute this phasing and slow or “plug” the motion of the
information as a message over the CAN Bus. All motor. The brake is applied once the Traction
controllers attached to the bus decode the Motor Controller senses no movement from the
message. When the Traction Motor Controller traction speed encoder.
receives a message from the Sicos/Display Unit After the request for travel has been accepted,
controller for a travel request, it will first check the Traction Motor Controller will begin to pulse
the operator presence input at connector XA1F:4 the three separate inputs (U, V, W) of the AC
for B+. If B+ is present at this input and there are drive motor. Depending on the frequency and
no internal errors with the Traction Motor duty cycle, the Traction Motor Controller can vary
Controller will accept the request. the speed of the drive motor. (See Figure 1.1)
The outputs (U, V, W) from the Traction Motor
Controller are pulsed with both a positive and

2-5
THEORY OF OPERATIONS

negative voltage. Figure 1.4 shows the varying The Traction Motor Controller determines speed
duty cycle along with the positive and negative of the motor by counting the number of pulses
values. The actual current passing through the from a single channel over a certain time period.
motor will be more sinusoidal than pulsed do to The faster the motor turns, the more pulses will
the characteristics of an inductor. be generated for that time period. Determining
the direction of the drive motor is accomplished
by comparing channel A to channel B. The
direction in which the motor is turning will
determine which channel is leading and which
channel is lagging. If we refer back to Figure 1.5
channel A is leading and channel B is lagging.
Channel A is leading because it rises before
channel B does. The two channels are 90
degrees out of phase thus allowing for the
comparison of the two channels. If the motor
were to rotate in the opposite direction then
channel B would rise prior to channel A.
Figure 1.4 Width modulation
of the AC Drive Motor Note: The handset allows for testing of the
encoder. Refer to the programming section of
The Traction Motor Controller determines the this manual for additional information.
speed and direction of the motor through the A temperature sensor is located in the drive
pulses sent from the traction speed encoder motor. The sensor for the drive motor enters the
(BM1) mounted within the motor. Traction Motor Controller on connector XA1F at
Note: The handset allows for adjusting the pins 6 and 12. The temperature sensor is
vehicles top travel speeds. nominally 600 ohms at room temperature.
The encoder plugs into the Traction Motor Plugging Request
Controller at connector XA1D on pins 1, 2, 3 and After the travel request has been accepted and
5. Refer to Electrical Schematic (page 3-22). Pin the Traction Motor Controller applies power to
1 is the 12v supply. Pin 2 is the ground. Pin 3 is the AC drive motor the operator may wish to
channel A and Pin 5 is channel B. Figure 1.2 retard the vehicle motion through a plug.
shows the pulse from channel A and B and their Plugging is accomplished by reversing the
phase orientation to each other. position of the control handle. Refer to TRAVEL
REQUEST within this section of the manual for
pin locations of the handle. If there are no errors
associated with the control system and the
operator presence switch is still engaged the
Traction Motor Controller will accept the request
to plug the vehicle. Plugging is accomplished
through the Traction Motor Controller by
reversing the phase of two of the three motor
inputs (U, V, W) Reversing the phase with two of
the three inputs will force the motor to turn in the
opposite direction. During a plug request the
reversing of phase between two inputs will
Figure 1.5 Traction encoder pulses initially retard the motion until the vehicle comes
(Channel A and B) to a rest. If the request continues after the
vehicle has come to rest the motor will begin to
turn in the opposite direction.

2-6
THEORY OF OPERATIONS

Note: The handset allows for adjusting of the

plugging characteristics. Refer to the
programming section of this manual for
additional information
Regenerative Braking
Regenerative braking occurs during the plugging
cycle. This is sometimes referred to as (inverse
braking). When the drive motor is turning in the
opposite direction of the way the motor is being
controlled, the motor is producing AC voltage on
each phase through the rectifier diodes turning
the voltage to DC positive and negative. As long
as the voltage is higher than battery voltage, the
charging procedure continues.

Figure 1.6 Regenerative Braking

2-7
THEORY OF OPERATIONS

Lift\Lower Request must be turned on and the control system must

Refer to Electrical Schematic have passed self-test. When the pump controller
receives a message from the Sicos/Display Unit
The request for lift or lower originates comes from controller for a lift request, it will first check for
the potentiometer module (R13) within the control internal errors. If there are no internal errors or
handle. Within the potentiometer module is an other limiting factors like lift cut out due to a low
internal sensor that will be able to determine battery or an activated lift limit switch or lifting
movement from the neutral position. The internal being limited by the optional height selector then
sensor status will exit the control handle at the lift request will be accepted. The
X14A:8 and be an input to the SICOS/Display MHYRIO/Valve Controller, will control the
Unit at XA4B:4. The potentiometer will exit the solenoids used for the hydraulic functions.
control handle at connector X14A:4, X14A:5 and
X14A:6,. The 5v supply for the lift potentiometer After the request for lift has been accepted, the
comes from the Sicos/Display Unit controller at pump controller will begin to pulse the three
connector XA4D:1. The ground will be supplied separate inputs (U, V, W) of the AC lift motor.
through the Sicos/Display Unit controller at Depending on the frequency and duty cycle, the
connector XA4D:3. The wiper or varying voltage pump controller can vary the speed of the lift
will be an input to the Sicos/Display Unit motor. (See Figure 1.6) The outputs (U, V, W)
controller at XA4D:2. In the neutral position, the from the pump controller are pulsed with both a
voltage at the wiper of the potentiometer will be positive and negative voltage. Figure 1.6 shows
approximately 2.5v. As the control handle is the varying duty cycle along with the positive and
moved to the left (Lower Request), the voltage on negative values. The actual current passing
the lift/lower potentiometer should gradually through the motor will be more sinusoidal than
increase to a nominal value of 4.5v at full speed pulsed do to the characteristics of an inductor.
lower request.. As the control handle is moved to At the same time the lift motor is pulsed the m2
the right (Lift Request), the voltage on the solenoid will be activated by the MHYRIO/Valve
lift/lower potentiometer should gradually decrease Controller at pin XA5G:7 causing the lift lower
to a nominal value of 0.5v at full lift request. spool to move to the lift position. As the pump
Note: If the lift potentiometer requires motor rotates hydraulic fluid is delivered to the
replacement, the values of the potentiometer lifting cylinders through the lift valve. (Section 3:
must be learned. Hydraulic Schematic). See mast section
regarding the lift cylinder operation.
The SICOS/Display Unit controller will gather the
information from the wiper of the lift/lower Performance vehicles are equipped with a
potentiometer many times per second. As the second pump and motor assembly and an
voltage from the wiper of the lift/lower additional controller. When a lift function is
potentiometer increases or decreases in voltage requested AC-2 is starting the lift until 90% of the
above the neutral value of approximately 2.5v, lift pot change is activated and from 90-100% the
the SICOS/Display Unit controller will distribute AC-3 is assisting the lift function.
this information as a message over the CAN bus Note: Location of the hydraulic manifold used for
which would include request for lift or lower and both lifting and lowering functions is located
the velocity associated with it. All controllers under the floor panel of the operator’s
attached to the bus decode the message. compartment.

Lift Activation Lower Activation

Refer to Electrical Schematic & Hydraulic Refer to Electrical Schematic & Hydraulic
Schematic Schematic
Prior to a lift request being accepted, the battery The request and rate of lowering will be
must be plugged into the truck, the emergency transmitted by the SICOS/Display Unit over the
power off switch must be raised, the key switch CAN Bus to the MHYRIO/Valve Controller. The

2-8
THEORY OF OPERATIONS

Mhyrio/Valve Controller will activate the lowering Tilt Request

proportional valve (m2) at pin XA5G:8 and cause Refer to Electrical Schematic
the lift/lower spool to be moved to the lower
position. The amount of time that the valve is on The tilt request comes from the micro switches
will determine the amount the valve is open and within the control handle. The tilt up (S16) micro
the amount of fluid allowed exiting the lift switch will exit the control handle at connector
cylinders to control the vehicle lowering speed. X14B:7 and go to pin XA4C:6 of the
There are mechanical adjustments of the SICOS/Display Unit, the tilt down (S17) micro
hydraulic manifold to control the maximum switch will exit the control handle at X14B:6 and
lowering speed detailed called out further in this go to pin XA4C:5 of the SICOS/Display Unit
section. There is also an electrical adjustment of When any of the micro switches is depressed the
the lowering function that is described in the voltage on the SICOS/Display Unit connector for
Electric Lowering speed adjustment. the function requested should increase to a
nominal value of B+.
See mast section regarding the lift cylinder
operation. Tilt Activation
Auxiliary Functions: Refer to Electrical Schematic & Hydraulic
Schematic
The Sicos/Display Unit controller will gather the
information from the handle assembly micro After the request for the tilt has been accepted,
switches .All auxiliary functions (Reach/Retract, the pump controller will begin to pulse the three
Tilt Up/Down, Sideshift Left/Right) use the pump separate inputs (U, V, W) of the AC lift motor.
motor to supply fluid to the various cylinders. The Depending on the frequency and duty cycle, the
vehicle has the capability of programming the pump controller can vary the speed of the lift
auxiliary functions speed. The main hydraulic motor. (See Figure 1.6) The outputs (U, V, W)
manifold incorporates flow restrictors to reduce from the pump controller are pulsed with both a
the volume of oil flow to the auxiliary system and positive and negative voltage. Figure 1.6 shows
also contains the auxiliary function directional the varying duty cycle along with the positive and
solenoids (m3 and m4). The manifold is located negative values. The actual current passing
under the floor of the operator’s compartment. through the motor will be more sinusoidal than
The vehicle is also equipped with a reach/retract pulsed do to the characteristics of an inductor
and sideshift select manifold located on the The directional valve in the main hydraulic
mast, it includes a pilot operated counter balance manifold is used to determine whether a tilt up or
check valves for the reach cylinders, and the tilt down will occur. The control for these
solenoids used to route fluid to the reach/retract solenoids at the MHYRIO/Valve Controller are at
and sideshift functions. Listed as Table 1.7, is a connector XA5G:6 m3 (Tilt Down) and XA5G:5
chart that will show the various solenoids m4 (Tilt Up)
activated for a particular function.
Reach/Retract Request
The MHYRIO/Valve controller is used to activate
the solenoids to properly route the hydraulic fluid. Refer to Electrical Schematic
As the request from the handle enters the The reach request comes from the micro switch
Sicos/Display Unit controller, the information is (S14) within the control handle. The reach switch
sent to the MHYRIO/Valve Controller over the (S14) signal will exit the control handle at
CAN Bus. When the MHYRIO/Valve Controller connector X14B:4. As the reach micro switch is
receives a message from the SICOS/Display depressed the voltage on the connector
Unit controller for a auxiliary request, it will first XA4C:10 of the SICOS/Display Unit controller
check for internal errors. If there are no internal should increase to a nominal value of B+. The
errors or other limiting factors then the request retract request comes from the micro switch
will be accepted. (S15) within the control handle. The retract
switch (S15) signal will exit the control handle at

2-9
THEORY OF OPERATIONS

connector X14B:5. As the retract micro switch is values. The actual current passing through the
depressed the voltage on the connector motor will be more sinusoidal than pulsed do to
XA4C:20 of the SICOS/Display Unit controller the characteristics of an inductor
should increase to a nominal value of B+. The directional valve in the main hydraulic
Side Shift Request manifold is used to determine whether a
reach/retract or sideshift left/right will occur. The
The side shift request comes from the micro control for these solenoids at the MHYRIO/Valve
switches within the control handle The sideshift Controller are at connector XA5G:6 m3 (Reach,
left (S18) micro switch signal will exit the control Sideshift Left) and XA5G:5 m4 (Retract, Sideshift
handle at connector X14B:9 and go to pin Right).
XA4C:7 of the SICOS/Display Unit and sideshift
right (S19) micro switch signal will exit the Reach/Retract Activation
control handle at connector X14B:8 and go to pin In addition to the m3 and m4 valve being
XA4C:4 of the SICOS/Display Unit When any of activated S5 and S6 must be energized in order
the micro switches is depressed the voltage on to divert the hydraulic fluid from the tilt cylinder.
the SICOS/Display Unit connector for the The Mhyrio/Valve Controller will activate these
function requested should increase to a nominal solenoids using pin XA5G:5
value of B+.
Side Shift Activation
Reach/Retract and Side Shift Activation
In addition to the m3 and m4 valve being
Refer to Electrical Schematic & Hydraulic activated S5 and S6 must be energized in order
Schematic to divert the hydraulic fluid from the tilt cylinder.
After the request for the reach/retract or sides The MHYRIO/Valve Controller will activate these
shift has been accepted, the pump controller will solenoids using pin XA5G:5. Also S7 and S8
begin to pulse the three separate inputs (U, V, must be energized to direct the flow to the
W) of the AC lift motor. Depending on the sideshift cylinder. The Mhyrio/Valve Controller will
frequency and duty cycle, the pump controller activate these solenoids using pin XA5F:3
can vary the speed of the lift motor. (See Figure
1.6) The outputs (U, V, W) from the pump
controller are pulsed with both a positive and
negative voltage. Figure 1.1 shows the varying
duty cycle along with the positive and negative

2-10
THEORY OF OPERATIONS

Solenoid/Valve Activation Chart

Table 1.7

Figure 1.7

2-11
THEORY OF OPERATIONS

Lift Pressure Adjustment 4. Measure the lowering time (in seconds) from
top till forks in down position with max..
lowering speed.(Let’s call this measurement
! CAUTION original one)
Turn the key switch OFF and disconnect 5. Loosen the lowering speed valve locknut and
the battery connector before working on back-out the screw two full turns
lift system connections. 6. Repeat point 4 action.
Make sure that forks are in down position 7. Compare the lowering time with the original
and there is no pressure in the lift one, if the new lowering time is longer go to
point 8. If the lowering time isn’t longer,
repeat actions 5. and 6. until the result is
1. Install a calibrated pressure gauge (5000 psi
longer than the original time.
[34,470 KPa]) in the lift pressure test port (AS).
8. Now tighten the lowering speed valve screw
2. Loosen the relief valve locknut and back-out
two full turns, repeat point 4 action
the high-pressure relief-valve screw.
Compare the lowering time with the original
3. Place a rated load on the forks.
one, if the new lowering time is longer
4. Reconnect the battery connector and turn Repeat point 8 action. If the new lowering
the key switch ON time is equal to original one, you are close to
5. Start the lift system and turn the pressure Final result and have only to tighten the
relief valve screw clockwise until the carriage lowering valve screw ? turn and lock the nut.
starts to lift. Note the pressure required when 9. Check the lowering system for proper
the carriage elevates above the free lift stage operation.
(carriage and telescopics elevated).
This adjustment has now been carried out to
6. Adjust the pressure relief valve to a pressure make sure that the electrical and hydraulic
100 to 300 psi (689.4 to 2068 KPa) greater Functions are in balance to each others and
than the values observed in step 5. This can the system is working properly.
be done by chaining the mast sections
together or adding more weight to the forks. Emergency Lowering
7. After the adjustment is complete, tighten the 1. Rotate the emergency lowering valve screw
relief valve locknut. clockwise until the forks lower.
8. Check the pressure again. If the value has Don’t try to increase the lowering speed by
changed, repeat this procedure until the turning the valve screw further!
correct pressure is obtained. This can only cause external leakage after
9. Turn the key switch OFF. Disconnect the this action, because when the screw is to
battery connector. deep the internal sealing o-ring is passed
and the outer housing for the screw will be
10. Remove the pressure gauge from the lift
filled by oil causing slight leakage through
pressure test port and replace the cap screw.
the threads until the outer housing is empty.
11. Check the lift system for proper operation.
2. After lowering, rotate the emergency
Max. Lowering Speed Adjustment lowering valve screw counter clockwise until
(Mechanical) the forks stop lowering. Also here don’t turn
too much anticlockwise, the same might
1. Make sure your parameters for the lowering happen concerning leakage as by the
speeds (I,II,III and IV)are set OK! lowering action.
2. Choose performance mode IV from the 3. Check the lift and lowering system for proper
display operation.
3. Lift forks to top max. position without load

2-12
THEORY OF OPERATIONS

Electrical Lowering Speed Adjustment 4. Adjust MAX LOWER parameter upward 1-2
Handset operation is required. Refer chapter 11 steps per attempt to find out the exact
Handset basic instructions. parameter value that changes the maximum
lowering speed.
1. Connect the handset to SICOS-display and
navigate to MHYRIO-unit. Enter 5. After finding the exact value increase MAX
PARAMETER CHANGE menu and find MAX LOWER value 4 steps upward (e.g. if the
LOWER parameter. Adjust this parameter as exact value is 178, increase MAX LOWER
high as possible (above 200) in order not to value to 182). Write down the speed value
disturb mechanical adjustment of maximum (2). Compare recorded values (1) and (2),
lowering speed. they should be the same.

2. Take maximum load on the forks; adjust the 6. IMPORTANT!!! ELECTRICALLY ADJUSTED
maximum lowering speed with adjustment MAXIMUM LOWER SPEED MUST NOT BE
bolt A (see picture above). Write down the SET BELOW MECHANICALLY ADJUSTED
speed value (1) SPEED otherwise forks may start to bounce
because there is no pressure compensation.
3. Adjust MAX LOWER parameter downward 5
steps per attempt until the maximum
lowering speed begins to decrease (lowering
speed is now limited electrically and is below
mechanical adjustment level as done in point
2).

2-13
ELECTRICAL

3. ELECTRICAL
Diagram of Controllers ......................................................................................................... 3-1
How to Use Schematic ......................................................................................................... 3-2
Standard Performance Schematic - Power Supply 36 Volt.................................................. 3-3
Standard Performance Schematic - Main Power Circuits .................................................... 3-4
Standard Performance Schematic - Drive Circuits............................................................... 3-5
Standard Performance Schematic - Steering Circuits.......................................................... 3-6
Standard Performance Schematic - Hydraulic Control Circuits ........................................... 3-7
Standard Performance Schematic - Hydraulic Control Output Circuits ............................... 3-8
Standard Performance Schematic - Keypad Switches Hydraulic Sensing Circuits ............. 3-9
Standard Performance Schematic - Pump & Traction Encoders/Temp Sensing Ckts.........3-10
Standard Performance Schematic - Communications Connections ....................................3-11
Standard Performance Schematic - Horn, Lights and Travel Alarm ....................................3-12
Standard Performance Schematic - Fans ............................................................................3-13
Standard Performance Schematic - Cold Storage Use - Option .........................................3-14
High Performance Schematic - Power Supply 36 Volt.........................................................3-15
High Performance Schematic - Main Power Circuits ...........................................................3-16
High Performance Schematic - Drive Circuits......................................................................3-17
High Performance Schematic - Steering Circuits.................................................................3-18
High Performance Schematic - Hydraulic Control Circuits ..................................................3-19
High Performance Schematic - Hydraulic Control Output Circuits.......................................3-20
High Performance Schematic - Keypad Switches/Hydraulic Sensing Circuits ....................3-21
High Performance Schematic - Pump and Traction Encoders/Temp Sensing Circuits........3-22
High Performance Schematic - Communications Connections ...........................................3-23
High Performance Schematic - Horn, Lights and Travel......................................................3-24
High Performance Schematic - Fans ...................................................................................3-25
High Performance Schematic - Cold Storage Use - Option.................................................3-26
Standard Schematic 14.25 Optional - Power Supply 36 Volt...............................................3-27
Standard Schematic 14.25 Optional - Main Power Circuits .................................................3-28
Standard Schematic 14.25 Optional - Drive Circuits............................................................3-29
Standard Schematic 14.25 Optional - Steering Circuits.......................................................3-30
Standard Schematic 14.25 Optional - Hydraulic Control Circuits ........................................3-31
Standard Schematic 14.25 Optional - Hydraulic Control Output Circuits ............................3-32
Standard Schematic 14.25 Optional - Keypad Switches/Hydraulic Sensing Circuits ..........3-33
Standard Schematic 14.25 Optional - Pump & Traction Encoders/Temp Sensing Ckts ......3-34
Standard Schematic 14.25 Optional - Fans .........................................................................3-35
Standard Schematic 14.25 Optional - Horn, Lights and Travel Alarms................................3-36
Standard Schematic 14.25 Optional - Cold Storage Use - Option.......................................3-37
Standard Hydraulic Schematic/Diagram ..............................................................................3-39
High Performance Hydraulic Schematic/Diagram ................................................................3-40
High Performance Schematic - Description of Components on Electrical Schematic .........3-41
ELECTRICAL

Diagram of Controllers

Figure 3-1

Figure 3-2

Figure 3-3

3-1
ELECTRICAL

SCHEMATIC
How to use the schematic:
The electrical diagrams (schematics) are multiple
pages that give reference points to indicate
common connections, information relating to the
wire number(s) and component identifiers.
There are page numbers and sections
referenced. The schematics for this vehicle are
very similar to using a road map. There are
numbered zones shown on the topside of the
page to aid in locating specific areas (See figure
3-4). The example given is for a high
performance model and used to help explain
how to use the schematics. For your particular
vehicle, please use the corresponding
schematics as shown in this section.
Page 1 Locator Box: 22
This section of the schematic depicts a 10A fuse,
the label for the fuse is 8F1, the fuse has two
locations referenced 6, and F. The F side of the
fuse is connected to a wire that is labeled 8L1
Note the numbers below the wire identifier (8L1).
The 9/27 will direct you to the page (9) and
locator box (27) where the wire is connected.
The same procedure is used for following circuits
through out the schematic.
Note: Single numbers without ( / ) indicate
that the connection is on the same page.
These schematics provided do not differentiate
between power cables and control wires. There Figure 3-4
are no bolder lines to indicate a power cable, nor
is there a particular location used exclusive for
the power circuitry.

3-2
Standard Performance Schematic

3-3
ELECTRICAL

Power Supply 36 volt

Standard Performance Schematic
ELECTRICAL

3-4
Main Power Circuits
Standard Performance Schematic

3-5
ELECTRICAL

Drive Circuits
Standard Performance Schematic
ELECTRICAL

3-6
Steering Circuits
Standard Performance Schematic

3-7
ELECTRICAL

Hydraulic Control Circuits

Standard Performance Schematic
ELECTRICAL

3-8
Hydraulic Control Output Circuits
Standard Performance Schematic

3-9
ELECTRICAL

Keypad Switches Hydraulic Sensing Circuits

Standard Performance Schematic
ELECTRICAL

3-10
Pump and Traction Encoders/Temp Sensing Circuits
Standard Performance Schematic

3-11
ELECTRICAL

Communication Connections
Standard Performance Schematic
ELECTRICAL

3-12
Horn, Lights and Travel Alarm
Standard Performance Schematic

3-13
ELECTRICAL

Fans
Standard Performance Schematic
ELECTRICAL

3-14
Cold Storage Use - Option
High Performance Schematic

3-15
ELECTRICAL

Power Supply 36 Volt

High Performance Schematic
ELECTRICAL

3-16
Main Power Circuits
High Performance Schematic

3-17
ELECTRICAL

Drive Circuits
High Performance Schematic
ELECTRICAL

3-18
Steering Circuits
High Performance Schematic

3-19
ELECTRICAL

Hydraulic Control Circuits

High Performance Schematic
ELECTRICAL

3-20
Hydraulic Control Output Circuits
High Performance Schematic

3-21
Keypad Switches/Hydraulic Sensing Circuits
ELECTRICAL
High Performance Schematic
ELECTRICAL

3-22
Pump and Traction Encoders/Temp Sensing Circuits
High Performance Schematic

3-23
ELECTRICAL

Communication Connections
High Performance Schematic
ELECTRICAL

3-24
Horn, Lights and Travel Alarm
High Performance Schematic

3-25
ELECTRICAL

Fans
High Performance Schematic
ELECTRICAL

3-26
Cold Storage Use - Option
Standard 14.25 Optional

3-27
67
ELECTRICAL

Power Supply 36 volt

Standard 14.25 Optional
ELECTRICAL

3-28
Main Power Circuits
Standard 14.25 Optional

3-29
ELECTRICAL

Drive Circuits
Standard 14.25 Optional
ELECTRICAL

3-30
Steering Circuits
Standard 14.25 Optional

3-31
ELECTRICAL

Hydraulic Control Circuits

Standard 14.25 Optional
ELECTRICAL

3-32
Hydraulic Control Output Circuits
Standard 14.25 Optional

3-33
ELECTRICAL

Keypad Switches/Hydraulic Sensing Circuits

High Performance Schematic
ELECTRICAL

3-34
Pump and Traction Encoders/Temp Sensing Circuits
Standard 14.25 Optional

3-35
ELECTRICAL

Communication Connections
Standard 14.25 Optional
ELECTRICAL

3-36
Horn, Lights and Travel Alarm
Standard 14.25 Optional

3-37
ELECTRICAL

Fans
Standard 14.25 Optional
ELECTRICAL

3-38
Cold Storage Use - Option
Standard Hydraulic Schematic/Diagram

3-39
ELECTRICAL
High Performance Hydraulic Schematic/Diagram
ELECTRICAL

3-40
High Performance Schematic
Note: These schematics provided do not differentiate between power cables and control wires. There are no bolder lines to indicate a
power cable, nor is there a particular location used exclusive for the power circuitry.

Page Description of information included.

1 Power Supply
2 Main Power Circuits
3 Drive Circuits
4 Steering Circuits Hydraulic Control Input Circuits
6 Hydraulic Control Output Circuits
7 Keypad Switches/ Hydraulic Sensing Circuits

3-41
8 Pump and Traction Encoders/Temp Sensing Circuits
9 Communications Connections
10 Horn, Lights and Travel Alarm
11 Fans
12 Cold Storage
ELECTRICAL
Identifier Description Sheet Number/Box
1F1 B + (10A) fuse to Key Switch 1/13
1F2 B - (10A) fuse to Key Switch 1/13
2F1 B + (10A) fuse to Auxiliary Devices 1/14
2F2 B - (10A) fuse to Auxiliary Devices 1/14
ELECTRICAL

3F1 B + K2 (325A) fuse to Drive Motor Controller 1/17

4F1 B + K2 (500A) fuse to Pump Motor Controller 1/18
5F1 B + K2 (50A) fuse to Steer Motor Controller 1/19
6F1 B + K2 (325A) fuse to 2nd Pump Motor Controller 1/20
8F1 B + K2 (10A) fuse to Lift/Lower Valve 1/22
9F1 B + K1 (10A) fuse to Cold Storage Option 1/23
10F1 B + K1 (10A) fuse to Drive Control Circuit 1/24)
11F1 B + K1 (10A) fuse to Lift Control Circuit 1/25
12F1 B + (10A) fuse Auxiliary Control Devices 1/26
12F2 B - (10A) fuse to Auxiliary Control Devices 1/26
A1 Traction Motor Controller Pages 2,3,8,9

3-42
A2 Pump Motor Controller Pages 2,8,9
A3 Steer Motor Controller Pages 2,3,4
A4 SICOS/Display Unit Pages2, 4,5,7,9,10
A5 MHYRIO/Valve Controller Pages 5,6,7,9
A6 2nd Pump Motor Controller 2,8,9
B11 Steering Wheel Sensor 4/13
B41 Pulse Encoder Level Sensor (Option) 7/20
B42 Pressure Sensor (Future Option) 7/26
BM1 Speed and Direction Encoder (Drive motor) 8/12
BM2 Speed Encoder (Hydraulic Pump Motor) 8/17
BM4 Speed Encoder (2nd Hydraulic Pump Motor) 8/22
E51 Cabin Light (Option) 10/21
E52 Working Light (Option) 10/23
E53 Working Light (Option) 10/25
E54 Warning Light (Option) 10/27
E55 Reverse Travel/Horn (Option) 10/29
F101 Suppressor on K1 coil 3/11
F102 Fly Back Diode on K2 Coil 3/13
F103 Fly Back Diode on Brake Coil 3/17
F104 Suppressor on Horn Coil 10/13
F105 Suppressor on Alarm Coil 10/29
G1 36V Battery 36 volt 1/12
H1 Horn 10/14
H2 SICOS/Display Unit Buzzer 10/17
H55 Reverse Travel/Horn (Option) 10/30
K1 K1 Contactor Tips (B +) to 9F1, 10F1, 11F1, 12F1 1/15
K1(24V in box) K1 Coil 3/12
K2 K2 Contactor Tips (B +) to 3F1, 4F1, 5F1, 6F1, 8F1 1/16
K2 (24V in box) K2 Coil 3/14
K11 Horn B + Tips in K11 Relay 10/14
K11 (box) K11 Coil 10/19
K12 Warning Light B + Tips in K12 Relay 10/29

3-43
K12 (box) K12 Coil 10/20
M1 Traction Motor 2/11
M2 Hydraulic Pump Motor 2/15
M3 Steer Motor 2/19
M4 2nd Hydraulic Pump Motor 2/25
M7 Controller Fan 11/19
M8 Controller Fan 11/18
M9 Controller Fan 11/17
M10.1 Controller Fan 11/15
M10.2 Controller Fan 11/16
M51 Driver Fan 11/23
R1 25R/50W Resistor (K1 Coil) 3/12
R7 56R/10W Resistor (Controller Fan) 11/19
R8 56R/10W Resistor (Controller Fan) 11/18
R9 56R/10W Resistor (Controller Fan) 11/17
ELECTRICAL
R10 25R/10W Resistor (Controller Fan) 11/16
R12 Traction Speed and Direction Sensor Potentiometer 3/22
R13 Lift/Lower Potentiometer (Includes Center Switch) 5/12
R51 56R/10W Resistor (Driver Fan) 11/23
R341 100R Heater (Joystick) Cold Storage 12/18
ELECTRICAL

R342 100R Heater (Display) Cold Storage 12/18

R343 100R Heater (Steering Wheel) Cold Storage 12/18
R344 100R Heater (Brake Pedal) Cold Storage 12/18
RM1 Temperature Sensor (Traction Motor) 8/15
RM2 Temperature Sensor (Hydraulic Pump Motor) 8/20
RM4 Temperature Sensor (2nd Hydraulic Pump Motor) 8/25
S1 Emergency Stop Switch 3/12
S2 Key Switch 3/12
S11 Brake Pedal Switch 3/18
S12 Operator Presence Switch 3/20
S13 Horn Button 10/12

3-44
S14 Reach (Out) Switch 5/17
S15 Reach (In) Switch 5/18
S16 Tilt (Up) Switch 5/20
S17 Tilt (Down) Switch 5/19
S18 Sideshift (Left) Switch 5/22
S19 Sideshift (Right) Switch 5/21
S21 (_) Up Key on the Display 7/12
S22 (_) Down Key on the Display 7/13
S23 (__) Down/Left Enter Key on the Display 7/14
S24 (X) Escape Key on the Display 7/15
S25 Top Limit Over-Ride Switch (Lift Inhibit Bypass) 7/17
S32 Steering Feedback Sensor (Sensor B) 4/25
S33 Steering Feedback Sensor (Sensor C) 4/28
S34 Steering End Limit Sensor (Sensor A) 4/18
S36 Battery Lock Switch (Option) 3/28
S37 Speed Reduction Switch (Option) Mast Speed Limit 3/25
S43 Lifting Height Reference Sensor (Option) 7/23
S51 Cabin Light Switch (Option) 10/21
S52 Working Light Switch (Option) 10/23
S53 Undefined Switch (Option) 10/25
S54 Driver Fan Switch 11/23
S341 Switch joystick heater 12/18
S342 Switch display heater 12/20
S343 Switch steering wheel heater 12/22
S344 Switch brake pedal heater 12/24
SM2 + 50° C. N/O Thermostat 11/17

3-45
X1: - Battery SB Connector (Negative) 1/12
X1: + Battery SB Connector (Positive) 1/12
X2: - Battery Negative (Panel Ground) 1/25
X11 Reverse Steering Adapter schematic 4/11
Y31 (36V in box) Service Brake Coil 3/18
Y41 Lift/Lower Solenoid Coil (M1-M2 Coil) 6/13
Y43 Direction of Sideshift, Tilt, Reach (DIRA-DIRB) 6/17
Y44 Reach/Retract Solenoid (S5-S6) 6/21
Y45 Sideshift Solenoid (S7-S8) 6/24
Z1 Zener Diode (12 volt / 5W) 10/16
ELECTRICAL
SETTINGS

4. SETTINGS
Section Overview.................................................................................................................. 4-1
Traction Controller Inverter Diagram .................................................................................... 4-2
Set Options: (Traction Controller)......................................................................................... 4-3
Adjustments: (Traction Controller)........................................................................................ 4-4
Parameter Change: (Traction Controller) ............................................................................. 4-6
Tester: (Traction Controller).................................................................................................. 4-7
Alarms: (Traction Controller) ................................................................................................ 4-8
Default Settings for Traction Controller ................................................................................4-10
Pump Control Inverter Diagram............................................................................................4-11
Set Options: (Pump Controller) ............................................................................................4-12
Parameter Change: (Pump Controller).................................................................................4-14
Tester: (Pump Controller) .....................................................................................................4-15
Alarms: (Pump Controller) ....................................................................................................4-16
Default Settings for Pump Controllers ..................................................................................4-18
Reach Handset Settings.......................................................................................................4-19
Electric Steer Controller EPS Diagram ................................................................................4-20
Set Options: (Electric Steer Controller "EPS") .....................................................................4-21
Adjustments: (Electric Steer Controller "EPS") ....................................................................4-22
Parameter Change: (Electric Steer Controller "EPS")..........................................................4-24
Tester: (Electric Steer Controller "EPS") ..............................................................................4-25
Alarms: (Electric Steer Controller "EPS") .............................................................................4-26
Electric Steer Controller Default Settings .............................................................................4-29
General Information - Handset .............................................................................................4-30
Handset Tree Diagram .........................................................................................................4-31
Handset Menu Description ...................................................................................................4-32
4-33
SETTINGS

Section Overview
This section of the manual will provide an
explanation, and the correct settings for the
various controllers used on the vehicle. It will
include the default settings for each controller.
Information pertaining to the Sicos Display
Controller and how to use the handset is shown
in Section 4 of the manual.

4-1
SETTINGS

Traction Controller Inverter Flowchart

HEADING

MAIN MENU SET MODEL CONNECTED TO…

NEW HEADING
PARAMETER ACCELERATION DELAY 0
CHANGE RELEASE BRAKING 0
INVERSE BRAKING 9
PEDAL BRAKING 9
SPEED LIMIT BRAKING 9
MAX SPEED FORWARD 90 Hz SET OPTIONS HOUR COUNTER RUNNING
MAX SPEED BACKWARD 90 Hz BATTERY CHECK ON
FREQUENCY CREEP 0.30 Hz CUTBACK MODE ABSENT
MAXIMUM CURRENT 9 HYDRO K EY ON OFF
AUXILI ARY TIME 2.0 STOP ON RAMP OFF
AUX OUTPUT #1 BRAKE
PEDAL BRAKING DIGITAL
SET TEM PERATURE ANALOG

MOTOR VOLTAGE %
FREQUENCY Hz
ENCODER Hz
SLIP VALUE Hz ADJUSTMENTS SET BATTERY TYPE 36
CURRENT RMS A ADJUST BATTERY TBD
TEMPERATURE ºC THROTTLE 0 ZONE 7%
TESTER
MOTOR T EMP. ºC THROTTLE X POINT 63%
ACCELERATOR % THROTTLE Y POINT 36%
FORWARD SWITCH ON/ OFF ADJUSTMENT #04 120º
BACKWARD SWITCH ON/ OFF ADJUSTMENT #03 35º
ENABLE SWITCH ON/ OFF ADJUSTMENT #02 LEVEL = 3
SEAT SWITCH ON/ OFF ADJUSTMENT #01 LEVEL = 9
CUTBACK SWITCH ON/ OFF
BRAKE SWITCH ON/ OFF
EXCLUSIVE HYDRO NOT USED
BRAKE PEDAL POT NOT USED
HANDBRAKE NOT USED
VOLTAGE BOOSTER ON/ OFF
BATTERY VOLTAGE V
SAVE PARAMETER COS FI ??
BATTERY C URRENT A
BATTERY C HARGE %
PERFORMANCE 0,1,2,3
RESTORE
PARAMETER

CODE,
ALARMS
h, N, ßC

PROGRAM VACC VACC SETTING MIN/MAX

MOTOR DATA NOT AVAILABLE

4-2
SETTINGS

Set Options: (Traction Controller) Aux Output #1 – This option is used to manage
The Set Option menu allows the technician to either an electromagnetic brake or a hydraulic
change the options of the Traction Controller. steering function. Since this product has a
The following is a list of options that can be separate electric steering controller this option
changed and their definitions. should always be set to “BRAKE”. The other two
options “HYDRO CONT:” and “EX. HYDRO:”
Hour Counter – This option is used to define the are used if the traction controller is also
method of enabling the hour meter. If the option controlling the hydraulic steering functions. If this
is set to “RUNNING” the hour meter will field is set to “BRAKE” then the Hydro Key On
indicate hours on the traction motor . If the option option should be et to “OFF”.
is set to “KEY ON” the hour meter will indicate
key on hours. Pedal Braking – If the truck had a potentiometer
attached to the brake pedal this option would be
Battery Check – This option is used to set to “ANALOG”. This truck has a micro switch
determine whether or not an alarm will be attached to the brake pedal and should be set to
sounded when the battery state of charge drops “DIGITAL”. This must be set to “Digital”.
below 10%. If this option is set to “ON” the alarm
will be enabled. If the option is set to “OFF” the Set Temperature – If this option is set to
alarm will be disabled. Regardless of whether the “DIGITAL” then the truck has an on/off
alarm is enabled or not the maximum current for temperature sensor. If this option is set to
the drive motor will be reduced to half the “ANALOG” then the sensor is attached to
programmed value. Refer to the parameter (Connecter F pin #6) and the thermal sensing is
section of this section to set the maximum accomplished using a thermal resistance-varying
traction motor current. device. If this option is set to “NONE” then there
is no traction motor thermal sensor. This must be
Cutback Mode – Because “ Aux Output#1” is set to “ANALOG”.
used for “BRAKE” this parameter must be set to
“ABSENT”.
Hydro Key On – If this option is set to “ON” the
traction controller will also manage all hydraulic
functions. If the traction controller is to manage
the traction motor only then this option should be
set to “OFF”. This field works in conjunction with
the Aux Output #1. See below.
Stop On Ramp – This option determines the
method of holding the truck in position while on a
ramp. If this option is set to “ON” the truck will
hold its position on a ramp for a time interval
determined by the Auxiliary Time field. (Refer to
the parameter section). If this option is set to
“OFF” when the truck is on a ramp, the brake will
be applied in order to maintain position.

4-3
SETTINGS

Adjustments: (Traction Controller)

Note
To access this menu reference the Menu
Description section of the
Programming/Troubleshooting through the
Handset chapter.
The adjustments are used to “fine tune” the
vehicle. The technician uses the adjustments to
add offsets to those components that have
inconsistent values. The following is a list of
adjustments that can be altered on the Traction
Controller.
Set Battery Type – This adjustment defines the
voltage of he battery installed in the vehicle. If
the battery within the truck is 36 volts this field
should be set to “36”.
Adjust Battery – This adjustment provides the
offset to the battery voltage reading so as to
better match the battery.
Throttle 0 Zone – This adjustment is the range
in which the rotation of the traction
potentiometer, from neutral, will result in the
output of a creep speed. As this value is
increased so will the range of creep speed. See
Figure 2.1
Throttle X Point – This adjustment is the point
in which the rotation of the traction
potentiometer, from neutral, will result in the
output speed (Throttle Y). See Figure 2.1
Throttle Y Point – This adjustment is the output
speed at which the rotation of the traction
potentiometer, from neutral, is at Throttle Point
X. See Figure 2.1
Note
VACC MAX and VACC MIN are values read
through the Program Vacc function.
Programming is only obtainable through SICOS!

4-4
SETTINGS

SPEED f (Hz)

MAX SPEED

THROTTLE Y
POINT
FREQ. CREEP

VACC THROTTLE 0 THROTTLE X VACC

MIN ZONE POINT MAX

Figure 4.1 Throttle Zones

Adjustment #01 – This is the level at which the battery is considered fully charged. See table below.
Adjustment #02 – This is the level at which the battery will be considered fully discharged. See table
below.

Table below gives the relationship to the battery voltage:

Battery Nom. Voltage

36 Write in the cell A10 the battery nominal value. The levels are automatically changed accordingly
RESET IN CASE OF BATTERY RECHARGE
MDI LEDs ON 1R 1G 1G 2G 2G 2G 3G 3G 3G 4G
CONSOLE INDICATION 10 % 20 % 30 % 40 % 50 % 60 % 70 % 80 % 90 % 100 %
LEVEL 0 32,00 32,77 33,28 33,55 34,04 34,30 34,56 35,07 35,32
LEVEL 1 32,51 33,28 33,79 34,06 34,55 34,81 35,07 35,58 35,83
LEVEL 2 32,68 33,45 33,96 34,23 34,72 34,98 35,24 35,75 36,00
LEVEL 3 32,85 33,62 34,13 34,40 34,89 35,15 35,41 35,92 36,17
LEVEL 4 33,02 33,79 34,30 34,57 35,06 35,32 35,58 36,09 36,34
LEVEL 5 33,19 33,96 34,47 34,74 35,23 35,49 35,75 36,26 36,51
LEVEL 6 33,36 34,13 34,64 34,91 35,40 35,66 35,92 36,43 36,68
LEVEL 7 33,53 34,30 34,81 35,08 35,57 35,83 36,09 36,60 36,85
LEVEL 8 33,70 34,47 34,98 35,25 35,74 36,00 36,26 36,77 37,02
LEVEL 9 34,04 34,81 35,32 35,59 36,08 36,34 36,60 37,11 37,36

Adjustment #03 – Not used in this application!

Adjustment #04 – This is the temperature when the controller shuts down because of a too high
motor temperature (120 °C)

4-5
SETTINGS

Parameter Change: (Traction Controller) Max Speed Forward – This parameter

The Parameter Change menu is designed to determines the maximum speed in the forward
allow certain characteristics of the vehicle to direction. See Table 4.1
become modified. Those characteristics include Max Speed Reverse – This parameter
top travel and lift speeds, cutback speeds, determines the maximum speed in the reverse
auxiliary speeds, etc.., Below is a list of the direction. See Table 4.1
parameters and their definitions. Frequency Creep – This is the minimum speed
Acceleration Delay – This value determines the when the throttle has just engaged into a forward
acceleration ramp. See Table 4.1 or reverse direction. Refer to Throttle 0 Zone in
Release Braking – This parameter defines the the adjustments section to change the range of
amount of plugging used when bringing the creep speed. See Table 4.1
vehicle to a stop after the handle has been Maximum Current –This parameter determines
returned to neutral. See Table 4.1 the maximum current the traction controller will
Inversion Braking – This parameter defines the allow. The values allowed in this field are 0-9.
amount of plugging used when reversing the See Table 4.1
direction of the control handle during travel. See Auxiliary Time – This parameter determines the
Table 4.1 amount of time, in seconds, that the truck will
Pedal Braking – This parameter defines the hold its position on a ramp prior to applying the
amount of plugging that is used when the brakes. See Table 4.1
operator releases the operator presence switch Note
during travel. See Table 4.1 All of the parameters have a level or
Speed Limit Braking – This parameter defines percentage applied to them. Refer to the table
the deceleration ramp as the control handle below to determine the conversion from level
moves away from forward, or reverse, and begins to the actual value.
to travel back toward neutral. See Table 4.1

Programmed Level
Parameter Unit 0 1 2 3 4 5 6 7 8 9
Acceleration Delay (*) Sec. 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7
Release Braking (**) Sec. 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1
Inverse Braking (**) Sec. 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1
Pedal Braking (**) Sec. 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1
Speed Limit Braking (**) Sec. 8.9 8.3 7.7 7.1 6.6 6 5.5 4.9 4.4 3.8
Max Speed Forward Hz. 65 80 95 110 125 140 155 170 185 200
Max Speed Backward Hz. 65 80 95 110 125 140 155 170 185 200
Frequency Creep Hz. 0.3 0.6 0.9 1.2 1.5 1.8 2.1 2.4 2.7 3
Maximum Current % IMAX 47 53 58 64 70 76 82 88 94 100
Auxiliary Time Sec. 0 1 1.5 2 2.5 3 3.5 4 4.5 5

Table 4.1 Parameter Conversions

(*) The acceleration time shown is the time from 0 Hz to 100 Hz. This parameter can change
due to outside interferences. (I.e. a change in the load on the forks)
(**) The braking feature is based upon deceleration ramps. The value shown in the table is the
time it takes to go from 100 Hz to 0 Hz. This parameter can change due to outside
interferences. (I.e. a change in the load on the forks)

4-6
SETTINGS

Tester: (Traction Controller) Backward Switch - This test shows the position
of the reverse direction travel switch. The display
Note will show “ON” when the switch is closed and
To access this menu reference the Menu “OFF” when open.
Description section of the Enable Switch – Used to enable the traction
Programming/Troubleshooting Guide in the controller for travel request.
Handset Chapter.
Seat Switch – This is always set to “OFF”
The tester menu is designed to allow certain because this vehicle has no Seat Switch.
characteristics of the vehicle to become
Cutback Switch – This test shows the status of
modified. Those characteristics include top travel
the cutback switch. The cutback switch defines
and lift speeds, cutback speeds, auxiliary
the entry and exit from free lift. The display will
speeds, etc.., Below is a list of the parameters
show “ON” when the switch is closed and “OFF”
and their definitions
when open.
Motor Voltage – This test shows the amount of
Brake Switch – This test shows the status of the
voltage supplied to the drive motor. This is
brake switch. The display will show “ON” when
expressed as a percentage of the battery
the switch is closed and “OFF” when open. This
voltage.
is one of the switches under the operator
Frequency – This test shows the frequency of presence pedal
the voltage and current supplied to the drive
Exclusive Hydro – Not used in this application.
motor.
Brake Pedal Pot – Not used in this application.
Encoder – This test shows the speed of the
drive motor in Hz. Handbrake - This test shows the status of the
handbrake. The display will show “ON” when the
Slip Value – This test shows the difference of
switch is closed and “OFF” when open.
speed (Hz) between the rotating field and the
shaft of the motor Voltage Booster – When the current limit is
approached and the motor is not turning, the
Current RMS – This test shows the root mean
controller gives a higher voltage on the phases
square of the motor current.
for approx. 2 sec. This test shows the amount of
Temperature – This test shows the temperature boost voltage applied to the motor under load
(ºC) of the heat sink mounted to the mosfets. conditions. It is expressed in a percentage of the
The temperature device is located within the full voltage that could be applied.
traction controller.
Battery Voltage – This test shows the battery
Motor Temperature – This test shows the voltage measured off the key switch input.
temperature (ºC) of the drive motor. The
COS FI – This test shows the Cosine angle
temperature device is a 600 Ω thermistor
(Real Time Calculated) of the motor. This has no
connected to the traction controller on connector
meaning to the technician.
F pin 6 and 12.
Battery Current – This test shows the current
Accelerator – This test shows the value of the
from the battery. This current is calculated and
traction potentiometer wiper. The value of the
not actually measured.
wiper in volts is displayed on the left hand of the
display while the percentage of potentiometer Battery Charge – This test shows the
rotation is displayed on the right. percentage charge of the battery.
Forward Switch – This test shows the position Performance -The vehicle has four traction
of the forward direction travel switch. The display modes of operation: I, II, III, and IV, the
will show “ON” when the switch is closed and respective parameter set from display, valid level
“OFF” when open. readable from here as follows: 0=I, 1=II, 2=III
and 3=IV.

4-7
SETTINGS

Alarms: (Traction Controller) Handbrake – This alarm occurs when the

The alarms menu is designed to store all the operator is attempting to move the truck with the
codes that have occurred since the truck was handbrake switch in the open position. Not used
manufactured or until the last time the codes in this application
were cleared from memory. Below is a list of the Capacitor Charge – This alarm occurs when the
alarms and their definitions internal RC circuit does not charge at the rate
Watch Dog – This alarm occurs when the expected. If there is a permanent alarm present,
internal watch dog timer times out. If there is a replace the controller.
permanent alarm present, replace the controller. VMN Low, VMN High – This alarm will occur
EEPROM KO – This alarm occurs when there is during initial power up if a problem is detected
a failure to communicate with the internal with the motor connections to the traction motor.
memory. If there is a permanent alarm present, There may be a possibility of one of the three
replace the controller. phases improperly connected. There may also
be a short from the traction motor to the frame of
Logic Failure #1 – This alarm occurs when the truck.
there is an under or over voltage occurrence.
The voltage is from the battery, if the battery Pedal Wire KO – This alarm indicates the power
voltage is correct the fault is in the control circuit. has been interrupted through the power or
If there is a permanent alarm present, replace negative side of the acceleration potentiometer.
the controller. STBY I High – This alarm indicates that while in
Logic Failure #2 – This alarm indicates a failure idle no current was present. This indicates an
within the logic card that manages the feedback open circuit. This test is carried out in standby
when determining the phases of the drive motor. inside of the controller. Checks if the current is 0.
If there is a permanent alarm present, replace If not verified it means that Standby I is high.
the controller. If there is present a permanent alarm replace the
Logic Failure #3 – This alarm indicates a failure controller.
with the circuit that monitors the current that Main Contactor Alarms – The following alarms
flows through the drive motor. . If there is a may occur depending on the status of the Main
permanent alarm present, replace the controller. Power Contactor.
Check Up Needed – This alarm occurs when Coil Shorted – The microprocessor is
the time left before conducting the planned constantly monitoring the Main Power
maintenance has expired. The interval for Contactor Assembly. If it detects an abnormal
planned maintenance can be set in the Display high amount of current passing through the
Controller Menu under the OPTIONS section as coil this alarm will occur.
Check Up Type. Driver Shorted – This alarm occurs if the
Incorrect Start – This alarm occurs when the microprocessor determines the internal coil
sequencing of the control handle is incorrect. driver has shorted.
This alarm could occur if the operator presence Contactor Driver – This alarm occurs if the
switch were malfunctioning. Make sure the microprocessor determines the internal driver
operator presence switch is activated prior to is not sinking current through the Main Power
requesting a travel function. Contactor coil.
Forw + Back – This alarm occurs when a Contactor Open – This alarm occurs when
request to travel both forward and reverse occurs the driver for the Main Power Contactor is
simultaneously. Check to make sure wiring is sinking current through the contactor coil but
correct and travel switches are functioning there is no indication the contactor has
properly. If there is a permanent alarm present, closed. This could be related to the wiring
replace the controller. going to the contactor. The other possibility is
the contacts need to be replaced.

4-8
SETTINGS

Aux Output KO – This alarm occurs if the Waiting Pump – This alarm is present for those
microprocessor determines that the coil for the systems that incorporate both the traction and
electromechanical brake is not responding to the pump within one controller. (Not applicable with
coil driver. There are two possible reasons for this model) The pump side has detected a failure
the alarm list. 1. The coil is energized even and has communicated via the CAN Bus that
though the microprocessor has not commanded there is a problem. Contact the factory for more
it to energize. 2. The coil is not energized when information.
commanded by the microprocessor. Can Bus KO – This alarm occurs when the
High Temperature – This alarm occurs when the traction controller can not communicate over the
temperature for the traction controller exceeds Can Bus. Check the wiring for the Can Bus
75˚C. The maximum current through the drive throughout the system.
motor is reduced when this alarm occurs. At Battery Low – This alarm occurs if the “battery
100˚C the traction controller will stop pulsing the check” option is ON and the battery has been
traction motor. Should this alarm occur under determined to drop below 10%. When this alarm
conditions where the temperature does not occurs the current through the traction motor is
exceed the 75˚C the problem may be a result limited to 50%.
from the following..
a). The wiring to the thermal sensor is bad.
b). The thermal sensor has failed
c). There is a failure with the traction controller.
Motor Temperature – This test shows the
temperature (ºC) of the drive motor. The
temperature device is a 600 Ω thermistor
connected to the traction controller on connector
F pin 6 and 12.
Set Temperature – If this option is set to
“DIGITAL” then the truck has an on/off
temperature sensor. If this option is set to
“ANALOG” then the sensor is attached to
(Connecter F pin #6) and the thermal sensing is
accomplished using a thermal resistance-varying
device. If this option is set to “NONE” then there
is no traction motor thermal sensor.
All trucks are fitted with a thermal resistance-
varying device.
This parameter must be set “ANALOG”.
Thermic Sensor KO – This alarm occurs when
the internal temperature device for the traction
controller is out of range. Contact the factory for
more information.

4-9
SETTINGS

Default Settings for Traction Controller

Reach Handset Settings 36V Rev. 1
Controller: AC2T2BD 36V 450A
Program version: TRACTION INVERTER RO1.08

Controller Model # 2

DEFAULT
Mode IV
Mode III
Mode II
Mode I
COMMUNICATION THROUGH
SICOS

MAIN MENU/ Push ROLL

PARAMETER CHANGE: Up Button
ACCELERATOR DELAY 6 6 6 6 6
RELEASE BRAKING 3 3 3 3 3
INVERSE BRAKING 8 8 8 8 8
PEDAL BRAKING 8 8 8 8 8
SPEED LIMIT BRAKING 0 0 0 0 0
MAXIMUM SPEED FORWARD 90Hz 100Hz 110HZ 120Hz 80Hz TO 110Hz
MAXIMUM SPEED BACKWARD 90Hz 100Hz 110Hz 120Hz 80Hz TO 110Hz
FREQUENCY CREEP 0.30Hz 0.30Hz 0.30Hz 0.30Hz
MAXIMUM CURRENT 9 9 9 9
AUXILIARY TIME 2.0 2.0 2.0 2.0

CONFIG MENU/
SET MODEL:
CONNECTION TYPE 2 2 2 2 2
SET OPTIONS:
HOUR COUNTER RUNNING RUN RUN RUN RUN RUN
BATTERY CHECK ON ON ON ON ON
CUTBACK MODE ABSENT ABSENT ABSENT ABSENT ABSENT
HYDRO KEY ON OFF OFF OFF OFF OFF
STOP ON RAMP OFF OFF OFF OFF OFF
AUX OUTPUT #1 BRAKE BRAKE BRAKE BRAKE BRAKE
PEDAL BRAKING DIGITAL DIGITAL DIGITAL DIGITAL DIGITAL
SET TEMPERATURE ANALOG ANALOG ANALOG ANALOG ANALOG
LIFT -> BRAKE FREE OFF OFF OFF OFF OFF
ADJUSTMENTS: HANDSET
BATTERY VOLTAGE 36V 36V 36V 36V 36V
ADJUST BATTERY 37.4V 37.4V 37.4V 37.4V BATTERY VOLTS
THROTTLE 0 ZONE 7% 7% 7% 7% 7%
THROTTLE X ZONE 63% 63% 63% 63% 63%
THROTTLE Y ZONE 36% 36% 36% 36% 36%
ADJUSTMENT #04 120° 120° 120° 120° 120°
ADJUSTMENT #03 35° 35° 35° 35° 35°
ADJUSTMENT #02 3 3 3 3 3 CHECK
ADJUSTMENT #01 9 9 9 9 5 CHECK

4-10
SETTINGS

Pump Controller Inverter Flow Chart

HEADING

MAIN MENU SET MODEL CONNECTED TO…

NEW HEADING
PARAMETER ACCELERATION DELAY 0
CHANGE DECELER. DELAY LEVEL 0
MAX SPEED UP 125Hz
MIN SPEED UP 0 Hz
MAX. CURRENT LEVEL 9
SET OPTIONS HOUR COUNTER RUNNING
SET TEM PERATURE ANALOG

MOTOR VOLTAGE %
FREQUENCY Hz
ENCODER Hz
SLIP VALUE Hz ADJUSTMENTS SET BATTERY TYPE 36
CURRENT RMS A ADJUST BATTERY TBD
TEMPERATURE ºC THROTTLE 0 ZONE 7%
TESTER THROTTLE X POIN T 63%
MOTOR T EMP. ºC
ACCELERATOR % THROTTLE Y POIN T 36%
LIFT SWITCH ON/ OFF ADJUSTMENT #04 120º
HYDRO SPEED REQ. ON/ OFF ADJUSTMENT #03 55º
CUTBACK SWITCH ON/ OFF
VOLTAGE BOOSTER ON/ OFF
BATTERY VOLTAGE V
COS FI ??
VMN

SAVE PARAMETER

RESTORE
PARAMETER

CODE,
ALARMS
h, N, ßC

PROGRAM VACC VACC SETTING MIN/MAX

MOTOR DATA

4-11
SETTINGS

Set Options: (Pump Controller) Set Battery Type – This adjustment defines the
The Set Option menu allows the technician to voltage of he battery installed in the vehicle. If
change the options of the Pump Controller. The the battery within the truck is 36 volts this field
following is a list of options that can be changed should be set to “36”.
and their definitions. Adjust Battery – This adjustment provides
Hour Counter – This option is used to define the the offset to the battery voltage reading so as
method of enabling the hour meter. If the option to better match the battery. To have “LIFT
is set to “RUNNING” the hour meter will CUTOUT at the same time as the Traction
indicate hours on the traction motor . If the controller reduces the speed, the parameter in
option is set to “KEY ON” the hour meter will Sicos under “SET OPTIONS” called “BATTERY
indicate key on hours. CHECK” must be set ON. Otherwise the pump
controller is not acting on this item. This should
Set Temperature – If this option is set to be adjusted to equal the value on the traction
“DIGITAL” then the truck has an on/off controller. The traction controller is managing the
temperature sensor. If this option is set to battery control!
“ANALOG” then the sensor is attached to
(Connecter B pin #6 and #12) and the thermal Throttle 0 Zone – This adjustment is the range
sensing is accomplished using a thermal in which the rotation of the lift potentiometer,
resistance-varying device. If this option is set to from neutral, will result in the output of a creep
“NONE” then there is no traction motor thermal speed. As this value is increased so will the
sensor. range of creep speed. See Figure 3.1
Throttle X Point – This adjustment is the point
Adjustments: (Pump Controller) in which the rotation of the lift potentiometer,
from neutral, will result in the output speed
Note
(Throttle Y). See Figure 3.1
To access this menu reference the Menu
Throttle Y Point – This adjustment is the output
Description section of the
speed at which the rotation of the lift
Programming/Troubleshooting through the
potentiometer, from neutral, is at Throttle Point
Handset chapter.
X. See Figure 3.1
The adjustments are used to “fine tune” the
vehicle. The technician uses the adjustments to Note
add offsets to those components that have VACC MAX and VACC MIN are values
inconsistent values. The following is a list of programmable through the Program Vacc
adjustments that can be altered on the Pump function.
Controller.
NOTE
Only read, programming through SICOS!

4-12
SETTINGS

SPEED f (Hz)

MAX SPEED

THROTTLE Y
POINT
FREQ. CREEP

VACC THROTTLE 0 THROTTLE X VACC

MIN ZONE POINT MAX

Figure 4.2 Throttle Zones

Adjustment #03 – Not used in this application

Adjustment #04 – This is the temperature when the controller shuts down because of too high motor
temperature (120 °C)

4-13
SETTINGS

Parameter Change: (Pump Controller) Max Speed Up – This parameter determines the
The parameter change menu is designed to maximum lifting speed using a potentiometer as
allow certain characteristics of the vehicle to the lifting input See Table 4.2
become modified. Those characteristics include Min Speed Up – This parameter determines the
top travel and lift speeds, cutback speeds, minimum lifting speed using a potentiometer as
auxiliary speeds, etc.., Below is a list of the the lifting input. The minimum lifting speed
parameters and their definitions. becomes active after the lifting enable switch is
Acceleration Delay – This value determines the closed. See Table 4.2
acceleration ramp. See Table 4.2 This is the time Maximum Current –This parameter determines
from zero to full speed for the pump motor if the the maximum current the pump controller will
lift pot. is in max. position. allow. The values allowed in this field are 0-9.
Deceleration Delay – This value determines the See Table 4.2
deceleration ramp. See Table 4.2 This is the time Note
from full speed to zero for the pump motor if the
lift pot is released to zero position. All of the parameters have a level or percentage
applied to them. Refer to the table below to
determine the conversion from level to the actual
value.

Programmed Level
Parameter Unit 0 1 2 3 4 5 6 7 8 9
Acceleration Delay (*) Sec. 0.5 0.7 1.0 1.4 1.9 2.5 3.2 4.0 4.8 5.5
Deceleration Delay (**) Sec. 0.5 0.7 1.0 1.4 1.9 2.5 3.2 4.0 4.8 5.5
Max Speed UP Hz. 65 80 95 110 125 140 155 170 185 200
Min Speed UP Hz 0 13.5 15.0 16.5 18.0 19.5 21.0 22.5 24.0 25.5
Maximum Current % IMAX 47 53 58 64 70 76 82 88 94 100

Table 4.2 Parameter Conversions

(*) The acceleration time shown is the time from 0 Hz to 100 Hz. This parameter can change
due to outside interferences. (I.e. a change in the load on the forks)

(**) The braking feature is based upon deceleration ramps. The value shown in the table is the
time it takes to go from 100 Hz to 0 Hz. This parameter can change due to outside
interferences. (I.e. a change in the load on the forks)

4-14
SETTINGS

Tester: (Pump Controller) Accelerator – This test shows the value of the
lift potentiometer wiper. The value of the wiper in
Note volts is displayed on the left hand of the display
To access this menu reference the Menu while the percentage of potentiometer rotation is
Description section of the displayed on the right.
Programming/Troubleshooting through the Lift Switch – This test shows the position of the
Handset chapter. lifting switch. The display will show “ON” when
The tester menu is designed to allow certain the switch is closed and “OFF” when open.
characteristics or components of the vehicle to Hydro Speed Req. – This test shows the
become monitored. Those characteristics include position of the hydro speed request switch. The
top travel and lift speeds, cutback speeds, display will show “ON” when the switch is closed
auxiliary speeds, etc.., Below is a list of the and “OFF” when open. Not used in this
parameters and their definitions application
Motor Voltage – This test shows the amount of Cutback Switch – Not used in this application
voltage supplied to the lift motor. This is
Voltage Booster – This test shows the amount
expressed as a percentage of the battery voltage.
of boost voltage applied to the lift motor under
Frequency – This test shows the frequency of load conditions. When the current limit is
the voltage and current supplied to the lift motor. approached and the motor is not turning the
Encoder – This test shows the speed of the controller gives a higher voltage on the phases
drive motor in Hz. for approx. 2 sec. It is expressed in a percentage
Slip Value – This test shows the difference of of the full voltage that could be applied.
speed (Hz) between the rotating field and the Battery Voltage – This test shows the battery
shaft of the lift motor voltage measured off the key switch input.
Current RMS – This test shows the root mean COS FI – This test shows the Cosine angle
square of the lift motor current. (Real Time Calculated) of the motor.
Temperature – This test shows the temperature
(ºC) of the heat sink mounted to the mosfets.
The temperature device is located within the
traction controller.
Motor Temperature – This test shows the
temperature (ºC) of the lift motor. The
temperature device is a 600 ohm thermistor
connected to the pump controller on connector B
pin #6 and #12.

4-15
SETTINGS

Alarms: (Pump Controller) Pedal Wire KO – This alarm indicates the power
The alarms menu is designed to store all the has been interrupted through the power or
codes that have occurred since the truck was negative side of the acceleration potentiometer.
manufactured or from the last time the codes VACC Not OK – The test is made in standby.
were cleared from memory. Below is a list of the This alarm indicates the accelerator voltage is 1
alarms and their definitions volt greater than the minimum value
Watch Dog – This alarm occurs when the programmed by the PROGRAM VACC function.
internal watch dog timer times out. If there is a Possible causes would be the potentiometer is
permanent alarm present replace the controller. not correctly calibrated or the potentiometer is
EEPROM KO – This alarm occurs when there is defective.
a failure to communicate with the internal STBY I High – This alarm indicates that while in
memory. If there is a permanent alarm present idle no current was present. This indicates an
replace the controller. open circuit. This test is carried out in standby
Logic Failure #1 – This alarm occurs when inside the controller. Checks if the current is 0. If
there is an under or over voltage occurrence. not verified it means that Standby I is high. If
The voltage is from the battery, if the battery there is a permanent alarm present replace the
voltage is correct the fault is in the control circuit. controller.
If there is a permanent alarm present replace the Main Contactor Alarms – The following alarms
controller. may occur depending on the status of the Main
Logic Failure #2 – This alarm indicates a failure Power Contactor. These alarms are only
within the logic card that manages the feedback applicable to those systems that use a single ac
when determining the phases of the drive motor. inverter (Controller) for both the traction and
If there is a permanent alarm present replace the lifting functions.
controller. Coil Shorted- The microprocessor is
Logic Failure #3 – This alarm indicates a failure constantly monitoring the Main Power
with the circuit that monitors the current that Contactor Assembly. If it detects an abnormal
flows through the drive motor. If there is a high amount of current passing through the
permanent alarm present replace the controller. coil this alarm will occur.

Incorrect Start – This alarm occurs when the Driver Shorted – This alarm occurs if the
sequencing of the control handle is incorrect. microprocessor determines the internal coil
This alarm could occur if the operator presence driver has shorted.
switch were malfunctioning. Make sure the Contactor Driver – This alarm occurs if the
operator presence switch is activated prior to microprocessor determines the internal driver
requesting a travel function. is not sinking current through the Main Power
Capacitor Charge – This alarm occurs when the Contactor coil.
internal RC circuit does not charge at the rate Contactor Open – This alarm occurs when
expected. If there is a permanent alarm present the driver for the Main Power Contactor is
replace the controller. sinking current through the contactor coil but
VMN Low, VMN High – This alarm will occur there is no indication the contactor has
during initial power up if a problem is detected closed. This could be related to the wiring
with the motor connections to the lift motor. going to the contactor. The other possibility is
There may be a possibility of one of the three the contacts need to be replaced.
phases improperly connected. There may also High Temperature – This alarm occurs when
be a short from the lift motor to the frame of the the temperature for the lift controller exceeds
truck. 75˚C. The maximum current through the lift
motor is reduced when this alarm occurs. At
100˚C the traction controller will stop pulsing the

4-16
SETTINGS

lift motor. Should this alarm occur under Waiting Pump – This alarm is present for those
conditions where the temperature does not systems that incorporate both the traction and
exceed the 75˚C the problem may be a result pump within one controller. (Not applicable with
from the following.. this model) The pump side has detected a failure
a). The wiring to the thermal sensor is bad. and has communicated via the CAN Bus that
there is a problem. Contact the factory for more
b). The thermal sensor has failed information.
c). There is a failure with the lift controller. Can Bus KO – This alarm occurs when the lift
Motor Temperature – This alarms if the digital controller can not communicate over the Can
temperature sensor (Not applicable with this Bus. Check the wiring for the Can Bus
model) opens during operation. If this error throughout the system.
occurs while temperatures are cold then the Battery Low – This alarm occurs if the “battery
problem may be a result from the following.. check” option is ON and the battery has been
a). The wiring to the thermal sensor is bad. determined to drop below 10%. When this alarm
b). The thermal sensor has failed occurs the current through the lift motor is limited
to 50%.
c). There is a failure with the traction controller.
This is currently unused as the motors are
equipped with a thermal resistance-varying
device.
Thermic Sensor KO – This alarm occurs when
the internal temperature device for the pump
controller is out of range. Contact the factory for
more information.

4-17
SETTINGS

Default Settings For Pump Controllers

Reach Handset Settings 36V Rev. 1
Controller: ZAPI AC2P2B 36V 450A
Program version: PUMP CONTROLLER RO1.06

Controller Model # 5

DEFAULT
Mode IV
Mode III
Mode II
Mode I
COMMUNICATION THROUGH
SICOS

MAIN MENU/ Push ROLL

PARAMETER CHANGE: Up Button
ACCELERATOR DELAY 0 0 1 0 0
DECELERATOR DELAY 0 0 0 0 0
MAXIMUM SPEED UP 125Hz 125Hz 125Hz 125Hz 125Hz
MINIMUM SPEED UP 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.0Hz
MAXIMUM CURRENT 9 9 9 9 9
CONFIG MENU/
SET MODEL:
CONNECTION TYPE 5 5 5 5 5
SET OPTIONS:
HOUR COUNTER (RUNNING) RUN RUN RUN RUN RUN
SET TEMPERATURE ANALOG ANALOG ANALOG ANALOG ANALOG
ADJUSTMENTS: HANDSET
BATTERY VOLTAGE 36V 36V 36V 36V 36V
ADJUST BATTERY 37.8V 37.4V 37.4V 37.4V BATTERY VOLTS
THROTTLE 0 ZONE 11% 7% 7% 7% 11%
THROTTLE X ZONE 63% 63% 63% 63% 63%
THROTTLE Y ZONE 36% 36% 36% 36% 36%
ADJUSTMENT #04 120° 120° 120° 120° 120°
ADJUSTMENT #03 55° 35° 35° 35° 55°

4-18
SETTINGS

Reach Handset Settings 36V Rev. 1

Controller: ZAPI AC3P2B1 36V 550A
Program version: PUMP CONTROLLER RO1.06
Performance Lift

Controller Model # 5

DEFAULT
Mode IV
Mode III
Mode II
Mode I
COMMUNICATION THROUGH
SICOS

MAIN MENU/ Push ROLL

PARAMETER CHANGE: Up Button
ACCELERATOR DELAY B
DECELERATOR DELAY 0 0 0 0 0
MAXIMUM SPEED UP 125Hz 125Hz 125Hz 125Hz 125Hz
MINIMUM SPEED UP 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz
MAXIMUM CURRENT 9 9 9 9 9
CONFIG MENU/
SET MODEL:
CONNECTION TYPE 5 5 5 5 5
SET OPTIONS:
HOUR COUNTER (RUNNING) RUN RUN RUN RUN RUN
SET TEMPERATURE ANALOG ANALOG ANALOG ANALOG ANALOG
ADJUSTMENTS: HANDSET
BATTERY VOLTAGE 36V 36V 36V 36V 36V
ADJUST BATTERY 37.6V 37.4V 37.4V 37.4V BATTERY VOLTS
THROTTLE 0 ZONE 11% 11% 11% 11% 11%
THROTTLE X ZONE 63% 63% 63% 63% 63%
THROTTLE Y ZONE 36% 36% 36% 36% 36%
ADJUSTMENT #04 120° 120° 120° 120° 120°
ADJUSTMENT #03 55° 55° 55° 55° 55°

4-19
SETTINGS

Electric Steer Controller EPS Flowchart

HEADING

* CONFIG MENU* CONNECTED TO…

SET MODEL

NEW HEADING
*MAIN MENU* SPEED LIMIT 7
PARAMETER CHANGE AUX FUNCTION 3 4
SENSIBILITY 3
AUX FUNCTION 2 4
CREEP SPEED 0
COMPENSATION 2 *CONFIG MENU* HOUR COUNTER RUNNING
AUXILIARY TIME 7 SET OPTIONS MICRO CHECK PRESENT
ANTIROLLBACK 40% ENCODER CONT. OFF
FEEDBACK DEV. OPTION #1
LIMIT DEVICE OFF
DIR. GUAGE OPTION #1
AUTO INP ACT. 1
AUX FUNCT 1 0

DT V ADJUSTMENT #01 0
* CONFIG MENU*
SET POINT POT V ADJUSTMENTS SET CURRENT 0
FEEDBACK POT V ADJUSTMENT #02 100.0
*MAIN MENU* TEM PERATURE ˚C ADJUSTMENT #03 95.6
TESTER FREQUENCY Hz ADJUSTMENT #04 95.2
MOTOR VOLTAGE % SET BATTERY TYP E 36V
MOTOR CURRENT A SET SAT FREQ 100 Hz
ENC % OVERSAT FREQ 100 Hz
ENC SPEED Hz MAXIMUM SLIP 5.00 Hz
PERFORMANCE 0,1, 2,3 AUX VOLTAGE #1 2504 mv
ENDSTROKE CW ON/OFF AUX VOLTAGE #2 2495 mv
ENDSTROKE ACW ON/OFF
CW LIMIT LEVEL ON/OFF
ACW LIMIT LE VEL ON/OFF
AUTOMATIC REQ. ON/OFF
DIRECTION INPUTS ON/OFF
*MAIN MENU* MM ALARM SWITCH ON/OFF
SAVE PARAMETER SM ALARM SWITCH ON/OFF

*MAIN MENU*
RESTORE P ARAMETER

MAIN MENU CODE,

ALARM S h, N, ßC

MAIN MENU VACC SETTING MIN/MAX

PROGRAM VACC

MAIN MENU NOT AVAILABLE

MOTOR DATA

4-20
SETTINGS

Set Options: (Electric Steer Controller This vehicle is set up for level 1. Setting this
“EPS”) vehicle to other than the appropriate level may
cause erratic results.
Hour Counter – This option determines the hour
meter mode. If this option is set to “KEYON” the Aux Function 1 – This option sets up the
hour meter will work of the key switch. If this steering mode after the feedback pot has
option is set to “RUNNING” the hour meter will reached the final position.
only activate with the request for travel, steering Level 0 = The steering motor is turned on when a
or lifting. travel demand is active.
Micro Check – This feature is used to support Level 1 = The steering motor is turned off (15
the debugging activity option. This option may seconds) and on
inhibit Supervisor microprocessor operation and
(3 seconds) regardless of the travel demand
allow the system to run with just the main
state.
microprocessor support.
Level 2 = The steering motor is turned off (15
WARNING! This option should be set to
seconds) and on (3 seconds) but only
PRESENT to ensure proper operation of the
when a travel demand is active.
vehicle.
In this application the steering controller is
Encoder Control – This option will use the
working in manual mode only without any
encoder within the electric steer motor. This
feedback potentiometers.
option is not used with this vehicle. This option
should be set to OFF. This vehicle is set up for level 0. Setting this
vehicle to other than the appropriate level may
Feedback Device – This option enables the
cause erratic results
steer pot as a feedback device to determine
steer angle. This option should be set to
OPTION #1.
Limit Device – When this option is set ON the
steer angle feedback pot will be used instead of
limit switches. This option should be set to OFF.
Direction Gauge – There are two options for
trucks equipped with a steer angle direction
gauge. This setting permits the indicated turning
direction displayed on the gauge to be reversed.
This option should be set toOption#1
Auto Input Active – This option sets up the
active logic for auto centering. This input can be
set up as active on a logic level or as an edge
triggered input.
Level 0 = External automatic request is active
high.
Level 1 = External automatic request is low.
Level 2 = External automatic request is active on
the rising edge of every odd numbered
input.
Level 3 = External automatic request is active on
the falling edge of every odd numbered
input.

4-21
SETTINGS

Adjustments: (Electric Steer Controller Adjustment #02 –This adjustment is used to

“EPS”) define the stator resistance in mili-ohms. This
value can be adjusted using the handset. Make
Note sure to save your changes if this value needs to
To access this menu reference the Menu be adjusted. The stator resistance value is used
Description section of the for stator resistance drop compensation when
Programming/Troubleshooting through the COMPENSATION parameter is at a Level = 2.
Handset chapter. Adjustment #03 - This adjustment is used to set
The adjustments are used to “fine tune” the the first phase current gain. This is factory
vehicle. The technician uses the adjustments to adjusted.
add offsets to those components that have Adjustment #04 – This allows for adjustment of
inconsistent values. The following is a list of the second phase current gain. This adjustment
adjustments that can be altered on the Electric is set at the factory.
Steer Controller.
Set Battery Type - This adjustment defines the
Adjustment #01 – This adjustment supports the voltage of he battery installed in the vehicle. If
acquisition of the motor resistance and of the the battery within the truck is 36 volts this field
current amplifiers gain (Factory Adjusted). When should be set to “36”.
level 1 is set, a stator resistance acquisition
Set Sat Frequency – This adjustment defines
procedure is enabled. The stator resistance is
the frequency from which the constant voltage
used for the flux compensation when the
weakening region will begin and where the
COMPENSATION parameter is Level = 2. When
constant flux region will end.
Level is set to a 2 both stator resistance and
current gain amplifiers acquisition procedure is
enabled. This adjustment should be set to a 0 for
this vehicle
Set Current – If ADJUSTMENT #01 is changed
to a value other than 0, the technician should
connect a DC ammeter in series with the motor
phase U or W. Next depress the Set button
on the handset until the motor current is
increased to a DC current level equal to1/2 of
the maximum current. When finished return to
ADJUSTMENT #01 and return its value back to
0. Make sure to save your settings after
changing the current settings.

4-22
SETTINGS

OverSat Freq. – This adjustment sets the Note

maximum frequency for over saturation. In an The slip is the difference between the speed and
open loop system the OVERSAT FREQ should frequency applied to the motor.
be set to 1. A motor used as power steering does
not need to work in the weakening region Aux Voltage #1 – This adjustment is for those
therefore we recommend not setting this vehicles that use a stepper motor as a means of
adjustment up as 0. Setting this value up as a 0 communicating steering velocity and direction.
will produce a square wave and could generate The voltage that can be adjusted is acquired the
unwanted noise. first time the steer controller is turned on. This
value is determined from connector B pin # 3 (D
Maximum Slip – This adjustment allows the Line). This value is collected prior to rotating the
technician to set the maximum slip. motor. This value is typically 2.5v.
The typical value is 5 Hz. Aux Voltage #2 - This adjustment is for those
vehicles that use a stepper motor as a means of
communicating steering velocity and direction.
The voltage that can be adjusted is acquired the
first time the steer controller is turned on. This
value is determined from connector B pin # 9 (Q
Line). This value is collected prior to rotating the
motor. This value is typically 2.5v.

4-23
SETTINGS

Parameter Change: (Electric Steer voltage. This ensures torque is available when
Controller “EPS”) the battery is low.
Speed Limit – This parameter regulates the Level 0 = No compensation but a flux
maximum steer motor turning speed. The speed degradation when current is too high.
is set from 0 to 9 with the 0 being the slowest Level 1 = Compensates for the power drop of
speed and 9 being the highest. the motor cables and power mosfets.
Note Level 2 = Compensates for power drop across
The speed limit may be adversely affected if the the motor cables, power mosfets and
SET BATTERY TYPE was set incorrectly. stator resistance.
Aux Function 3 – This parameter is used to Level 3 = No compensation.
vary the steering sensitivity with the speed of the This parameter should normally be set to Level 2
traction motor. Certain applications will require as a strong compensation reduces the slip.
less or more steering sensitivity at the higher or
lower travel speeds. This parameter has 10 Note
different settings ( 0-9) with 0 having no effect The slip is the difference between the speed and
with the sensitivity with the varying travel speed frequency applied to the motor.
and 9 having the most effect. As the number is
Auxiliary Time – This parameter is the time,
increased from 0 to 9 the steering sensitivity will
after the steering wheel is released, for which the
become less responsive.
standstill torque is applied.
Sensibility – This parameter determines how
Level 0 = No stand still torque.
much rotation of the steering wheel is required
before the steer controller will respond. If this Level 1 = Standstill torque is applied for 6
parameter is set to 0 the steering is less seconds after steering wheel is
sensitive to slight steering wheel movements. As released.
this number is increased to 9 the steering will Level 9 = Standstill torque is applied for 90
become more sensitive with slight movements of seconds after steering wheel is
the steering wheel. released.
Aux Function 2 – This parameter has the same Increasing the value between 1 and 9 will
purpose as Aux Function 3. The only difference increase the amount of time the standstill torque
is the aux function 2 varies the value of the will be applied to the steer motor after the
steering speed when the steering wheel is steering wheel is released.
turning slowly. Anti Rollback – This parameter is used to set
Creep Speed – This parameter provides for the amount of standstill torque to be applied after
additional torques at low turning speeds. If this release of the steering wheel. This setting is a
parameter is set to 0 then there will be no torque percentage of the maximum current.
compensation. As the number is increased to 9
there will be more torque applied at slow turning
speeds. This parameter is useful in two ways.
First of all it provides additional torque if
required. Secondly the additional torque will
neutralize the elastic tire effect when the steering
wheel is released.
Compensation – This parameter provides the
stator flux compensation. This parameter is
useful for applications without the encoder
providing feedback for motor velocity. Setting this
value to a number different than 0 gets the motor
flux (and torque) independent from the battery

4-24
SETTINGS

Tester: (Electric Steer Controller “EPS”) working in manual mode only without any
DT – This test provides the value of the stepper feedback potentiometers.
motor input from the steering wheel with its sign ACW Limit Level – Provides in real time the
in real time. The value is scaled for the A/D status of the steer potentiometer if it has
converter. The range is between± 0>5V exceeded the maximum SET MIN FB POT value.
depending on turning speed of steering wheel. In this application the steering controller is
Set Point Pot – Not Used. This test would working in manual mode only without any
indicate the value of the steering potentiometer. feedback potentiometers.
(Not available on this model). Automatic Req. – This test provides in real time
Feedback Pot – This test provides the voltage the steering state In this application the steering
from the steering feedback potentiometer. This controller is working in manual mode only without
model does not have a feedback pot. any feedback potentiometers.
Temperature – This test provides in real time the Direction Inputs – This test provides in real time
temperature (˚C) of the heat sink mounted to the the request for travel. It turns “ON” when either a
steer controller. There will be an alarm set if this Forward or Reverse travel command is
temperature is above requested. In this application the steering
controller is working in manual mode only without
76 ˚C. any feedback potentiometers.
Frequency – This test provides the frequency of MM Alarm Switch – This test provides in real
the signal applied to the steer motor with its sign. time the state of the Master Microprocessor
By turning the steering wheel, the range controlled safety switch. When the safety circuits
approx.± 100Hz are ok the display will indicate the internal safety
Motor Voltage – This test provides the voltage switch to be in the “ON” position. If the circuits
of the signal applied to the steer motor as a are not ok the display will show the switch to be
percentage of battery voltage. The value is in the “OFF” position.
almost full battery voltage, when turning the SM Alarm Switch – This test provides in real
steering wheel. time the state of the Slave Microprocessor
Motor Current – This test provides in real time controlled safety switch. When the safety circuits
the phase motor current (Rms). Around 30A are ok the display will indicate the internal safety
depending load and friction between the drive switch to be in the “ON” position. If the circuits
wheel and the floor. are not ok the display will show the switch to be
ENC – Not Used. This test is for the optional in the “OFF” position.
encoder.
ENC Speed – Not Used. This test shows the
encoder speed and direction.
End Stroke CW – This test provides in real time
the active state of the clockwise (right) limit
switch.
Performance – Displays the performance mode
choosen from the display.
End Stroke CCW – This test provides in real
time the active state of the counter clockwise
(left) limit switch.
CW Limit Level – Provides in real time the
status of the steer potentiometer if it has
exceeded the maximum SET MAX FB POT
value. In this application the steering controller is

4-25
SETTINGS

Alarms: (Electric Steer Controller “EPS”) Micro Slave #6 – This alarm occurs when the
The alarms menu is designed to store all the Supervisor Microprocessor has detected the
codes that have occurred since the truck was steer motor turning in the opposite direction to
manufactured or until the last time the codes the stepper motor request.
were cleared from memory. Below is a list of the Micro Slave #7 – This alarm occurs when the
alarms and their definitions Supervisor Microprocessor has opened its safety
Micro Slave KO – The Master Microprocessor contact but has not specified the reason on the
(MM) has detected a status signal coming from local Can Bus. Contact the factory for additional
the Supervisor Microprocessor (SM) that does information.
not agree with the present command values. The KM Closed – This alarm occurs when the
Master Microprocessor and Supervisor Master Microprocessor has detected the safety
Microprocessor are constantly comparing values contact has closed prior to being commanded.
read from the stepper motor (Steering Wheel), This alarm can be caused by reading both the
limit switches, etc. If the comparisons do not mid voltage point along with the low voltage
match this alarm will occur. If there is a point. See Figure 4.3 below.
permanent alarm present, replace the controller.

Figure 4.3 Master and Supervisor Safety Switch Configuration

If the Master controlled switch is closed and the If the Supervisor controlled switch is open and
Supervisor controlled switch is open the voltages the Master controlled switch is open the voltage
at the mid and low voltage point should be about at the high voltage point should be Battery
6v. The high voltage point should be at Battery Voltage. The voltage at the mid voltage point
Voltage. should be 12 volts. The voltage at the low
If the Supervisor controlled switch is closed and voltage point should be 0 volts.
the Master controlled switch is open the voltage KS Closed – This alarm occurs when the Master
at the mid voltage and high voltage point should Microprocessor has detected the Supervisor
be _ (Battery Voltage – 12 v). The voltage at the Microprocessor safety contact was closed before
low voltage point should be 0 volts. it was commanded open. There are three levels of

4-26
SETTINGS

diagnostic points; low voltage point, mid voltage contactor, the driver mosfet in traction controller
point and high voltage point. When the three gives the voltage and current to activate the
switches are open these three points are expected contactor coil for energizing, if the contactor is
to be at three different levels. See Figure 5.2. If mechanically bound and does not close the tips
any of these two levels are identical when the this alarm will appear.
switch is commanded open an alarm will occur. Can Bus – This alarm occurs if the traction
KM Open – This alarm occurs when the Master controller is not connected or if there is some
microprocessor has detected its safety contact problems on the Can Bus line. Check the Can
open after being commanded closed. There are Bus lines.
three levels of diagnostic points; low voltage D Line Sensor KO – This alarm occurs when
point, mid voltage point and high voltage point. the stepper motor channel on the connector B
See Figure 5.2. pin #3 is open. Check the stepper motor wires
KS Open – This alarm occurs when the Master and measure the stepper motor line D
Microprocessor has detected the Supervisor resistance. This value should be close to 30
Microprocessor safety contact to be open after ohms between connector B pin #3 and ground. If
commanded closed. the problem is not in the wiring, and there is a
Data Acquisition – This alarm occurs when the permanent alarm present, replace the controller.
technician sets the ADJUSTMENT #1 to level 1. Q Line Sensor KO – This alarm occurs when
Cycling the key switch clears this alarm. Wrong the stepper motor channel on connector B pin #
setting for this parameter gives wrong 9 is open. Check the stepper motor wires and
configuration. ADJUSTMENT#1 must always be measure the stepper motor line Q resistance.
set to level 0. This value should be close to 30 ohms between
Power failure #1, #2 or #3 – This alarm occurs connector B pin # 9 and ground.
when phases U, V and W of the motor are EEPROM KO – This alarm occurs with a
broken. This alarm occurs when at least one of hardware or software defect of the non-volatile
the phase currents is less than 6A while the on board memory. To remove this alarm run the
applied frequency is different from zero. Verify CLEAR EEPROM operation from the ALARM
motor cables and motor windings have continuity. CONFIG MENU. To enter the ALARM CONFIG
Logic Failure #1 – This alarm occurs when the MENU depress the two right side buttons on the
real voltage between phase U and V is different handset. Use the roll up and down button until
than expected. If there is a permanent alarm you see CLEAR EEPROM. Push the ENTER
present, replace the controller. button twice. If the alarm remains then replace
the logic unit.
Logic Failure #2 – This alarm occurs when the
real voltage between phase U and W is different High Temperature – This alarm occurs if the
than expected. If there is a permanent alarm heat sink for the Electric Steer controller exceeds
present, replace the controller. 76ºC. Allow the unit to cool down. If the higher
temperature remains after proper cool down
High Current – This alarm occurs when the contact the factory.
output current amplifiers determine the output
from the amplifiers are higher than the maximum STBY I High – This alarm occurs if the rest state
preset current. If there is a permanent alarm current signals (measured on the U and W
present, replace the controller. phases) are not in the window 2.5± 0.3 Vdc after
switching on the key and 2.5± 0.15 Vdc when in
Main Contactor Open – This alarm occurs the steady state. These values are factory
during initialization when the Can Bus adjusted. Contact the factory if these values are
announces from the traction controller that the out of tolerance. If there is a permanent alarm
main contactor has not closed. When the key present, replace the controller.
switch is turned on, the Sicos receives OK
information from every controller. Sicos gives VMN Not OK – This alarm occurs when in the
traction controller permission to close the main initial rest state at least one of the phases of the

4-27
SETTINGS

motor voltage is high. If this alarm occurs

permanently contact the factory. Higher than 0V.
If there is a permanent alarm present, replace
the controller.
Logic Failure # 3 – This alarm occurs when in
the rest state the Vv-Vu phase motor voltage is
high. This means the voltage internally to the
logic card is out of range. Contact the factory for
additional information.
Logic Failure #4 – This alarm occurs in the rest
state when the Vu-Vw phase motor voltage is
high. Contact the factory for additional
information.

4-28
SETTINGS

Electric Steer Controller Default Settings

Reach Handset Settings 36V Rev. 1
Controller: EPSB 36V 70A
Program version: ELECTRIC STEERING CONTROLLER (EPS) RO1.08
Performance Lift

DEFAULT
Controller Model # 5

Mode IV
Mode III
Mode II
Mode I
COMMUNICATION THROUGH
SICOS

MAIN MENU/ Push ROLL

PARAMETER CHANGE: Up Button
SPEED LIMIT 5 5 5 5 5
AUXILIARY FUNCTION # 3 7 7 7 7 7
SENSIBILITY LEVEL 4 0 4 4 4
AUXILIARY FUNCTION # 2 4 4 4 4 4
CREEP SPEED LEVEL 0 0 0 0 0
COMPENSATION LEVEL 2 2 2 2 2
AUXILIARY TIME 7 7 7 7 7
ANTIROLLBACK 40% 40% 40% 40% 40%
CONFIG MENU/
SET MODEL:
CONNECTION TYPE 6 6 6 6 6
SET OPTIONS:
HOUR COUNTER (RUNNING) RUN RUN RUN RUN RUN
MICRO CHECK PRE PRE PRE PRE PRESENT
ENCODER CONTROL OFF OFF OFF OFF OFF
FEEDBACK DEVICE OPTION #1 #1 #1 #1 #1
LIMIT DEVICE OFF OFF OFF OFF OFF
DIRECTION GAUGE OPTION #1 #1 #1 #1 #1
AUTO INPUT ACTIV 1 1 1 1 1
AUXILIARY FUNCTION # 1 0 0 0 0 0
ADJUSTMENTS: HANDSET
ADJUSTMENT # 01 0 0 0 0 0
SET CURRENT 0 0 0 0 0
ADJUSTMENT # 02 100.0 100.0 100.0 100.0 100
ADJUSTMENT # 03 100.7% 100.7% 100.7% 100.7% 107 FACTORY SET
ADJUSTMENT # 04 95.6% 95.6% 95.6% 95.6% 113 FACTORY SET
SET BATTERY TYPE 36V 36V 36V 36V 48
SET SATURATION FREQ. 100Hz 100Hz 100Hz 100Hz 100
OVER SATURATION FREQ. 1Hz 1Hz 1Hz 1Hz 1
MAXIMUM SLIP 5.00Hz 5.00Hz 5.00Hz 5.00Hz 5
AUXILIARY VOLTAGE # 1 2504 Mv 2504 Mv 2504 Mv 2504 Mv 2504 FACTORY SET
AUXILIARY VOLTAGE # 2 2500 Mv 2500 Mv 2500 Mv 2500 Mv 2500 FACTORY SET

4-29
SETTINGS

GENERAL INFORMATION
In order to turn on most options, the handset is
required. Handset part number 97M2204900 and
adapter RL463054 are needed to plug into the
connector accessible when the left side door is
opened.

! WARNING

Do not plug in the handset unless the

battery is disconnected

Adjustment of parameters and testing of each

individual controller can be accomplished
through the handset. See Figure 4.4. The
handset connects to the 8 pin connector located
behind the SICOS/Display Unit. The handset is
designed for the technician to adjust certain
characteristics of the vehicle. There is an
additional feature that allows the technician to
use the handset as a tool to diagnose the
various electrical components on the vehicle.
Alarms will also be visible through the use of the
handset. The next couple of pages will describe Figure 4.4 Handset with Adapter Cable
those options in better detail.

4-30
SETTINGS

HANDSET
Tree Diagram
After power up, the following menus are
available on the Handset.

Every module (Controller) connected to the Can on the menu provide a brief overview of that
Bus has the above menus available to the menu. Further detail will be provided for that
technician to make adjustments or complete a individual controller located within this chapter.
maintenance test. The descriptions of each item

4-31
SETTINGS

HANDSET
Menu Description
Heading – The heading indicates the model
(controller) the handset is presently
communicating with along with the attributes of
that model. See Figure 4.5 The upper right of the
The following is the model numbers and their
SICOS/Display Unit indicates which model is
associated controller.
connected. In this case the “SICOS” refers to the
SICOS/Display Unit controller. The “RO” refers to Model 1 = SICOS/Display Unit Controller
manufacturer assembling the control system. (SICOS)
The “0.07” is the version of the control unit. The Model 2 = Traction Controller (AC2)
“36V” is the configured voltage for this controller. Model 5 = Pump Controller (AC2)
Warning! Make sure the voltage on the Model 6 = Electric Steer Controller (EPS)
heading is the voltage of the truck. Refer to
the programming section of this chapter if Model 9 = Hydraulic Controller (MHYRIO)
the voltage needs to be changed. Model 37= Pump Controller (AC3)
The “500A” refers to the maximum current of the Note: If a number selected is different than the
controller. The “00180” is the hour meter of this above described options the SICOS will default
controller. as the controller to be accessed.
Once the model has been chosen select the
OUT (4) button on the handset. The next screen
will prompt the user to accept the changed value.

Figure 4.5 Heading Menu

Set Model – From time to time the technician

may want to access other controllers within the
system. In order to access this menu from the Depress the ENTER (3) button on the handset if
main menu the technician must simultaneously the desired number has been selected. Depress
depress the ROLL up (1) and SET up (5) buttons the OUT (4) button if you do not wish to make
on the handset. Refer to Figure 1.22. Use the the changes. Depress the OUT (4) button again
ROLL up (1) or ROLL down (2) buttons until the to return to the heading menu.
following menu appears. Set Options - In order to access this menu
from the main menu the technician must
simultaneously depress the ROLL up (1) and
SET up (5) buttons on the handset. Refer to
Figure 1.22. Use the ROLL up (1) or ROLL
down (2) buttons until the following menu
appears.
Press the ENTER (3) button on the handset. Use
the SET up (5) or SET down (6) button until the
model number of the controller is Sicos/Display
United on the SICOS/Display Unit. The following
example shows model 1 (SICOS or
SICOS/Display Unit Controller) is selected.

4-32
SETTINGS

Depress the ENTER (3) button to enter the SET Parameter Change – Depress the ENTER (3)
OPTIONS menu. The options within this menu button from the heading menu to enter the main
will differ from controller to controller. Refer to the menu. Use the ROLL up (1) and ROLL down (2)
controller set up section for the options each to have the following screen displayed.
controller will allow you to adjust. Use the ROLL
up (1) and ROLL down (2) buttons to select the
option you wish to change. Use the SET up (5)
and SET down (6) buttons to change the value of
the option you have chosen. Depress the OUT
(4) button to exit from the menu. When the
screen prompts you with “ARE YOU SURE?”
depress the ENTER (3) button to make any
changes you have made. Depress the OUT (4) Depress the ENTER (3) button to enter the
button to exit without making any changes. PARAMETER CHANGE menu. The options
Depress the Out (4) button again to return to the within this menu will differ from controller to
heading menu. controller. Refer to the controller set up section
Adjustments - In order to access this menu for the adjustments each controller will allow you
from the main menu the technician must to modify. Use the ROLL up (1) and ROLL down
simultaneously depress the ROLL up (1) and (2) buttons to select the field you wish to change.
SET up (5) buttons on the handset. Refer to Use the SET up (5) and SET down (6) buttons to
Figure 1.22. Use the ROLL up (1) or ROLL down change the value of the adjustment you have
(2) buttons until the following menu appears. chosen. Depress the OUT (4) button to exit from
the menu. When the screen prompts you with
“ARE YOU SURE?” depress the ENTER (3)
button to make any changes you have made.
Depress the OUT (4) button to exit without
making any changes. Depress the Out (4) button
again to return to the main menu.
Tester - Depress the ENTER (3) button from the
heading menu to enter the main menu. Use the
Depress the ENTER (3) button to enter the ROLL up (1) and ROLL down (2) to have the
ADJUSTMENTS menu. The options within this following screen displayed.
menu will differ from controller to controller. Refer
to the controller set up section for the
adjustments each controller will allow you to
modify. Use the ROLL up (1) and ROLL down (2)
buttons to select the field you wish to change.
Use the SET up (5) and SET down (6) buttons to
change the value of the adjustment you have
chosen. Depress the OUT (4) button to exit from
the menu. When the screen prompts you with Depress the ENTER (3) button to enter the
“ARE YOU SURE?” depress the ENTER (3) TESTER menu. The options within this menu will
button to make any changes you have made. differ from controller to controller. Refer to the
Depress the OUT (4) button to exit without controller set up section for the adjustments each
making any changes. Depress the Out (4) button controller will allow you to modify. Use the ROLL
again to return to the heading menu. up (1) and ROLL down (2) buttons to select the
component you wish to test. Depress the OUT
(4) button to return to the main menu.

4-33
SETTINGS

Save Parameter – From time to time the Use the ROLL up (1) and ROLL down (2) buttons
technician may want to clone the parameters to select the model you wish to upload. Depress
from one truck to another. The SAVE the ENTER (3) button to start the save routine.
PARAMETER in conjunction with the RESTORE The following display appears
PARAMETER allows the technician to upload
parameters from one truck and download those
parameters into multiple trucks. Depress the
ENTER (3) button from the heading menu to
enter the main menu. Use the ROLL up (1) and
ROLL down (2) to have the following screen
displayed.

The display will continue to change as the

different parameters are being uploaded. When
the handset is finished uploading the parameters
the following display will appear.

Depress the ENTER (3) button to enter the

SAVE PARAMETER menu. The following display
will appear.

Use the OUT (4) button to return to the main

menu.
Restore Parameter - From time to time the
technician may want to clone the parameters
from one truck to another. The SAVE
PARAMETER in conjunction with the RESTORE
The display will let the technician know which PARAMETER allows the technician to upload
model is being selected by the parameters from one truck and download those
“MOD XX” designator. parameters into multiple trucks. Depress the
ENTER (3) button from the heading menu to
enter the main menu. Use the ROLL up (1) and
Model 1 = Sicos/Display Unit Controller (SICOS) ROLL down (2) to have the following screen
Model 2 = Traction Controller (AC2) displayed.
Model 5 = Pump Controller (AC2)
Model 6 = Electric Steer Controller (EPS)
Model 9 = Hydraulic Controller (MHYRIO
Model 37=Pump Controller (AC3)
If the model has not been uploaded into the
handset memory the word “FREE” will be located
under the SELECT: Mod XX.
Press the ENTER (3) button to go into the
RESTORE PARAMETER function. The fol-
lowing screen is displayed

4-34
SETTINGS

Press the ENTER (3) button to view the alarms.

The display will show the most recent alarm.

The display will show you which controller

parameters have been stored. Use the Roll up
(1) and ROLL down (2) buttons to determine
which model parameters you wish to restore.
Press the ENTER (3) button to begin the The “00007” represents the controller hour meter
download operation. The display will ask “ARE reading at last failure time. The “#03” represents
YOU SURE?”. Press the ENTER (3) button to the number of times this alarm has occurred.
continue. Press the OUT (4) button to cancel the (Refer to the controller set up section for the
operation. If the ENTER button is depressed the definition of each alarm code). The “18˚ C”
screen will show those parameters that are being represents the temperature (Celsius) at which
downloaded. When the parameters are finished the controller’s heat sink was recorded. If there
downloading the following screen appears. has been no alarms that have occurred then
“ALARM NULL” will appear on the display.
When you have finished looking at the alarms
press the OUT (4) button to exit. The display will
ask the technician to “CLEAR THE LOGBOOK”.
Press the ENTER (5) button to clear the alarms.
Press the OUT (4) button to exit without clearing
the alarms. Press the OUT (4) button to return to
the main menu.
Depress the OUT (4) button to exit back to the Program VACC –(READ ONLY) This function
main menu. If there are other parameters that may or may not be accessible from the handset.
need to be downloaded from other controllers This function determines the maximum and
repeat the previously described steps. minimum values of the potentiometer(s) attached
Alarms – The history of alarms for each to the controller communicating to the handset.
controller may be viewed using the handset. This Depress the ENTER (5) button from the heading
proves to be very helpful with intermittent menu to enter the main menu. Use the ROLL up
problems and error codes that may have been (1) and ROLL down (2) to have the following
forgotten by the operator. Depress the ENTER screen displayed.
(3) button from the heading menu to enter the
main menu. Use the ROLL up (1) and ROLL
down (2) to have the following screen displayed.

4-35
SETTINGS

Press the ENTER (5) button to enter the Press the ENTER (5) key to clear these values.
PROGRAM VACC screen. If this option is The display will change the “4.8” to “0.0”. If the
available for the controller the handset is in potentiometer attached to the controller in
communication with the following display will be communication with the handset is rotated the
shown values will again become displayed on the
screen. The purpose of this function is to store
the min and max values of the potentiometer(s).
The technician may need to use this function to
determine the functionality of the potentiometer
along with possible misalignment. When finished
press the OUT (4) button. The display will ask
“ARE YOU SURE?”. Press the ENTER for yes
Can not be adjusted or settled on the controller and OUT (5) to remain in this menu. Press the
itself only through the display under a different EXIT (5) button a second time to return to the
position. main menu.

4-36
CONSOLE PROGRAMMING

Programming and Set Up of Performance

Values
The vehicle console switches are located directly
beneath the operator display on the vehicle.
Without entering a password into the console
display, the operator has very limited options as
it relates to programming. Set up and
performance level values require a password to
be entered.
Console Switches And Functions

The enter button is used to select the The X button is used to exit a selected
option or enter a changed value. The enter menu and to select the optional height
button is also used as a “Yes” answer selector. The X button is also used as a
when asked to “clear alarms”. “No” answer when asked to “clear
alarms?”.
The up arrow button is used to move up
through the menus or to increase a Mast Lift Limit Bypass Button. This is an
selected value. optional button provided with the Mast Lift
Limit with Bypass option.
The down arrow button is used to move
down through the menus or to decrease a
selected value.

5-1
CONSOLE PROGRAMMING

Insert Password Program Password

• Press the ENTER button to access *** Programming of a password is only possible
Main Menus. by first inserting the Master Password.
• Use the UP/DOWN buttons to scroll to *** Five different operator passwords composed
Insert Password. of six digits are available.
• Press the ENTER button to begin • Access the display menus by pressing the
inserting the Master Password. ENTER button.
• Press the UP/DOWN buttons to • Use the UP/DOWN buttons to scroll
change the selected value of each character. to program password, then press ENTER
• Press the ENTER button to confirm the button.
selected value and move the cursor to the • Use the UP/DOWN buttons to
next value. choose passwords one through five.
• Press the ENTER at completion of • Press the UP/DOWN buttons to
entering Master Password. change selected value of each character.
*** Screen will indicate one of two conditions. • Press the ENTER button to confirm and
“Correct Password” if password is good. move the cursor to the next character.
“Incorrect Password” if password is bad. • Press the ENTER button at completion
If password is incorrect, enter password again. of entering password.
If password is correct, press the X button to exit *** Screen will indicate one of two conditions.
the master password item and return to the “Correct Password” if password is good.
graphic display screen. You will now be able to “Incorrect Password” if password is bad.
access additional information at the console. If password is incorrect, enter password again
If password is correct, press the X button to exit
the program password menu item and return to
the graphic display screen.

5-2
CONSOLE PROGRAMMING

Parameters
Press the ENTER button to access the
display menu.
Use the UP/DOWN buttons to scroll
through Parameter menu items.

Parameter 1
• Lift Speed Maximum lift speed selection
• Lower Speed Maximum lowering speed
• Reach Out Speed Reach out maximum speed selection
• Retract Speed Reach in maximum speed
• Tilt Speed Maximum Tilt forward/backward speed.
• Side Shift Speed Side shift left/right maximum speed.
Parameter 2
• Traction Acceleration Traction acceleration time.
• Max Speed Forward Traction maximum speed in forward direction (forks leading)
• Max Speed Backward Traction maximum speed in backward direction (forks trailing)
• Coast Distance Braking time while releasing the pedal completely.
• Inverse Braking Braking time while changing traction direction.
• Lift Acceleration Lifting acceleration time.
Parameter 3
• Steer Sensitivity Steering sensitivity.
• Lift Cut Out Option that enables lifting block with battery low.
• High Lift Limit 1 Traction speed reduction #1.
• High Lift Limit 2 Traction speed reduction #2.

• Press the ENTER button to access • Press the ENTER button to access
Parameter items. Tester Master menu.
• Use the UP/DOWN buttons to • Use UP/DOWN buttons to scroll
change the parameter values. through tester 1 menu items.
• Press the ENTER button to save the • Press the X button to exit Tester 1 menu
new value. Value is performance dependent. items and return to the graphic display
• Press the X button to exit parameter menu screen or press ENTER to access Tester 2
items and return the the graphic display menu.
screen. • Push the X button to exit the tester menu
item and return to the graphic display.
Tester Master (Diagnostics)
• Press the ENTER button to access the Tester Slave
display menu. • Press ENTER button to access the
• Use the UP/DOWN buttons to locate display menu.
Tester Master. • Use the UP/DOWN buttons to locate
Tester Slave menu

5-3
CONSOLE PROGRAMMING

• Press ENTER button to access the If you used the service or master password to
Tester Slave menu. access the alarm, you will see a message on the
• Use the UP/DOWN buttons to go display screen:
between the six different tester positions and CLEAR ALARMS?
tester item menus. • Press the ENTER to clear the complete
To Access AutoTeaching (Option) logbook or press the X button to exit without
saving and return to the graphic display.
AutoTeaching enables the programming of the
heights of the pre-height selector. To access Lift Limit (option)
• Push ENTER button to access the Enables the programming of the lift block height.
display menu. • Press the ENTER button to access the
• Use the UP/DOWN buttons to locate display menu.
Autoteaching. • Use the UP/DOWN buttons to scroll
• Press the ENTER button to access the to the lift limit in menu.
AutoTeaching menu. • Press the ENTER button to access lift
• Change the Level Number using the limit menu.
UP/DOWN buttons. • Press the ENTER button to save the
• Change the Height Value using the encoder value in HEIGHT VALUE (block
ENTER button. height).

• Change the Encoder Value by lifting/lowering • ENCODER VALUE - lift/lower until the
until the desired height is reached. desired height.

• Press the X button to exit the Autoteaching • Press the X button to exit the lift limit menu
menu item and return to the graphic display. item return to the graphic display.

To Access Alarms To Access Adjust Time and Date

• Push ENTER button to access the • Press ENTER button to access the
display menu. display menu.

• Use the UP/DOWN buttons to scroll • Use the UP/DOWN buttons to scroll
to alarms. Then press the ENTER button. to the adjust time and date in menu.

*** Note: Sicos can save up to 16 different • Press the ENTER button to access the
alarms. Use the UP/DOWN buttons adjust time and date menu.
to scroll between the different alarms. A • Press the UP button to move the cursor.
number will appear and change in the upper • Press the DOWN button to change the
right corner of display as you press as you value.
scroll between the different alarms.
• Press the ENTER to save. The word
“Memo” will be displayed on the time and
The following information will be displayed: date screen.
CODE = alarm code and alarm description • Press the X button to exit the adjust time and
NODE = module in alarm date menu item and return to the graphic
display.
DATEV = date at the moment of the alarm
TIME = time at the moment of the alarm
HOURS = truck hours at the moment of the
alarm

5-4
SET UP AND OPTION INSTALLATION

6. SET UP AND OPTION INSTALLATION

Potentiometer Adjustment Overview .................................................................................... 6-1
Traction Speed & Direction Sensor Potentiometer R12 & Related Config Menu Items ...... 6-1
Lift/Lower Potentiometer R13 and Related Config Menu Items........................................... 6-1
Non - Adjustable Items ......................................................................................................... 6-1
Potentiometer Calibration Procedure ................................................................................... 6-1
Date and Time Settings ........................................................................................................ 6-2
Setting the Date and Time.................................................................................................... 6-3
Enabling the Maintenance Alarm.......................................................................................... 6-3
Setting Hours for the Maintenance Alarm ............................................................................ 6-4
Metric or English Values Displayed ...................................................................................... 6-4
Height Detection Overview ................................................................................................... 6-5
Height Detection Installation................................................................................................. 6-6
Height Display Activation ......................................................................................................6-10
Pre-Height Selector Activation..............................................................................................6-10
Operation Instructions for Pre-Selected Shelf Height Selector ............................................6-11
Lift Limit Cutout with Bypass ................................................................................................6-12
Load Weight Installation .......................................................................................................6-13
Weight Function Installation .................................................................................................6-13
Maximum Weight Setting......................................................................................................6-14
Minimum Load Adjustment ...................................................................................................6-14
Maximum Load Adjustment ..................................................................................................6-14
Cooler/Freezer Condition Option..........................................................................................6-14
Weight Function Installation .................................................................................................6-13
Maximum Weight Setting......................................................................................................6-14
Minimum Load Adjustment ...................................................................................................6-14
Maximum Load Adjustment ..................................................................................................6-14
Cooler/Freezer Condition Option..........................................................................................6-14
SET UP AND OPTION INSTALLATION

This section of the manual will give instructions Non Adjustable Items
regarding calibration of the traction and lift lower MIN POT. LOAD. Minimum Potentiometer
potentiometers, and to set up a vehicle that is Loaded
already functional. In the unlikely event that a (0.0V) Do not touch!!!!
controller has to be replaced refer to Section 5 to
obtain the information to program controllers. MAX POT. LOAD. Maximum Potentiometer
Loaded
Potentiometer Adjustment Overview: (5.0V) Do not touch!!!!
Whenever a potentiometer module R12 (Traction Potentiometer Calibration Procedure
Speed And Direction Sensor Potentiometer) or
R13 (Lift/Lower Potentiometer) has been When calibrating the “MIN” values the position of
changed, it is necessary to calibrate the control the handle should be so that there is a slight
system. The neutral position is preset but the tension on the spring. When properly adjusted,
minimum and maximum activation values must the handle will spring return to neutral, and a
be calibrated. request for a function should not occur. The
approximate value shown on the handset for a
The calibration will determine the amount of “MIN” calibrated potentiometer module should be
handle movement that is needed to occur prior to approximately 2.8 for one direction and
the SICOS/Display Unit recognizing a request for approximately 2.2 for the other.
a function, and to recognize at what point a full
speed request exists. When calibrating the “MAX” values the position
of the handle should be to the full range of
Traction Speed and Direction Sensor movement for the corresponding item selected.
Potentiometer R12 and Related Config Excessive force should not be applied to the
Menu Items handle! The approximate value shown on the
handset for a “MAX” calibrated potentiometer
MIN ACC TRAC BW is used to set the minimum
module should be approximately 4.4 for one
value that a request for forks trailing travel will
direction and approximately 0.6 for the other.
occur.
To calibrate the potentiometer module proceed
MAX ACC TRAC BW is used to set the value
as follows:
that a request for maximum travel speed in forks
trailing direction will occur. 1. Verify that the handle assembly has no
mechanical binding.
MIN ACC TRAC FW is used to set the minimum
value that a request for forks leading travel will 2. With the key switch off connect the handset
occur. to the SICOS/Display Unit.
MAX ACC TRAC is used to set the value that a 3. Turn the key on and using the handset select
request for maximum travel speed in forks the programming to gain access to the
leading direction will occur. adjustment menu for the Sicos/Display Unit.
Lift/Lower Potentiometer R13 and Related 4. Press ROLL up (1) and SET up (5) buttons at
Config Menu Items the same time to enter the Config menu.
MIN ACC LOW is used to set the minimum value 5. Press either ROLL up (1) (or ROLL down (2)
that a request for lowering will occur button) until the Config Menu Adjustment is
MAX ACC LOW is used to set the value that a visible.
request for maximum speed lowering will occur 6. Press the ENTER (3) button to access the
MIN ACC LIFT is used to set the minimum value adjustment menu.
that a request for lifting will occur 7. Using Up button (1) (ROLL buttons) and
MAX ACC LIFT is used to set the value that a scroll to select the menu item that you would
request for maximum speed lifting will occur like to program.

6-1
SET UP AND OPTION INSTALLATION

Example: MIN ACC LOW 2.5V (Minimum

Acceleration Lowering)
8. Press the ENTER (3) button
Example: MIN ACC LOW 2.5V (Voltage will
start to move when control is moved) Lower
function is disabled. Note: While in the
adjustment menu the voltage values are
visible.
9. Move and hold the control handle to the
menu item that you are programming. When
desired voltage setting is achieved press
OUT (4) on the handset, then press the
ENTER (3) button to confirm.
10. Test for correct operation of lift and travel
after calibration is completed.
11. IMPORTANT! Repeat the steps for each
menu item related to the device being
calibrated.
Date And Time Settings:
To adjust the way that the date and time are
presented on the display you need to use the
handset and program accordingly.

DATE FORMAT allows the user to display the order of the month and date being displayed:

OFF = day/month /year

ON = month/day/year

CLOCK FORMAT enables the selection of a 24 hours clock or an AM/PM clock:

Parameter name CLOCK FORMAT

Parameter location SICOS // CONFIG MENU / SET OPTIONS
Available values OFF,ON

OFF = 24hours
ON = AM/PM

6-2
SET UP AND OPTION INSTALLATION

Setting The Date And Time:

To set the date and time requires using the
vehicle console and the proper password
entered into it.
Scroll to Main Menu 2 and enter ADJ TIME &
DATE
Press ENTER to access the menu, OUT(X)
to exit
adj time & date press “UP” to move the cursor,
press DOWN to change the value, ENTER to
save
Actual Date=
Actual Clock=
Enabling The Maintenance Alarm:
The vehicle has the capability of monitoring the
hours that the vehicle has been running and
trigger visual, and or speed reduction to occur
after a programmed time. The number of hours is
programmable between 0 and 800.

To enable the alarm, you need to use the handset and program accordingly.

Parameter name CHECK UP TIME

Parameter location SICOS // CONFIG MENU / SET OPTIONS
Available values 0,1,2,3

Select the status of the CHECKUP value.

0 = no check up (alarm is disabled)
1 = alarm CHECK UP NEEDED after programmed time
2 = alarm CHECK UP NEEDED after programmed time speed reduction
after an additional 40hours
3 = alarm CHECK UP NEEDED after programmed time+ speed reduction

6-3
SET UP AND OPTION INSTALLATION

Setting Hours For The Maintenance

Alarm:
To set the number of hours for the planned
maintenance alarm to occur requires using the
vehicle console and the proper password
entered into it.
Scroll to Main Menu 3 and enter CHECK UP
TIME
Press ENTER to access the menu, OUT(X)
to exit.
Check Up Setting
SET TIME =
ACTUAL TIME =
ACTUAL TIME is the hour counter at the
moment of the last check-up
SET TIME gives the hours between two
check-up, range is from 0 to 800 hours.
Press UP/DOWN to change the check-up
maximum time. Press ENTER to save
Metric Or English Values Displayed
When the vehicle is equipped with the optional
weight and or height selector, it is possible to
display the information in either kg/lbs or in/mm.
To select how the value is displayed, you need to
use the handset and program accordingly.

Parameter name MEASURE SYS. TYPE

Parameter location SICOS // CONFIG MENU / SET OPTIONS
Available values OPTION#1,OPTION#2

OPTION #1 = Weight is displayed in kilograms; height is displayed in millimeters.

OPTION #2 = Weight is displayed in pounds; height is displayed in inches

6-4
SET UP AND OPTION INSTALLATION

Height Detection Overview

The vehicle is capable of having an option
installed that will enable it to calculate the vehicle
fork height once the vehicle is out of the free lift
stage. The vehicle is also capable of having
programmed shelf height selections that will
automatically position the height of the forks to
either store or retrieve a load. It is able to
accomplish this using the MHYRIO Controller, a
switch (S43), an encoder (B41) and cable, and
associated brackets.
The switch (S43) is mounted near the top of the
mast assembly; it is a proximity style switch that
is activated by a bracket that is mounted to the
vehicle telescopic. As the vehicle is elevated
above the free lift stage, the bracket will move up
and away from the free lift reference switch S43.
Once the switch S43 has been transitioned the
controller is able to establish a height reference
point. As the vehicle telescopic is raised or
lowered the cable attached to the encoder
assembly will cause the assembly to rotate and
the encoder pulse count will be converted to a
height value.

6-5
SET UP AND OPTION INSTALLATION

Height Detection Installation

Sensor

Bracket
RL472017

Bracket
RL472021

• Install bracket RL472017 to the mast, with M10x20 DIN 912 bolts, torque is 45 Nm
• Install bracket RL472021to the mast, with M10x20 DIN 912 bolts, torque is 45 Nm
• Install free lift sensor to the bracket RL472017
• Adjust clearance between sensor and bracket RL472021. Clearance should be 5 mm
• Connect XS43 and X46 together

6-6
SET UP AND OPTION INSTALLATION

Clearance ~ 5mm (3/16) M10x20 DIN 912,

torque 45 Nm

6-7
SET UP AND OPTION INSTALLATION

• Install encoder to the bracket RL472023

• Install bracket and encoder to the mast
• Install spring to the other end of the cable with wire lock
• Install M6 x 60 DIN 444 –bolt to the spring
• Install M6 x 60 DIN 444 –bolt to the cable end with wire lock
• Install cable around the encoder wheel
• Install cable to the mast. Spring to the top.
• Secure M6 x 60 DIN 444 –bolts with M6 DIN 985 nuts

Bolt type Torque [Nm] Quantity [pcs]

M8 x 20, DIN 912 25 2
M6 x 60, DIN 444 - 2
Nut M6, DI 985 10 2

6-8
SET UP AND OPTION INSTALLATION

Bracket
RL472023

Install spring and

cable to this hook Use existing bolts
to install bracket
on the mast

Once the associated hardware has been installed, several settings using the handset and the console
keypad are required to properly install the option.

6-9
SET UP AND OPTION INSTALLATION

Height display
To activate the height display, pulse encoder B41
must be assembled to the mast and connected
to the wire harness (connector XB41).
Handset operation is required.

Parameter name HEIGHT DISPLAY

Parameter location SICOS // CONFIG MENU / SET OPTIONS
Available values OFF and ON

Select the status of the height display:

OFF = no height is shown on the display (default)
ON = encoder height is shown on the display

Pre-height selector
To activate the pre-height selector, pulse encoder
B41 must be assembled to the mast and
connected to the wire harness (connector XB41).
Handset operation is required

Parameter name PRE-HEIGHT SEL

Parameter location SICOS // CONFIG MENU / SET OPTIONS
Available values OFF and ON

Select the status of pre-height selector:

OFF = no pre-height selector function (default)
ON = pre-height selector function enabled
From console, you need to program the height
indicator as follows:
Using the console keypad enter the password
and select Main Menu 2,( PROGRAM OFFSET)
to indicate at what height the forks are when the
switch (S43) is activated. Once the program
offset is set, the encoder (B41) pulses will be
used to calculate the actual vehicle fork height.
B41 is the pulse encoder used to help calculate
the vehicle fork height.

PROGRAM OFFSET press ENTER to access the menu, OUT to EXIT

OFFSET VALUE = change it with UP/DOWN; offset value will be added to encoder
value to display the correct height

6-10
SET UP AND OPTION INSTALLATION

Once the above hardware is installed and the • Operator is ready to raise the forks to the
program offset has been performed, it is now pre-selected shelf height.
possible to program the various shelf heights. • Pull the control handle to the right, raising the
To Access AutoTeaching (option) load until it stops at the pre-selected shelf
AutoTeaching enables the programming of the height. As the load is being raised, the height
heights of the pre-height selector. of the forks will be displayed in the center of
the operator display
• Push ENTER button to access the
display menu. • Once the procedure is completed, release
the control handle to the neutral position. The
• Use the UP/DOWN buttons to locate highlighted diamond shown in the shelf
Autoteaching. height select will disappear and the
• Press the ENTER button to access the information in the center of the operator
AutoTeaching menu. display will revert back to state of battery
• Change the Level Number using the charge.
UP/DOWN buttons.
Note
• Change the Height Value using the ENTER
Shelf Height Selector also works when lowering
button.
the forks.
• Change the Encoder Value by lifting/lowering
With the key switch in the on position and the
until the desired height is reached.
display lit:
• Press the X button to exit the autoteaching • Press X to enter 01 in the shelf height
menu item and return to the graphic display. section of the display will be highlighted.
Operating Instructions for Pre-Selected • Use the up/down buttons to select the
Shelf Height Selector number designated for the preset shelf
The reach truck operator has the ability to height.
choose fifty pre-selected shelf heights. • If loading choose Deposit Load, hit Enter.
The operator cannot change the settings of the Highlighted diamond will appear to the right
shelf heights – only use them. of the shelf height selected.
An authorized dealer or trained factory technician • If unloading, choose Retrieve Load, hit
using a handset and display can only program Enter. Highlighted diamond will appear to the
shelf height settings. right of the shelf height selected.
With the key switch in the on position and the • Operator is ready to lower the forks to the
display lit: pre-selected shelf height.
• Press X to enter 01 in the shelf height • Push the control handle to the left, lowering
section of the display will be highlighted. the load until it stops at the pre-selected shelf
height. As the load is being lowered, the
• Use the up/down buttons to select the height of the forks will be displayed in the
number designated for the preset shelf center of the operator display
height.
• Once the procedure is completed, release
• If loading, choose Deposit Load, hit Enter. the control handle to the neutral position. The
Highlighted diamond will appear to the right highlighted diamond shown in the shelf
of the shelf height selected. height select will disappear and the
• If unloading, choose Retrieve Load, hit information in the center of the operator
Enter. Highlighted diamond will appear to the display will revert back to state of battery
right of the shelf height selected. charge.

6-11
SET UP AND OPTION INSTALLATION

Lift Limit Cutout with Bypass

To activate the lift limit cutout, pulse encoder B41
must be assembled to the mast and connected
to the wire harness (connector XB41).
Lift limit cutout is activated through SICOS-
display and buttons.

Parameter name ENCODER VALUE

Parameter location SICOS / MAIN MENU 1 / LIFT LIMIT

1. Press ENTER to access LIFT LIMIT menu.

2. Select ENCODER VALUE.
3. Move forks to the desired cutoff height.

Parameter name HEIGHT VALUE

Parameter location SICOS / MAIN MENU 1 / LIFT LIMIT

1. Press ENTER to save ENCODER VALUE into

HEIGHT VALUE (= cutoff height).
2. Press OUT to exit the menu.
3. Test the function of lift limit cutoff and bypass:
• Lift forks until they stop at the desired height.
• Press blue bypass button on the panel.
• Continue lifting.

6-12
SET UP AND OPTION INSTALLATION

Load Weight Installation

AS — port

Bolt type Torque [Nm] Quantity [pcs]

M6 x 25, DIN 912 10 1

Weight Function
To activate the weight function, pressure sensor B42 must be assembled to the hydraulic system and
connected to the wire harness (connector XB42).
Handset operation is required.

Parameter name AUX VOLTAGE #1

Parameter location SICOS // CONFIG MENU / SET OPTIONS
Available values OFF and ON

Select the status of the weight function

OFF = no weight function (default)
ON = weight function enabled

6-13
SET UP AND OPTION INSTALLATION

Maximum Weight Setting

Handset operation is required.

Parameter name MAXIMUM WEIGHT

Parameter location SICOS // MAIN MENU / PARAMETER CHANGE
Available values 0, 1, 2, 3, 4, 5, 6 and 7

Select the nominal capacity of the truck:

0 = 1200 lbs. (default)
1 = 600 lbs.
2 = 2000 lbs.
3 = 2500 lbs.
4 = 3000 lbs.
5 = 3500 lbs.
6 = 4000 lbs.
7 = 4500 lbs.
Minimum Load Adjustment
Handset operation is required.

Parameter name MIN POT LOAD

Parameter location SICOS // CONFIG MENU / ADJUSTMENTS

Set the maximum weight:

1. Lift empty forks above the ground.
2. Press [out], then [enter] on the handset.

Maximum Load Adjustment

Handset operation is required.

Parameter name MAX POT LOAD

Parameter location SICOS // CONFIG MENU / ADJUSTMENTS

Set the maximum weight:

1. Place maximum rated load on the forks.
2. Lift forks above the ground.
3. Press [out], then [enter] on the handset.

6-14
SET UP AND OPTION INSTALLATION

Lift Cutback Lift speed reduction before reaching the programmed height
Low Cutback Lowering speed reduction before reaching the programmed height
Adjustment #01 Height at which, when lifting, starts the lift speed reduction
Adjustment #02 Height at which, when lowering, starts the lowering speed reduction
Adjustment #03 Distance between the stop height level and the level at which you have to lift to
retrieve the load
Adjustment #04 Distance between the stop height level and the level at which you have to lower
to deposit the load

6-15
SET UP AND OPTION INSTALLATION
COLD STORAGE OPTION

7. Tie cold storage wire harness to existing

wire harness with 10 cable ties.
Connect 9F1:D to fusebox
Connect X2:- to insulation support
Disconnect X12:3 from key switch
3. Uninstall panels
Connect XS2.1:44.2 to key switch
31. Install panels
Connect XS2.1:44.1 to X12:3
1. Disconnect
battery
Insulation
33. Connect
support
battery

6. Uninstall
display
29. Install
display, torque
10 Nm

5. Uninstall pedal
28. Install peda l, torque
2. Open doors or
25 Nm
uninstall sideplates
32. Install sideplates

4. Uninstall floor plate

30. Install floor plate

15. Connect wires, 13. Connect wires,

connectors S342 connectors X345

12. Install
thermostat 9. Connect wires,
with 2 connectors X343
screws 11. Install 56
R resistor
with 2 screws 8. Install resistor M3x6 DIN 7985
120 R with 2 Torque 1 Nm
M3x6 DIN 7985 10. Install 120 R screws
Torque 1 Nm resistor with 2
screws 14. Connect wires,
connectors X342

6-16
SET UP AND OPTION INSTALLATION

17. Install seals to buttons

16. Loose nuts from

buttons
18. Tighten nuts

M3 x 8 DIN 7985 Bolts

and M3 DIN 985 Nuts,
torgue 1 Nm

20. Install thermostat

to plate with 2 screws
23. Connect wires,
and 2 nuts
connectors XS345

19. Loose nut from

AC-2 controller
21. Install plate on
controller
22. Tighten nut,
torque 6 Nm

6-17
SET UP AND OPTION INSTALLATION

M3x35 DIN 7985 bolts and

M3 DIN 985 nuts, torque 1
Nm

24. Install resistor

120 R to plate with
2 x M3x6 DIN
7985, torque 1 Nm

25. Uninstall micro switches.

27. Connect wires, 26. Install micro switches
connectors X344 and resistor plate with 2
screws and 2 nuts

• Class II – Change gearbox oil to SAE 75W/90

• Recommendation on class I – Hydraulic oil ISO VG 32
• Recommendation on class II – Hydraulic oil ISO VG 15

6-18
MAST

7. MAST
Installation Instructions ......................................................................................................... 7-1
How the Truck is Shipped .................................................................................................... 7-1
Uprighting a Cradled Truck................................................................................................... 7-1
Option 1: Uprighting with Two Chain Hoists......................................................................... 7-1
Option 2: Uprighting with One Chain Hoist and a Lift Truck ................................................ 7-2
Mast Mounting Bolts and Torque Specifications .................................................................. 7-3
Overhead Guard Mounting Bolts and Torque Specifications ............................................... 7-4
Jacking Truck........................................................................................................................ 7-5
Load Wheel Replacement Procedure for 4", 5" and 6" Diameter Wheels ........................... 7-5
Caster Adjustment ................................................................................................................ 7-8
Brake Assembly Inspection and Adjustment ........................................................................ 7-9
Installation Instructions .........................................................................................................7-10
Truck System Requirements ................................................................................................7-10
Mast Inspection ....................................................................................................................7-10
Chain Lubrication..................................................................................................................7-10
Upright and Carriage Position - Chain Tension ....................................................................7-10
Channel Lubrication..............................................................................................................7-10
Mast Skewing .......................................................................................................................7-10
Periodic Maintenance ...........................................................................................................7-11
Inspection .............................................................................................................................7-11
500 Hour Inspection .............................................................................................................7-11
Troubleshooting ....................................................................................................................7-12
Cylinders...............................................................................................................................7-14
Main Lift Cylinder..................................................................................................................7-14
Free Lift Cylinder ..................................................................................................................7-15
Cylinder Operation................................................................................................................7-16
Main Lift Cylinder Service.....................................................................................................7-17
Free Lift Cylinder Service .....................................................................................................7-19
Mast Uprights ......................................................................................................................7-21
Upright Description ...............................................................................................................7-21
Upright Chain Inspection ......................................................................................................7-22
Cracked Plates ....................................................................................................................7-23
Ultimate Strength Failure......................................................................................................7-23
Tight Joints ...........................................................................................................................7-23
Chain Length Adjustment .....................................................................................................7-24
Periodic Inspection - Triple-Stage Upright (TSU) Chain Length Adjustments......................7-25
Periodic Inspection - Chain Lubrication................................................................................7-27
Chain Removal and Replacement........................................................................................7-28
Lift Bracket............................................................................................................................7-29
Periodic Inspection Upright & Lift Bracket Removal & Replace Roller Shim Adjustments ..7-29
Lift Bracket Removal Preparation.........................................................................................7-29
Upright & Lift Bracket Removal ............................................................................................7-30
Upright Removal...................................................................................................................7-34
Upright Disassembly.............................................................................................................7-36
Shimming .............................................................................................................................7-42
Fork Removal .......................................................................................................................7-61
Lift Bracket Service ..............................................................................................................7-62
Fork Carriage Removal - Side Shift Only .............................................................................7-62
Fork Carriage Removal - Tilt Only........................................................................................7-63
Servicing Lift Bracket Arm Rollers Thrust Pads (Scissor Arm Roller "B" & "C" ...................7-64
Tilt Cylinder Overhaul - Cylinder Removal ...........................................................................7-66
ITA Lift Bracket with Side Shifter ..........................................................................................7-67
ITA Lift Bracket without Side Shifter .....................................................................................7-68
Cylinder Removal .................................................................................................................7-69
Preparation, Cleaning and Inspection ..................................................................................7-69
Disassembly .........................................................................................................................7-70
Retainer Assembly................................................................................................................7-70
Piston Rod and Piston..........................................................................................................7-70
Cleaning and Inspection .......................................................................................................7-71
Reassembly ..........................................................................................................................7-71
Reach Cylinder Overhaul .....................................................................................................7-72
Cylinder Removal .................................................................................................................7-72
Preparation, Cleaning and Inspection ..................................................................................7-74
Disassembly .........................................................................................................................7-75
Retainer Assembly................................................................................................................7-75
Piston Rod and Piston..........................................................................................................7-75
Cleaning and Inspection .......................................................................................................7-76
Reassembly ..........................................................................................................................7-76
Retainer Assembly................................................................................................................7-76
Side Shift Cylinder Overhaul ................................................................................................7-78
Cylinder Removal .................................................................................................................7-78
Preparation, Cleaning and Inspection ..................................................................................7-79
Disassembly .........................................................................................................................7-79
Retainer Assembly................................................................................................................7-79
Cleaning and Inspection .......................................................................................................7-81
Reassembly ..........................................................................................................................7-81
Reach and Side Shift Selector Valve ...................................................................................7-82
Reach and Tilt Selector Valve ..............................................................................................7-86
Mounting Selector Valve.......................................................................................................7-88
Side Shifter Solenoid Control Valve .....................................................................................7-89
Servicing a Double Reach Bracket ......................................................................................7-93
MAST

INSTALLATION • There should be no distractions during setup

of this truck.
How the Truck is Shipped
• Do not allow observers to stand nearby.
Before doing the inspection, take note of how the
truck was prepared for shipping from the factory: Items Needed
• The Mast/Tractor Assembly is laid down on a To upright the truck, you will need:
skid (this is known as cradling). Usually if the • A hoist with a minimum working capacity of 5
Overall Lowered Height (OAL) is 107 in. tons (4536 kg).
(2717.8 mm) or more, the truck will be
• An assembly area with a ceiling clearance in
secured to a cradle and shipped lying down
excess of the truck’s collapsed height.
(with its mast horizontal). Instructions for
uncradling a truck are detailed in “Uprighting • A hoist sling for the mast.
a Cradled Truck” on page 7-1. Option 1:Uprighting with Two Chain
• The carriage is strapped to the truck’s Hoists
baselegs (for cradled trucks).
Use this procedure when two chain hoists of
In the battery compartment. suitable weight capacities are available.
• A glass mast guard is installed (if used). 1. Before lifting the truck into the upright
• Two battery doors are strapped in place. position, remove the forks from the cradle.
Use a lifting device to prevent personal injury
Uprighting a Cradled Truck because the forks weigh more than 50 lbs.
This section includes instructions for uprighting a (23 kg) each.
cradled truck. Generally, when the OAL (Overall 2. Position the cradled truck so it is lying
Lowered Height) of a truck is 107 in. (2717.8 directly beneath and parallel to the chain
mm) or higher, it will be secured to a cradle and hoist rail.
shipped lying down (with the mast horizontal).
3. Attach the first chain hoist to the upper cross
Warnings and Cautions piece of the cradled truck’s mast.
Be sure to follow these important warnings and 4. Attach the second chain hoist to the
cautions before uprighting a cradled truck: baselegs of the cradled truck.
CAUTION ! 5. Slowly raise each chain until all slack is gone.
Two technicians are required for erecting and
assembling the unit.
! WARNING
CAUTION !
Remove all jewelry from hands and wrists before While performing the next step, be sure that the
doing the installation. chain on the baselegs does not lift the cradle off
WARNING! the floor. Also, be sure not to let it become slack
To prevent possible injury or damage to the unit, as this will allow the truck to lower too quickly.
use extreme caution when handling a cradled lift
truck. Place the mast, truck, and pallets in an
open area where it will be safe to work. The 6. Begin lifting the chain attached to the upper
truck components are heavy, unstable, and cross piece of the cradled truck’s mast.
difficult to handle. Use extreme care when lifting
and assembling this truck. Proceed with extreme 7. Once the lifting chain reaches a certain
caution. point, the center of gravity will shift, causing
the weight of the cradled truck to shift to the
• Anyone involved in setting up this unit should chain hoist attached to the baselegs.
wear gloves, safety glasses, steel-toed
boots, and a safety helmet.

7-1
MAST

8. Once the weight has shifted, continue to

! WARNING
lower the truck with the baseleg chain hoist
until it is standing on the floor in the upright While performing the next step, be sure that
position. the chain on the baselegs does not lift the
9. Remove the chains from the base legs. cradle off the floor. Also, be sure not to let it
become slack as this will allow the truck to
10. Remove the chain from the upper cross
lower too quickly.
piece of the truck’s mast and attach it to the
upper cross piece of the cradle.
11. Remove the bolts from the bottom cradle 6. Begin to raise the upper end of the cradle
cross piece that secures the cradle to the with the forks of the lifting truck.
truck’s front bumper. 7. Once the forks have lifted the cradle to a
12. Lift the cradle up and away from the truck certain point, the center of gravity will shift.
and slowly lower it to the floor. This causes the weight of the cradled truck
to shift to the chain hoist.
Option 2:Uprighting with One Chain Hoist
8. Once the weight has shifted, continue to
and a Lift Truck
lower the truck with the chain hoist until the
Use this procedure when one chain hoist is truck is standing on the floor in the upright
available. This procedure uses a lift truck and a position.
chain hoist, both of suitable weight capacity.
9. Remove the chain between the lifting truck
1. Before lifting the truck into the upright carriage and the upper cross piece of the
position, remove the forks from the cradle. cradle. Back the lifting truck away.
Use a lifting device to prevent personal injury
10. Remove the chain from the baselegs and
because the forks weigh more than 50 lbs.
attach it to the upper cross piece of the
(23 kg) each.
cradle.
2. Position the cradled truck so it is lying
11. Loosen and remove the nuts holding the
directly beneath and parallel to the chain
wooden cradle cross piece to the mast, then
hoist rail.
remove the wooden cross piece.
3. Position the forks of the lift truck you’re using
12. With the chain still attached to the cradle, lift
to upright the truck under the upper cross
the cradle up and away from the truck and
piece of the cradle.
slowly lower it to the floor.

! WARNING
Once the forks are positioned under the
cradle, attach a safety chain between the fork
carriage of the lifting truck and the upper
cross piece of the cradle. This prevents the
cradle from slipping off the forks during the
uprighting procedure.

4. Attach the chain hoist to the baselegs of the

cradled truck.
5. Slowly raise the chain hoist until all slack is
gone.

7-2
MAST

Mast Mounting Bolts and Torque Specifications

Figure 1.8

Mast is mounted with M16 bolts from top and with M20 bolts from below. The M16 bolts are assembled
from the mast side and the M20 bolts are assembled from the chassis side.

Bolt type Torque [Nm] Quantity [pcs]

M16 x 45 DIN 912 8.8 200(147.5122ft lbs.) 4 Mast from the top
Washer 16 DIN 127 - 4 Mast from the top
M20 x 40 DIN 933 8.8 400(295.02 ft. lbs.) 4 Mast from below
Washer 20 DIN 127 - 4 Mast from below

7-3
MAST

Overhead Guard Mounting Bolts and Torque Specifications

Figure 1.9

Bolt type Torque [Nm] Quantity [pcs]

M20 x 40 DIN 933 10.9 400 (292.0244 ft. lbs.) 4
Washer, Lock 20 - 4

Only jack in this

area no more than
2 in. (50.8 mm) off
the floor

Only jack this area no more than

0.5 in. (13 mm) off floor.

7-4
MAST

Jacking Truck 2. Carefully remove the sideplates and tandem

Anytime the truck is jacked up for any reason, wheels.
the service technician should take extra time and 3. Using a driver, remove 2 of the spring pins
caution to ensure that the truck will not tip over from one side of the tandem joints, and
or otherwise pose a hazard to himself or others. remove it from the shafts.
The following diagram illustrates the correct 4. Slide the plate, and two washers off from the
jacking points on the truck frame. Whenever the shafts.
truck is jacked up, there should not be any load 5. Remove the load wheel.
on the forks. The forks should be lowered all the
way to the lowest possible point. Disconnect the Installation:
battery and remove the key. Always use solid 1. Check to make sure there is one washer on
blocks to support the vehicle. Never rely on jacks each shaft prior to installing the replacement
or chains to hold the vehicle. When the truck is load wheels. Install replacement load wheels
jacked up at the chassis-end of the vehicle, it onto the shafts.
should not be lifted more than two inches (50.8
2. Insert one more washer on each shaft.
mm) off the floor. When jacking on the side of
the truck, the load wheels should not be lifted off 3. Slide the plate and joint onto the shafts.
the floor more than one-half inch (13 mm). 4. Insert the 2 spring pins.
5. Slide the wheel plate mounting bolts through
! WARNING one side of the plates, and insert them into
the baseleg assemblies.
Attach a chain to the top of the mast and an
overhead hoist to stabilize the mast if 6. Carefully slide the tandem wheels and the
jacking higher than described in this other plate into position.
procedure. 7. For closed front style vehicles, install the
front bolt loosely then on both types,. torque
the sideplate mounting bolts to 550
! WARNING [Nm}(405.66 ft.lbs.). If equipped, tighten the
front bolt to 80[Nm] (59 ft. Lbs.)
Before jacking truck, check the caster
assembly. It should be securely in place.
Make sure that the caster travel limiting
bolts are properly adjusted.
Tandem Wheels

Load wheel replacement procedure for 4”,5”

Sideplate
and 6” Diameter Wheels (See figures that
follow):
Jack the vehicle up.
Removal:
1. Remove the M20 wheel plate mounting
bolts, on closed (Straddle) front style wheel
plates, remove the M12 bolt in front as well.
M20
Mounting
Bolts

Figure 1.11

Open Front Load Wheel Plates

7-5
MAST

Removal:
1. Remove the M20 wheel plate mounting
bolts.
2. Carefully remove the sideplates and wheel.
Installation:
1. Slide the wheel plate mounting bolts through
one side of the plates, and insert them into
M12 Front Bolt the baseleg assemblies.
2. Carefully slide the wheel and the other plate
into position.
M20
Mounting
Bolts
3. Torque the sideplate mounting bolts to 550
[Nm}(405.66 ft.lbs.).

Figure 1.12
Closed (Straddle) Front Load Wheel Plates

M20
Washer Mounting
Bolts

Seal
Spring pin

Shaft

Bearing
Ring
Retainer
Screw

10.5” Diameter Wheel Assembly

Joint
Plate

Figure 1.13
Tandem wheel assembly

Load Wheel Replacement Procedure for 10.5”

Diameter Wheels (See figures xyz):
Jack the vehicle up

7-6
MAST

Contents
This section of the manual provides the
installation Instructions, periodic maintenance
requirements, troubleshooting and service
procedures for the mast.
The masts provide excellent visibility for the lift
truck driver. The mast carriage and upright
channels are all roller-mounted which provides
smooth operation and long service life.
In any communication about the mast, refer to
the mast serial number stamped in the
nameplate. If the nameplate is missing, these
numbers are also stamped on the left-hand lower
outer rail.

7-7
MAST

Caster Adjustment 1. Caster wheel load setting

Adjustment can be done by hook wrench with
NOTE
nose end DIN 1810 A (size 58-62). Rocla item
Caster height adjustment differs, depending number is RL472467.
upon the mast on the truck. Refer to the
following for caster height adjustment
instructions. All adjustments should be done with
the rated capacity battery installed and on a
level surface.

! CAUTION

Use extreme care whenever the truck is

jacked up for any reason. Never block
the truck between the telescopic and the
floor. Use a suitable hoist to stabilize the
mast. Keep hands and feet clear from • More load to caster wheel - turn adjustment
beneath vehicle while jacking. Use jack nut to + direction
stands or solid blocks to support truck • Less load to caster wheel - turn adjustment
do not rely on jacks. Refer to "Jacking nut to -- direction
Truck" in the mast section area.

Spring load setting

+ -- + --

7-8
MAST

Brake Assembly Inspection and

Adjustment
Inspections:
a.) Friction disc thickness:
1.) Measure the disc thickness E, (see
figure x)
2.) Minimum thickness is 8.0 mm (5/16
inch).
Figure x
3.) If necessary, replace the
friction disc. Friction Disk Min. Air Gap Torque Coil Resistance
b.) Air gap (see figure. y) brake 8.0mm 0.3-0.4mm 23.0 (Nm) 31.4 ohms
applied 5/16 inch (.012 -.016) inches 17 ft. lbs.
1.) Measure the air gap
between the armature plate and stator
using a feeler gauge
2.) Air gap should be 0.3-0.4mm (.012-.016
inch).
Adjustment Of Air Gap (See Figure Y) Brake
Applied
1.) Unbolt screws (10)
2.) Slightly turn threaded sleeve (9).
• If the air gap is too large, screw them
into the stator (7).
• If the air gap is too small, screw them
out of the stator (7).
• 1/6 turn changes the air gap by
approx. 0.15 mm (.006 inch)
3.) Tighten screws (10) 23.0 (Nm) 17 ft. lbs.
4.) Check air gap again and if necessary,
repeat the adjustment.
Friction Disc Replacement
Figure y
1.) Loosen the screws (10) evenly and
remove them.
2.) Remove the stator (7) from the
endshield.
3.) Pull friction disc from hub.
4.) Check hub splining, if it is worn it
must be replaced.
5.) Install the new disc and adjust the
brake.

7-9
MAST

INSTALLATION INSTRUCTIONS Upright and Carriage Position, Chain

Tension cont.
Truck System Requirements
All chains should also be adjusted for equal
IMPORTANT: The mast is compatible with SAE tension of the pairs to ensure proper load
10W petroleum base oil per Mil. Spec. MIL-0- distribution and mast operation.
5606 or MIL-0-2104B only. Use of synthetic or
aqueous base hydraulic oil is not recommended. Chains are adjusted at the chain anchors (see
Figure 6). To determine equal tension, extend
Mast Inspection the unloaded mast to put the chains under
Check each of the following before using the tension. Then press the center of the strand with
Mast for the first time. your thumb. Then press at the same place on
the other chain of the pair. Each chain in a pair
1. Inspect all chains for lubrication. should have equal “give”.
2. Inspect all chains for any visible damage. If the uprights or carriage are not in correct
3. Inspect the main lift chain adjustment for adjustment, or if the chain pairs do not have
proper tension and upright position. equal tension, perform the Main Lift and Free Lift
4. Inspect the free lift chain adjustment for Chain Adjustments.
proper tension and carriage position. Channel Lubrication
5. Inspect for lubrication in the Mast upright Inspect the upright channels for lubrication. If
channels. necessary, lubricate the full length of each
6. Check for Mast skewing. upright channel with chassis lube or Kendall SR-
12X.
Chain Lubrication
Mast Skewing
The main and free lift chains have been factory
lubricated using heat and pressure to force the To adjust the Mast to eliminate skewing, perform
lubrication thoroughly into the chain links. Avoid the Mast Skewing Adjustment as described
removal or contamination of this factory-applied below.
lubrication. Do not wash, sand blast, etch, • Extend the mast to full lift height and inspect
steam clean, or paint the chains for initial for mast skewing.
Mast installation. If chains need lubrication,
• If the mast bends to the right at full
refer to Page 7-27 Periodic Insepction Chain
extension, a shim(s) needs to be removed
Lubrication.
from the left main lift cylinder rod.
Upright and Carriage Position, Chain • If the mast bends to the left at full extension,
Tension a shim(s)needs to be installed on the left
The main lift chains should be adjusted so that main lift cylinder rod.
when the unloaded Mast is fully lowered, the
uprights are flush at the bottom. The free lift
chains should be adjusted so that when the
unloaded Mast is fully lowered, the carriage is
properly positioned depending on the truck type.

7-10
MAST

PERIODIC MAINTENANCE CAUTION: The chains must be coated with a

film of lubricant at all times.
For proper operation and an extended service
lift, the Mast should be inspected and serviced 3. Lubricate the full length of each mast upright
regularly as part of your normal lift truck rail.
maintenance schedule according to the following 4. Measure load roller clearances in the
outlines and ANSI B56.1 procedures. The carriage/lift bracket and Mast uprights. Pry
recommended intervals are for Masts operating between the upright and load roller so that
under normal conditions. If operation is in severe the opposite load roller is tight against the
conditions or corrosive atmospheres, inspect the upright. Total side-to-side clearance should
Mast more frequently, be 0.020 in. (.5 mm) max. across the tightest
WARNING: Never work on a raised mast with a point throughout the travel of the upright. If
load without supports, or while anyone is near shimming is required.
the lift truck control handles per ANSI B56.1. 5. Check chains for wear and stretch.
Inspection 6. Check the backrest capscrews for tightness.
Tighten capscrews to 145 ft.-lbs. (195 Nm).
Perform the following at the beginning of each
work shift:
1. Check cylinder rods and retainer for obvious
damage, nicks, marring, scratches that might
damage the cylinder packings. Check the
condition of hydraulic plumbing and
connections. Tighten connections if loose.
2. Check lift chains for damage.
3. Check the chain anchor pins. Be sure the
cotter pins (6) are in place and not damaged.
4. Examine the hydraulic plumbing and
connections. Tighten loose connections.
5. Check harness hold-down clamps, brackets,
and connectors for security of mounting and
damage.
6. Inspect the lift chains. They must be coated
with a film of lubricant at all times.
500 Hour Inspection
After each 500 hours of lift truck operation, and
in addition to the Daily and 100 Hour
Inspections:
1. Clean and lubricate lift bracket assembly.
2. Inspect and lubricate the full length of the
chains with SAE 40 wt. oil or Bowman Heavy
Load Red Grease.

7-11
MAST

TROUBLESHOOTING
The following table lists hydraulic or mechanical problems that may be encountered on your
Mast, the probable causes, and the recommended corrective action that should be taken to
restore the Mast to normal operating condition.
PROBLEM PROBABLE CAUSE SOLUTION

Cylinders don’t lift load or

won’t move

Empty a) Plugged inlet hose a) Unplug hose or replace.

b) Insufficient oil. b) Check the truck hydraulic system
for correct oil level in tank, defective
pump or pump drive, leaks in the
lines or disconnect control valve linkage.
Repair or replace as necessary.
c) Bent or jammed plunger. c) Repair or replace as necessary.

Loaded a) Plugged piston check valve. a) Unplug check valve or replace.

b) Truck relief valve setting low. b) Raise truck relief setting to specified
level
c) Over capacity. c) Reduce load to specified capacity.
d) Mechanical bind due to d) Remove mechanical bind by
bent plunger or bad rollers replacing/freeing plunger and rollers.

! WARNING
Extreme care should be used when working on a unit when
the carriage (with or without a load) is in the raised position.

Cylinders drift a) External leak in pressure line. a) Tighten or replace as necessary.

b) Truck valve defective-cycle
to ful lift height to verify. b) Repair or replace truck valve.
c) External leaks at retainer. c) Replace all cylinder seals.
d) Piston check valve leaking. d) Replace check valve.
Spongy or jerky action a) Sticky or defective truck relief valve. a) Remove and check the truck relief valve.
If contaminated oil caused the
malfunc- tion, drain and flush the system,
change the filter and refill with fresh oil.
b) Bent or damaged cylinder plunger. b) Disassemble, check and repair cylinder
assembly.
c) Load rollers not properly adjusted or defective. c) Adjust or repair as necessary.
d) Mast channels improperly lubricated. d) Lubricate mast.
e) Low Battery charge. e) Charge battery.
f) Low pump volume. f) Install accumulator.
g) Low oil level. g) Fill oil reservoir.

! WARNING
Extreme care should be used when working on a unit when
the carriage (with or without a load) is in the raised position.

7-12
MAST

MAST REMOVAL
It is recommended that the lift bracket assembly
be removed before attempting to remove the
uprights. Start at Page 7-29.

7-13
MAST

CYLINDERS
Main Lift Cylinder
Description
The main lift cylinders (see Figure 9) are single
stage displacement type cylinders consisting of a
shell and a telescoping plunger/piston assembly.
During extension hydraulic pressure is acting
Retainer
against the plunger outer diameter due to the
internal porting through the piston. The piston
seals do not affect cylinder extension. The Retainer
vehicles hydraulic controls hold the cylinders in Seals
place once extension has stopped.
O-Ring
The shell is internally threaded at the top end to Wear Ring
hold the retainer. The retainer seals provide a high
pressure hydraulic seal against the plunger. The Back-Up
retainer also limits the upward stroke of the
O-Ring
plunger.
A piston is attached to the bottom end of the
plunger. The piston seal provides a high-pressure
hydraulic seal against the shell that engages the
cushion valve when the cylinder is fully lowered.
A hydraulic fuse/cushion valve is located in the left
hand cylinder’s inlet port. In case of a hose failure
between the lowering control valve and the Shell
cylinders, the fuse limits the lowering speed of the
Rod
cylinder. The valve also cushions the piston when
the cylinder nears the fully lowered position.

Spacer

Split Piston
Spring
Bleed Screw
Plug
Retainer

Washer
Ball
MA2213.eps

Figure 9. Main Lift Cylinders

7-14
MAST

Free Lift Cylinder

Description
The free lift cylinder (see Figure 10) is a single
stage piston type cylinder consisting of a shell
and plunger/piston assembly. During extension
Retainer
hydraulic pressure is acting against the fill piston
area. The vehicles hydraulic controls hold the
cylinder in place once extension has stopped. Retainer Seals
The shell is internally threaded at the top end to
hold the retainer. The retainer seals provide a O-Ring
high-pressure hydraulic seal against the plunger.
The retainer also limits the upward stroke of the
plunger. Back-Up
A piston is attached to the bottom end of the O-Ring
plunger. The piston seal provides a high-
pressure seal against the shell. A check valve Rod
located in the bottom of the piston allows
residual oil between the shell and plunger to Shell
escape when the cylinder is extending.
A hydraulic fuse/cushion valve is located in the
cylinder inlet port. In case of hose failure
between the lowering control valve and the
cylinder, the fuse limits the lowering speed of the
cylinder.
Set Screw
Nylon Plug

Back-Up
O-Ring
Ball
Seal W/O-Ring
Piston
Wear Ring
Retainer
Plug

MA2212.eps

Figure 10. Free Lift Cylinder.

7-15
MAST

Cylinder Operation Cylinder Lowering

Cylinder Raising 1. Actuating the truck hoist control valve to
lower the mast causes the main lift cylinder
1. As mentioned in theory section the pump plungers then free lift cylinder plunger to
motor controller will vary the volume on the lower, forcing hydraulic fluid out through the
fluid that is sent to the lift cylinders. The fluid hydraulic fuse/cushion valves.
that is entering the cylinders will flow
unrestricted through the lowering control Note: The restriction setting of each
cartridge. hydraulic fuse is lower (allows more flow)
than the setting of the lowering control valve.
2. Hydraulic fluid flows to the cylinder inlet The hydraulic fuses restrict flow only during
ports. Due to the larger bore diameter of the failure of a lowering control valve or hose.
free lift cylinder compared to both main lift
cylinders, the free lift cylinders raise first. 2. Hydraulic fluid flows to the lowering control
valve where it is restricted at a controlled
3. Hydraulic fluid flows through the free lift speed determined by the load being
cylinder hydraulic fuse/cushion valve to the handled.
bottom of the piston. Lifting force is created
against the bottom of the piston causing the 3. As the main lift cylinder pistons lower over
plunger to raise. Hydraulic fluid in the areas the spear in the bottom of the shell, a high
between the plunger and the shell is allowed pressure area is developed between the
to escape through the Check valve in the piston and the shell which engages the
piston as the plunger raises to the end of its cushion valve to restrict flow. This allows the
stroke. plunger/piston just prior to bottoming,
providing a smooth transition to free lift
4. Hydraulic fluid flows through the hydraulic cylinder lowering.
fuse/ cushion valve to the bottom of the
pistons as the free lift cylinder has fully
extended, lifting force is created against the
bottom of the main lift cylinder pistons
causing their plungers to raise. Hydraulic
fluid in the area between the plunger and the
shell is allowed to escape through the check
valve in the piston as the plunger raises.
5. When hydraulic fluid flow from the truck hoist
control valve is discontinued, the cylinders
are held in position by the closed center
spool of the truck valve.

7-16
MAST

Main Lift Cylinder Service

Main Lift Cylinder Disassembly
1. Wash the exterior surface of the cylinder
thoroughly before disassembling.
• A soft fiber brush should be used to
remove debris and foreign objects from
grooves and threaded areas, etc.
• A Stoddard type cleaning solvent should Retainer
be used to wash the cylinder.
2. Place retainer end of cylinder in a vise Retainer
equipped with soft jaws. Do not over tighten. Seals

3. Using a spanner wrench or a bronze (brass) O-Ring

drift, remove the retainer assembly from the Wear Ring
cylinder barrel.
• Remove back-up ring and o-ring from Back-Up
cylinder retainer.
O-Ring
• Remove rod wiper and seal from cylinder
retainer.
4. Pull piston rod from barrel assembly.
• Remove spacer and split piston from piston
rod.
5. Remove snap ring, retaining washer,
plunger, ball and spring from base end of
piston rod. Shell

Cleaning and Inspection Rod

1. Discard old seals, o-rings, back-up rings,

wiper and lock washer.
2. Wash remaining parts in a stoddard type
cleaning solvent and dry with a clean shop rag.
Spacer
3. Inspection threaded parts for damage.
4. Examine the piston rod, inner surfaces of the
retainer assembly and cylinder
barrel for scoring, nicks Split Piston
or scratches. A crocus Spring
Bleed Screw
cloth may be used to Plug
Retainer
clean up light scratches,
etc.. Be careful not to Washer
remove the chrome Ball
plating when MA2213.eps
polishing surfaces.

Figure 12

7-17
MAST

Main Lift Cylinder Reassembly Note

Piston Rod and Piston Placing a plastic parts bag over the retainer
threads when installing the O-Ring and back-up
1. Lubricate all parts with clean hydraulic fluid. ring will help protect parts against damage,
2. Lubricate and install the spring, plunger, cutting, etc.
washer, snap ring and ball into base end of 5. Carefully start the retainer assembly over the
the piston rod. Refer to Figure 12. piston rod and screw it into the barrel finger
3. Lubricate and install spacer onto the piston tight. Do not cut or nick sealing lips upon
rod. Refer to Figure 12. installation.
4. Now, lubricate and place split piston onto the 6. Using a spanner, tighten the retainer against
piston rod. Start piston rod into cylinder the shell assembly.
barrel and gently push rod inward until it
bottoms out. Be careful no to nick or scratch
the chrome surfaces.

Retainer / Retainer Assembly

1. Lubricate new seals, wiper ring and retainer
assembly with clean hydraulic fluid.
2. Install the inner seal into the retainer groove.
Be certain the sealing lip faces inward. Use
a seal installation tool for best results. Be
careful not to nick or scratch the chrome
surfaces.
3. Install a new wiper ring into the retainer.
4. Lubricate and install a new o-ring and back-
up ring into the outer groove on the retainer.
Install lock washer on outside of retainer.

7-18
MAST

Free Lift Cylinder Service

Free Lift Cylinder Disassembly
1. Wash the exterior surface of the cylinder
thoroughly before disassembly
• A soft fiber brush should be used to
remove debris and foreign objects from
grooves and threaded areas, etc. Retainer
• A stoddard type cleaning solvent should be
used to wash the cylinder.
Retainer Seals
2. Place retainer end of cylinder in a vise
equipped with soft jaws. Do not over tighten O-Ring
vise.
3. Using a spanner wrench or a bronze (brass)
drift, remove retainer assembly from cylinder Back-Up
barrel. O-Ring
4. Remove and discard lock washer, back-up
ring and o-ring located inside cylinder Rod
retainer.
Shell
5. Remove and discard both o-rings and back-
up ring located on the outside of the cylinder
retainer.
6. Pull piston rod from barrel assembly.
7. Remove wear ring (ring bearing) from piston
rod. Refer to Figure 13
Set Screw
Cleaning and Inspection
Nylon Plug
1. Discard old seals, o-rings, back-up rings,
wiper and lock washer Back-Up

2. Wash remaining parts in a Stoddard type O-Ring

cleaning solvent and dry with a clean shop Ball
rag. Seal W/O-Ring
3. Inspect threaded parts for damage. Piston

4. Examine the piston rod, inner surfaces of the Wear Ring

retainer assembly and cylinder barrel for Retainer
Plug
scoring, nicks or scratches. A crocus cloth
may be used to clean up light scratches, etc.
Be careful that you do not remove the
chrome plating when polishing surfaces.

MA2212.eps

Figure 13

7-19
MAST

Free Lift Cylinder Reassembly Note

Piston Rod and Piston Placing a plastic parts bag over the retainer
threads when installing the o-rings and back-up
1. Lubricate all parts with clean hydraulic fluid. rings will help protect parts against damage,
2. Lubricate and install wear ring onto the cutting, etc..
piston rod. Refer to Figure 13. 4. Next, lubricate and install a new back-up ring
3. Now, start piston rod into cylinder barrel and and o-ring into the outer groove at the base
gently push rod inward until it bottoms out. end of the retainer.
Be careful that you do not nick or scratch 5. Install a new wiper into the retainer.
chrome surface.
6. Now, carefully place the retainer assembly
Retainer Assembly over the piston rod and after applying lube to
1. Lubricate new seals, o-rings, back-up rings, threads, screw it into the barrel finger tight.
wiper ring and retainer assembly with clean Do not cut or nick sealing lip(s) upon
hydraulic fluid. installation.

2. Install back-up ring and the inner seal into 7. Using a spanner wrench, tighten retainer
the retainer groove. Be certain the sealing lip against barrel assembly.
faces inward. Use a seal installation tool. Be 8. Next, using drift as shown in opposite
careful that you do not cut or nick the sealing illustration, deform lock washer into groves
lip upon installation. provided in both the retainer and barrel to
3. Lubricate and install (large) o-ring into the securely lock them together.
outer groove nearest to end of retainer.

7-20
MAST

MAST UPRIGHTS
Upright Description
Outer Upright Assembly
The outer upright assembly is mounted
to the truck. A pair of shim adjustable
load rollers are attached to stub shafts
Pantograph Pantograph
located near the top of the upright. Rollers Rollers
A pair of adjustable hoist chain anchors
are located in the top crossmember. The
secondary cylinders rest on an integral lower
crossmember.
Intermediate Upright Assembly
The intermediate upright assembly telescopes
within the outer upright assembly. A pair of shim
adjustable load rollers are attached to stub shafts
located at the top and bottom of the upright. A
pair of chain sheaves are located near the top of
the upright to provide a rolling surface for the
main lift chains.
Inner Upright Assembly
The inner upright assembly telescopes within the
intermediate upright assembly. A pair of shim Inner
Upright
adjustable load rollers are attached to stub shafts Rollers Intermediate
Intermediate
located at the bottom of the upright. The free lift Upright Outer Upright
Rollers
chain anchors are attached to the center Rollers Upright
Rollers
crossmember. The free lift cylinder rests on a
cradle which is integral with the lower
crossmember.

MA2191.eps

Figure 14

7-21
MAST

Upright Chain Inspection outside plates and pins has been altered, it
Each 50-250 hours of operation (more frequently cannot be restored. Any wear pattern on the pin
in severe or extreme environments), chains heads or the sides of the link plates indicates
should be inspected and lubricated. Inspection misalignment in the system. This condition
should involve the following: damages the chain and increases frictional
loading, and should be corrected. See Figure 15.
Elongation
When a length of 12.00 inches (305 mm) of a
new chain has elongated to a length of 12.360
inches (315 mm), it should be discarded and
replaced. It is important to measure the chain in
the section that moves over the sheaves
because it receives the most frequent
articulation. Measuring the chain near its clevis
terminals could give an erroneous reading as it
would not have flexed as frequently, if indeed at
all, as nearer the middle of the assembly. See
figure 15. Chains should be replaced when wear
exceeds 3% of the pitch or when 12 inches (305
mm) of chain is stretched 3.8 inch (10 mm).
Edge Wear
Check the chain for wear on the link plate edges
caused by running back and forth over the
sheave. The maximum reduction of the material
should not exceed 5%. This can be compared to
a normal link plate height by measuring a portion
of chain that does not run over the sheave.
Distorted or battered plates on the leaf chain can
cause tight joints and prevent flexing. See figure
15. Worn contours and worn surfaces on the
outside links or pin heads should not exceed 5%
of new height.
Turning or Protruding Pins
Highly loaded chain operated with inadequate
lubrication can generate abnormal friction forces
between pin and link plates. In extreme
instances, the torque could surpass the press fit
force between the pins and the outside plates,
resulting in pin rotation. When chain is allowed to
operate in this condition, a pin, or series of pins,
can begin to twist out of the chain resulting in
failure. The pin head rivets should be examined
to determine if the “VEE” flats are still in correct
alignment. Chains with rotated/displaced heads
or abnormal protrusion should be replaced
immediately. Do not attempt to repair the chain
by welding or driving the pin(s) back into the
chain. Once the press fit integrity between Figure 15

7-22
MAST

Cracked Plates If a plated chain is required, consult the factory.

The chains should be periodically inspected very Plated chains are assembled from modified,
carefully, front and back as well as side to side, individually plated components which may
for any evidence of cracked plates. If any one reduce the chain rating.
crack is discovered, the chain(s) should be
replaced. It is important, however, to determine
the causes of the crack before installing new
chain so the condition does not repeat itself.
Fatigue Cracking - Fatigue cracks are a result
MA1002.eps
of repeated cyclic loading beyond the chains
endurance limit. The magnitude of the load and
frequency of its occurrence are factors which
determine when fatigue failure will occur. The
loading can be continuous or intermittent Figure 16. Arc-Like Cracks in plate are
(impulse load). a sign of stress corrosion
Fatigue cracks almost always start at the link
plate pin hole (point of highest stress) and are Corrosion Fatigue - Corrosion fatigue cracks
perpendicular to the chain pitch line. They are are very similar (in many cases identical) to
often microscopic in their early stage. Unlike a normal fatigue cracks in appearance. They
pure tensile failure, there is no noticeable generally begin at the pin hole and move
yielding (stretch ) of the material. perpendicular (900) to the chain pitch line.
Stress-Corrosion Cracking - The outside link Corrosion fatigue is not the same as stress
plates which are heavily press fitted to the pins, corrosion.
are particularly susceptible to stress corrosion Corrosion fatigue is the combined action of an
cracking. Like cracks, these initiate at the point aggressive environment and a cyclic stress (not
of highest stress (pin hole) but tend to extend in a static stress alone, as in stress corrosion).
an arch-like pattern between the holes on the
plate. Ultimate Strength Failure
More than one crack can often appear on a link This type of failure is caused by overloads far in
plate. In addition to rusting, this condition can be excess of the design load. See Figure 17.
caused by exposure to an acidic or caustic
medium or atmosphere.
Stress corrosion is an environmentally assisted
failure. Two conditions must be present: a
corrosive agent and static stress. In the chain,
static stress is present at the pin hole due to the MA1003.eps

press fit pin. No cycle motion is required, and the

plates can crack during idle periods. The reaction
of many chemical agents (such as battery acid
fumes) with hardened steel can liberate
hydrogen which attacks and weakens the steel Figure 17
grain structure.
Tight Joints
For this same reason, never attempt to
electroplate a leaf chain or its components. The All joints in leaf chain should flex freely. Tight
plating process liberates hydrogen and hydrogen joints resist flexure and increase internal friction,
embrittlement cracks will appear. These are thus increasing chain tension required to fit a
similar in appearance to stress corrosion cracks. given load. Increased tension accelerated wear
and fatigue problems. See figure 23, Page 7-31.

7-23
MAST

Chain Length Adjustment

! WARNING

An upright or carriage can move

unexpectedly:
• Do not walk or stand under raised
forks.
• Keep clear of load and carriage when
making any check or adjustment.
• Keep your arms and fingers away from
moving parts of the upright.
• Block the carriage or upright when
working with the components in a
raised position.
• Do not reach through open areas of
the upright.
• Never attempt to move or align the
rails by hand. Use a prybar.
Failure to follow these warning can result in
serious injury.

IMPORTANT
• Threaded chain anchors must be left free
to pivot in mounting hole.
• Anchor pin heads must be to the inside
of the upright.
• Torque jam nuts to adjustment nuts to
100 - 200 Nm (74 - 148 Ft-Lbs).
• Make sure chain anchors are secured so
that no twist is evident in the chains.
IMPORTANT
The carriage stop must not be allowed to
contact the upright stop under any
circumstances during normal operations.

7-24
MAST

Periodic Inspection IMPORTANT

Triple-Stage Upright (TSU) Chain Length • Threaded chain anchors must be left free
to pivot in mounting hole.
Adjustments
• Anchor pin heads must be to the inside of
Triple-Stage uprights use two chain set; one set
the upright.
for carriage lift and one set for rail lift. Adjustment
anchors for the lift cylinder stage are located at • Torque jam nuts to adjustment nuts to
the back of the outer rail. Adjustment anchors for 100 - 200 Nm (74 - 148 Ft-Lbs).
the primary lift stage are behind the primary • Make sure chain anchors are secured so
cylinder. Carriage chain anchors are not intended that no twist is evident in the chains.
for adjustment.
For TSU inner rail lift chains, chain length must
be adjusted if the difference between the bottom
of the inner rail and the outer rail is greater 10
mm (0.40 in.)
For the TSU primary cylinder lift chain, the chain
length must be adjusted if:
• The fork-to-ground clearance is less than 5
mm (0.20 in.) or more than 25 mm (1.0 in.)
when the upright is vertical.
To inner rail
• The center of the bottom carriage roller
comes within 20 mm (0.80 in.) of the bottom
edge of the inner rail.
• The carriage safety stop hit the inner rail MA1004.eps

stop at full extension height.

Adjust chain length here
To adjust the cylinder lift chains on a TSU use
the following illustration and procedures:
Figure 18
1. Set the upright in the vertical position.
2. Break the jam nuts loose on the chain
anchors.
3. Adjust the chain anchor adjustment nuts until
the bottom of the inner rail is within 2.5 mm
(0.10 in.) of the bottom of the outer rail.
To adjust the primary cylinder lift chains on a
TSU use the following illustration and
procedures:
1. Fork-to-ground clearance:
a. Set the upright to vertical position. To Carriage
b. Break the jam nuts loose on the chain
anchors.
c. Turn the chain adjustment nuts until
Adjust Chain
clearance between forks and ground is Length Here
10-20 mm (0.40-0.80 in.).
Figure 19

7-25
MAST

Chain Length Adjustments (continued)

2. Carriage roller position:
a. Raise carriage about 1M (3.2 ft.) and
smear a bead of grease on the bottom
75 mm (3 in.) of the inner rail in the area
of the roller pattern.
b. Tilt upright fully back and completely
lower.
c. Measure the distance from where the
center of the bottom carriage roller
stopped to the bottom edge of the inner
rail. Distance should not be less than 20
mm (0.80 in.) or chain length adjustment
is required.
3. Carriage Stop-to-Upright:
a. Lift upright to its full height and check for
clearance on the carriage safety stop.
b. If carriage stop hits the upright stop,
adjust the chain anchor adjustment nuts
out until there is at least 3 mm (0.12 in.)
clearance between the stops.
If all three chain length requirements listed
previously cannot be met, the tire diameter may
be out of the design range allowance. Also,
excessive tire wear will decrease carriage stop
clearance.
IMPORTANT
The carriage stop must not be allowed to
contact the upright stop under any
circumstances during normal operations.

7-26
MAST

Periodic Inspection General Guidelines

Chain Lubrication Chain Movement - Make sure that the chain
operating path is clear and that the chain
Like all bearing surfaces, the precision articulates freely through its full range of
manufactured, harden-steel, joint-wearing operation.
surfaces of a leaf chain require a film of oil
between all mating parts to prevent accelerated Lubrication - Assure that the chain is well
wear. Maintaining a lubrication film on all chains lubricated with the heaviest oil that will penetrate
surfaces will: the void between the link plate apertures and the
pins.
• Minimize joint wear.
Paint - Make sure the chain does not get painted
• Improve corrosion resistance. over at any time.
• Reduce the possibility of pin turning. Protection - Where necessary, as a protection
• Minimize tight joints. from atmosphere or sliding wear, the chain may
• Lower chain tension by reducing internal be covered with a layer of grease. It should be
friction in the chain system. noted, however, that the grease will have to be
removed at a later date for chain inspection and
Laboratory wear test indicate that #40 oil has the relubrication.
ability to prevent wear better than #10 oil.
Generally, the heaviest (highest viscosity) oil that Chain Mountings - Double check to be sure all
will penetrate the joint is best. chain fastening devises are secures and all
adjustments have been made to assure uniform
Whatever method is used, the oil must penetrate loading of multiple chain applications. Check
the chain joint to prevent wear. Applying oil to chain anchors and pins for wear, breakage and
external surfaces will prevent rust, but oil must misalignment. Damaged anchors and pins
flow into the live bearing surfaces for maximum should be replaced.
wear life.
Sheaves - Sheaves with badly worn flanges and
To prepare the chain for oil. The leaf chain plates outside diameter should be replaced. This wear
should be brushed with a stiff brush or wire may be due to chain misalignment or frozen
brush to clear the space between the plates so bearings.
that oil may penetrate the live bearing areas.
Oil may be applied with a narrow paint brush or
directly poured on. Chain should be well flooded
to be sure the oil penetrates the joint.
In locations difficult to reach, it may be
necessary to use a good quality oil under
pressure such as an aerosol can or pump
pressure spray.

7-27
MAST

Chain Removal and Replacement Primary Cylinder/Carriage Chains (TSUs)

1. Tilt the upright forward, lower it and
! WARNING completely collapse the primary cylinder to
create slack in the chains. The carriage may
The procedures for removing and also be lifted and blocked in position and the
replacing chain set involve hoisting and primary cylinder completely collapsed to
blocking components. create slack in the chains.
• Do not walk or stand under raised 2. Remove the chain anchor pins from the back
forks. of the primary cylinder. Pull the chains
• Keep your arms and fingers away from through the chain sheave and lay them over
moving parts of the upright. the carriage load backrest.
• Do not reach through open areas of 3. Remove the chain anchor pins from the back
the upright. of the carriage.
Failure to follow these warnings can 4. Use these steps in reverse order to replace
result in serious injury. the primary cylinder/carriage chain. Perform
the chain length adjustment and chain
tension check before returning the truck to
Lift Chains (Standard & TSU) service.

To remove and replace the lift cylinder and/or Other Chain Service Notes
carriage chain set on standard and triple-stage • Use lengths of factory assembled chain. Do
uprights (TSU): not build lengths from individual
1. Attach a hoist strap on the carriage of the components.
standard upright or inner of the TSU. • Do not attempt to rework damaged chains by
2. Lift the carriage or inner rail slightly to create replacing only the components obviously
slack in the chains. Block the carriage or faulty. The entire chain may be compromised
inner rail up for safety. and should be discarded.
3. Remove the chain anchor pins on the outer • Never electroplate assembled leaf chain or
rail and pull the chains off of the sheaves on its components. Plating will result in failure
the inner or intermediate rails. from hydrogen embrittlement. Plated chains
4. Remove the chain anchor pins from the are assembled from modified, individually
carriage on the standard upright or the inner plated components.
rail on the TSU. On the TSU, the inner rails • Welding should not be performed on any
must be lowered to the floor to access the chain or components. Welding splatter
chain anchor pins. should never be allowed to come in contact
with chain or components.
Note
• Leaf chains are manufactured exclusively
If a hose adapter is used, the chain sheaves from heat treated steels and therefore must
must be loosened and removed to prevent the be annealed. If heating a chain with a cutting
hoses from stretching when the inner rails of the torch is absolutely necessary for removal,
TSU are lowered to access the chain anchor the chain should not be used.
pins.
• Always replace chains in sets, Failure to
5. Use the steps in reverse order to replace the do so may damage new chain.
lift chain set.

7-28
MAST

Periodic Inspection
Upright & Lift Bracket
Removal & Replace Roller Shim
Adjustments
It is recommended that the lift bracket carriage
assembly be removed before attempting to
remove the uprights.
Lift Bracket Removal Preparation
1. Truck should be parked on a level surface.
Extend the lift bracket fully. Lower the lift
bracket onto hardwood (oak) blocks. Refer
to figure 20.
2. Place a support (2 X 4 or 4 X 4) between the
front and rear members of the lift bracket to
prevent the lift bracket from retracting once
the hydraulic supply is disconnected.
3. The lowering control long enough for the
primary cylinder to collapse and slacken the
chains. Release the control.
4. Turn the key to the “OFF” position and
remove the key.
5. Disconnect the battery.
Note
If the upright is to be removed, a 5-ton chain
hoist equipped with safety hooks is required.

Support Block

Disconnect
Battery
MA1028.eps

Hardwood (Oak) Blocking

Figure ??
MA1035.eps

Figure 21

7-29
MAST

Periodic Inspection Note

Upright & Lift Bracket Lift chains may be disconnected at the primary
Removal & Replace Roller Shim lift cylinder crosshead (see next page) or from
(continued) the carriage as shown.
6. Remove two bolt (1) from cable retainers (2).
7. Remove front and rear retainers.
8. Disconnect electrical plug (3).
9. Remove both harness clamp bolts (4). Backup truck just enough to provide clearance
Between pantograph and upright rails.
10. Disconnect hydraulic hoses from tube
connections (5) using two wrenches. One
wrench to hold the tube connection(s) while
loosening the hose connection(s). There will
be some hydraulic fluid leakage upon
disconnecting fittings.
Clearance
11. Remove cotter pins (6).
12. Remove chain anchor pins (7) securing the Pantograph

lift chains to the carriage chain anchors. Truck

Fully lower intermiate and inner rails.

Support Block

Disconnect hoist safety hook from lifting device.

Hardwood (Oak) Blocking

Safety Hook

Lifting Straps
or
Chains

Move truck away from pantograph.

Truck

Support Block

MA2196.eps
Hardwood (Oak) Blocking

Figure 22

7-30
MAST

Lift Bracket Removal Note

Upright & Lift Bracket Removal Once a lift chain has been disconnected, lay it
over the Lift Bracket. Then, using wire, tie the
Note chain end to the load backrest. This will keep the
Carriage chains may be disconnected at the chains out of the way and from falling to the
primary cylinder. Remove cotter pins securing lift ground.
chains to the chain anchors. Remove lift chains
one at a time from the chain anchors.

Primary Cylinder
crosshead

Lift Chain

Chain Anchor

Cotter Pin

MA1031.eps

Figure 23

7-31
MAST

Lift Bracket Removal (continued)

Upright & Lift Bracket Removal
13. Using a 5-ton chain hoist, attach hoist to the
inner and intermediate rail assemblies, See
Figure 24 below. Be sure hoist is equipped
with safetyhook(s).
14. Raise both inner and intermediate rails until
the inner rails clear the upper carriage
rollers.

5 Ton Chain Hoist

Safety Hook

Lifting Straps
Raise both inner and or
Chains
intermediate rails until the
inner rail channels are
clear of the carriage
rollers.

Inner Rail

Carriage Roller

Support Block

MA2183.eps

Hardwood (Oak) Blocking MA2195.eps

Figure 24

7-32
MAST

Lift Bracket Removal (continued) Note

Upright & Lift Bracket Removal If the upright rail lift cylinders are to be removed,
15. Move truck away from lift bracket just far refer to the following pages.
enough to allow the intermediate and inner The free lift (center) cylinder may be removed
rails to clear the lift bracket. without removing the upright.
16. Completely lower the intermediate and inner
rail assemblies.
17. Disconnect hoist and move truck away from
lift bracket.

Backup truck just enough to provide clearance

Between pantograph and upright rails.

Clearance

Pantograph

Truck

Fully lower intermiate and inner rails.

Support Block

Disconnect hoist safety hook from lifting device.

Hardwood (Oak) Blocking

Safety Hook

Lifting Straps
or
Chains

Move truck away from pantograph.

Truck

Support Block

MA2196.eps
Hardwood (Oak) Blocking

Figure 25

7-33
MAST

Lift Bracket Removal (continued) 5.4-1

Upright & Lift Bracket Removal
Upright Removal
It is recommended that the lift bracket carriage
assembly be removed before attempting to
remove the upright.
Preparation
1. Turn key switch off.
• Remove key from switch.
2. Disconnect truck battery at the battery
disconnect.
3. Remove battery from truck.
Note Disconnect
Battery
The lift bracket must be removed before
attempting to remove the upright.
Disconnect Battery
4. Remove any overhead guards and/or screen MA1035.eps

guards.
5. Elevate and support each side of truck with
suitable 3” hardwood (Oak) blocking.
Figure 26
6. Disconnect all hydraulic supply lines to the
upright. Cap all open lines and fittings.
7. Disconnect all electrical connections to the
mast and tie wires out of the way.

7-34
MAST

Upright & Lift Bracket Removal

! WARNING
Upright Removal (continued)
Do not stand on or near the Mast while it is
8. Place lifting strap beneath the upper tie bars
suspended by an overhead hoist.
of the outer, intermediate and inner rail
assemblies. Connect strap ends to the chain
hoist. Be certain the hoist is equipped with WARNING
safety hooks. See Figure 28.
!
9. Raise lift to remove slack in the strap. Strap Do not stand the Mast up vertically unless
should be taut enough to support the upright it is chained to a support.
after it is disconnected from the truck.
10. Remove all fasteners securing the upright to
the truck.
11. Use hardwood (oak) blocks to support the
bottom end of the upright and to keep it level
when laid horizontally on the floor. Avoid
resting the mast on hydraulic fittings.
12. Lower the upright onto the blocks with the
truck side down. This will allow the rail
assemblies to be pulled out of the outer rail
assembly to access rail rollers and
secondary cylinders.

MA1037.eps

Outrigger(s)
Inner Rail Assembly

Top
Bottom
MA1038.eps

Truck Side
Intermediate
Rail Assembly Outer
Rail Assembly Hardwood (Oak) Blocking

Figure 28

7-35
MAST

Upright & Lift Bracket Removal

Upright Disassembly
1. Pull the inner and intermediate rail
assemblies part way out of the outer rail
assembly to provide access for secondary
cylinder removal. The rail cylinders must be Left Hand
Cylinder

removed to adjust or replace the lower rail

rollers.
Right Hand
Cylinder
2. Loosen and remove the hydraulic fittings at
the base of the left and right secondary
cylinders. Discard old o-Rings. Install new o-
ring(s) at time of installation. Tube

3. Remove the snap ring at the base of each

cylinder.
Rail Cylinders O-Ring

Rollers and Shims Flow

Regulator

Pulling the rail assemblies part way out of the Elbow

bottom of the outer rail assembly will allow MA1039.eps

Fitting
access to remove and/or replace rollers and
shims. The rail cylinders must be removed to Figure 30
accomplish this.

Cylinder
Base

Snap Ring MA1040.eps

Figure 31
Outrigger(s)
Inner Rail Assembly

Top
Bottom
MA1038.eps

Truck Side
Intermediate
Rail Assembly Outer
Rail Assembly Hardwood (Oak) Blocking

Figure 31

7-36
MAST

Upright & Lift Bracket Removal WARNING

4. Remove the external snap ring from the top
!
of each cylinder piston rod. Rail cylinders are heavy and care must be
5. Remove the washer from each cylinder rod. taken to avoid personal injury.
6. Support the cylinders, and move the rails
outward far enough to allow removal of the Note
cylinders.
Record the number of shims removed for each
Note side. The same number of shim should be
Each cylinder is equipped with a weldment near reinstalled on each side to prevent “racking” of
the top end of each barrel assembly. This the upright assemblies.
weldment fits over an alignment pin that is part
of the chain anchor mount of the outer upright.

Snap Ring
Washer

Intermediate
Upright Shim

Cylinder
Alignment
Pin Tab

MA0980.eps

Alignment
Pin

Figure 32

7-37
MAST

Upright Disassembly (Continued) WARNING

!
Upright & Lift Bracket Removal
The free lift cylinder is heavy and care
Cable, Hose and Chain Sheaves must be taken to avoid personal injury.
• Remove snap rings (6) and sheaves (5).
1
• Remove screws (4) securing mounting 2

plates to crosshead (16) and remove

3
assembly from block.
• Remove pins (15) and crosshead (16) from
primary cylinder piston rod. 4

• Loosen and remove nuts (1), capscrews (3), 16 15

and spacers (2).
5
• Disassemble assembly. Replace and worn 6

and/or damaged components. 13

8
Installation is the reverse of removal.
Free Lift Cylinder 7
9
• Remove cotter pins (7), jam nuts (11), full 10
nuts (10) and ecentrical washer. 11
12
• Remove chain anchors (8) and lift chains Free Lift Cylinder
(13).
• Remove snap ring (14). Lift cylinder off
alignment pin (12) and out of upright.
Installation is reverse of removal.
13
Note 14
MA1041.eps

The free lift cylinder may be removed with

upright attached to truck.
Figure 33

Outrigger(s)
Inner Rail Assembly

Top
Bottom
MA1038.eps

Truck Side
Intermediate
Rail Assembly Outer
Rail Assembly Hardwood (Oak) Blocking

Figure 34

7-38
MAST

Upright & Lift Bracket Removal

Roller

1 Mounting
Nut Plate

2
Spacer

4
Allen Head
Screw
3
Capscrew

11 MA1042.eps

Block

10
Roll Pin 5
Secures Block Sheave
to Cylinder Rod 6
Snap Ring

Figure 35

7-39
MAST

Section 5 Upright & Lift Bracket Removal

Cable and Chain Sheaves
• Loosen and remove retainer bolt from stub
shaft.
• Remove washer, sheaves and spacer.
• Replace worn and/or damaged components.
Installation is the reverse of removal.
Removal

Sheave

Bolt Bushing

Washer

Chain
Sheave

Intermediate
MA1043.eps
Rail Assembly

Figure 36

MA1044.eps

Chain Sheave
Hose Sheave
Figure 37

7-40
MAST

Section 5 Upright & Lift Bracket Removal

Outside Spanner Tool

1 1/2"

4 1/2"

9"
2"

1 1/2" 700

Inside Spanner Tool

4 1/2"

200

3 400
1/
2"

9"
MA1046.eps

Figure 38

7-41
MAST

Shimming

4 3/4"

Top View
Handle 7/8"
Shim Set

Shim

Front View

450
Side View

Sliding T Bevel

Carpenter Square

Protractor

MA1047.eps

Figure 39

7-42
MAST

Shimming

Load Roller Carriage

Adjustment
Shims

Scissors

Lift Fork Carriage

Allen
Head
Screw

MA2190.eps

Figure 40

7-43
MAST

Lift Bracket Assembly

Shimming
Outrigger(s)
Inner Rail Assembly

Top
Bottom
MA1038.eps

Truck Side
Intermediate
Rail Assembly Outer
Rail Assembly Hardwood (Oak) Blocking

Figure 41

PANTOGRAPH CARRIAGE ROLLERS

The clearance between the upright inner rails
1. Span inner rail with inside spanner tool.
and the lift bracket carriage rollers must be
checked and adjusted. • Find the smallest distance between rails.
• After finding the smallest distance, place a
Checks and Adjustments roller shim between the spanner tool and
Note the inner rail. Lock the tool in position.

Roller clearance and adjustment may

accomplished with the upright mounted to the
truck or removed and laying on the floor as
shown above.

Inner Rail

MA1048.eps

Figure 42

7-44
MAST

Shimming
2. Set outside Outside Spanning Tool

spanning tool
to match the adjusted
inside spanning tool. Lock

3. Lock the outside spanning

tool in the adjusted position. Lock MA1050.eps

4. Span the upper carriage rollers

at their outer most camber point. Lock
Add or remove shims at the roller Lock
shaft to match tool size. Inside Spanning Tool
Figure 43
5. Center carriage rollers by counting
the shims and using equal numbers
of shims on both sides. If there is
an odd number of shims, place the
odd shim on the right hand side.
IMPORTANT Outer Upper
When upright is fully extended, the upper Spanning Carriage
carriage rollers extend beyond the inner Tool Roller
rail assembly. To allow the rollers to retract
smoothly back into the rail, one shim should
be removed from each side.
6. Install upper carriage rollers and securely
tighten the Allen head retaining capscrews.
Figure 43 MA1051.eps

Load Roller Carriage

Adjustment
Shims

Scissors

Allen
Head
Screw

MA1052.eps

Figure 45

7-45
MAST

Shimming
7. Span center carriage rollers at their outer
most camber point. Add or remove shims
to match tool size.
8. Center carriage rollers by using equal
amounts of shims on both sides. If an
odd number is used, place the odd Center
Outer
shim on the right hand side. Carriage
Spanning
Tool Roller

MA1053.eps

Figure 46

9. Place a carpenters square at the outer most

camber point of the center and lower rollers.
Hold the square tight against rollers and take
the following measurements.
• Measure the distance between the top of
the square and the straight edge at point
(A).
• Take a measurement at point (B). These
measurements should be the same. If they
are not, add or remove shims from the
lower rollers shaft(s) until the distance
measured at each point is equal.

Figure 47

7-46
MAST

Shimming
10. Span lower rollers. Add or remove shims to (
the roller that has not be squared) match the
size of the outside spanning tool.

Outer Bottom
Spanning Carriage
Tool Roller

MA1055.eps

Figure 48

11. Check and adjust rollers on the opposite side

of carriage. Place square at the outer most
camber of the center and lower rollers. Take
measurements as before. This side will be
square within 1/32:, if not , return to step 9
and repeat procedure. Make sure rollers are
center as previously described.

Figure 49

7-47
MAST

Shimming
12. The top rollers are checked last. Remember Carriage
1/32" Shim
that the top carriage rollers extend out of the
inner rails when the mast uprights are at full
extension. To make reentry of these rollers
into the inner rails easier, additional
clearance is required for the top rollers.
(Refer to steps 4,5 and 6).
* Place the square directly through the
center of the rollers as shown in the
illustration to the right.
* The rollers are shimmed properly when a Scissors
1/32” shim can be fit between the outer
most camber point of top roller and the
square. The clearance should not exceed
1/32”.
* If adjustments are necessary, remove the
Allen head capscrew and the roller. Add or
remove shims to correct the adjustment.
* Install Allen head capscrew and check
adjustment.
MA1057.eps

Carriage
1/32" Shim
Figure 50

13. Check opposite roller in use the same

procedure, adjusting if necessary.
Note
Upper Rollers are retained only with the Allen
head capscrews. Center and lower rollers are
always captive within the rails.
Scissors

MA1058.eps

Figure 51

7-48
MAST

Shimming
Upright Rails to Rollers
The following procedure explains how to:
• 1st - Measure rail-to-roller clearance.
• 2nd 6- Adjust rail-to-roller clearance.

Intermediate Inner
IMPORTANT Rail Rail
With age and wear, clearances between the
upright rails and the rollers can increase and
Roller
cause excessive looseness between rails and
rollers. Upright rollers become worn, rail surfaces
wear, and stress relieving due to handling heavy
loads over a period of time may cause slight
dimensional changes between upright rails. The
illustration shows clearance between rails and
rollers.
A roller clearance inspection should be
performed if, during normal operational checks of
the upright, noticeable looseness or binding
between rails sets, or if scoring is evident on the
rails. Proper roller clearance should be
maintained because the mast is designed to nest
the rails snugly while providing smooth
operation.

Outer Point of
Rail roller
MA1060.eps
Contact

Figure 52

7-49
MAST

Shimming

Inner
Rail

Check Clearance Here

Feeler
Gauge
(0.020) Intermediate
Rail
Pry Here

Check Clearance Here

Use "C" clamp
to force rollers
to one side.
Pry Here Torque on "C"
clamp should not
exceed 20 ft.lbs.

Outer
Rail

MA1062.eps

Intermediate Inner
Rail Rail

Roller

Check
Clearance
Here

Outer Point of
Rail roller
MA1060.eps
Contact

Figure 53

7-50
MAST

Shimming Checking Lower Roller Clearance with

upright 6” from fully retracted position
Evaluation of shim requirements generally
! CAUTION
dictates the a specific roller is acceptable until
Watch for overhead clearance when 0.040” clearance is exceeded, meaning
extending upright. adjustment requires one standard 1/32” shims to
reduce rail-to-roller clearance to proper
tolerances.
WARNING ROLLERS SHOULD BE INSTALLED “LINE-
! TO-LINE” 0.020” MINIMUM CLEARANCE
Use extreme care when working on the Refer to adjustment reference chart when using
upright to avoid placing hands or fingers feeler gauges.
into potential pinch points. Unexpected
movement of the upright can cause Step Feeler Gauge will Shimmed Shim
serious injury. Gauge Pass / Not Pass Correctly QTY
0.020” PASS Check with a
1 0.050” NOT PASS No, ADD 0
0.050” PASS Check with a
Roller Clearance Inspection 2 0.080” NOT PASS No, ADD 1
Service 0.080” PASS Check with a

Before checking the roller clearances, place the

3 0.120 NOT PASS No, ADD 2
intermediate rail approximately 6 inches out of
the outer rail and the inner approximately 6
inches out of the intermediate rail as illustrated
on the previous page. If the upright is mounted
and the rails are being elevated hydraulically, the
inner rail will automatically assume it’s correct
position. Note the procedure for checking the
clearance is basically the same whether the
upright is mounted or has been removed from
the truck.
There are two methods presented, one using a
pry bar to position the rails and rollers and the
other using a “C” clamp.
If the upright is mounted to the truck,, the use of
an approved safety platform or step ladder is
recommended when making inspections and
checking clearances at the upper levels. If the
upright has been removed and placed on the flat
floor, proper blocking of hardwood (Oak) or steel
supports must be used to keep the upright
horizontal with the floor. This is especially
important when fully extending the intermediate
and inner rails.

7-51
MAST

Shimming “C” Clamp Method:

• Install “C” clamp at the location shown in
When using a pry bar: Figure 53. It may be necessary to use a
block on the inside of the channel as shown.
Shimming
• Tighten the “C” clamp to displace the roller
• Insert the pry bar between the outer and
clearance on that side of the upright. Now,
intermediate upright rail on the right side ( as
check roller clearance on the opposite side
shown in Figure 53. Pry with moderate
of the upright.
pressure moving the intermediate and inner
rails to the left top end of the upright. • Using a 0.020” feeler gauge, try to insert it
between the roller and the rail at the point of
• Using a 0/020” feeler gauge, see if you can
contact as shown in Figure 53.
insert a shim between the roller and rail.
There needs to be some clearance but it is • If a 0.020” will pass between the roller and
not to exceeds 0.040”. If the clearance the rail, and 0.040” will not fit between the
between the roller and the rail is two or more rail and roller, it does not require adjustment.
shims, record the number of shims that will If clearance exceeds 0.040”, refer to the
fit in the space between the roller and rail. chart on 7-51.
Refer to the chart on page 7-51. • Record the number of shims needed to fill
• Pry the intermediate rail away from the inner the space between the roller and the rail.
rail. Check the clearance between the
IMPORTANT
intermediate rail roller and the inner rail.
There needs to be at least 0.020” of clearance
• Record the number of shims needed to fit in
but no more than 0.050”.
the space between the roller and the rail for
the outer and intermediate rail.

7-52
MAST

Shimming
Intermediate Inner
Rail Rail

Roller

Pry
Here

Check
Clearance
Here

Checking Lower Roller Clearance

with upright 6” from fully retracted
position
Now check the lower rollers in the same manner as for
the upper rollers.
Record the number of shim needed for the outer and
Outer Point of inner rails opposite the rollers checked.
Rail roller
MA1060.eps
Contact

Inner
Rail

Feeler
Gauge
(0.020)

Intermediate
Pry Here Rail

Use "C" clamp

Check Clearance Here to force rollers
to one side.
Torque on "C"
Pry Here clamp should not
exceed 20 ft.lbs.

Check Clearance Here Outer

Rail
MA1061.eps

Figure 54

7-53
MAST

Shimming
Checking Upper Roller Clearance With
Intermediate Inner upright extended Approximately 1/2 of full
Rail Rail
extension
Roller
Now check the roller clearance in the same manner as before.
Pry
Here Record the number of shim needed for the outer and inner rails
opposite the rollers checked.
Check
Clearance
Here

ROLLERS SHOULD BE INSTALLED

“LINE-TO-LINE”
0.020” MINIMUM CLEARANCE
Feeler
Outer Point of
Rail roller
Gauge Refer to adjustment reference chart
MA1060.eps
Contact (0.020) when using feeler gauges.
Check Clearance Here
Inner Step Feeler Gauge will Shimmed Shim
Rail Gauge Pass / Not Pass Correctly QTY
0.020” PASS Check with a
Pry Here 1 0.050” NOT PASS No, ADD 0
0.050” PASS Check with a
2 0.080” NOT PASS No, ADD 1
0.080” PASS Check with a
Intermediate 3 0.120 NOT PASS No, ADD 2
Rail

Check Clearance Here

Pry Here

Use "C" clamp

to force rollers
to one side.
Torque on "C"
clamp should not
exceed 20 ft.lbs.

Outer
MA1063.eps
Rail

Figure 55

7-54
MAST

Shimming
Checking Lower Roller Clearance With
Intermediate Inner
upright extended Approximately 1/2 of full
Rail Rail
extension
Roller

Pry
Now check the roller clearance in the same manner as before.
Here
Record the number of shim needed for the outer and inner rails
opposite the rollers checked.
Check
Clearance
Here

ROLLERS SHOULD BE INSTALLED

“LINE-TO-LINE”
0.020” MINIMUM CLEARANCE

Feeler
Outer Point of Gauge Refer to adjustment reference chart
Rail roller
(0.020) when using feeler gauges.
MA1060.eps
Contact

Inner
Step Feeler Gauge will Shimmed Shim
Rail Gauge Pass / Not Pass Correctly QTY
0.020” PASS Check with a
1 0.050” NOT PASS No, ADD 0
0.050” PASS Check with a
2 0.080” NOT PASS No, ADD 1
0.080” PASS Check with a
Intermediate
Rail
3 0.120 NOT PASS No, ADD 2
Pry Here

Check Clearance Here

Use "C" clamp

to force rollers
to one side.
Torque on "C"
clamp should not
Pry Here exceed 20 ft.lbs.

Check Clearance Here

Outer
Rail
MA1064.eps

Figure 56

7-55
MAST

Shimming
Checking Upper Roller Clearance With
Intermediate
Rail
Inner
Rail upright extended Approximately to full
Roller
extension
Pry
Here
Now check the roller clearance in the same manner as before.
Record the number of shim needed for the outer and inner rails
Check opposite the rollers checked.
Clearance
Here

ROLLERS SHOULD BE INSTALLED

“LINE-TO-LINE”
0.020” MINIMUM CLEARANCE
Feeler
Outer Point of
Rail roller
Gauge
MA1060.eps
Contact (0.020) Refer to adjustment reference chart
when using feeler gauges.

Step Feeler Gauge will Shimmed Shim

Inner
Rail Gauge Pass / Not Pass Correctly QTY
0.020” PASS Check with a
Check Clearance Here 1 0.050” NOT PASS No, ADD 0
0.050” PASS Check with a
Pry Here 2 0.080” NOT PASS No, ADD 1
0.080” PASS Check with a
3 0.120 NOT PASS No, ADD 2

Intermediate
Rail

Check Clearance Here

Pry Here
Use "C" clamp
to force rollers
to one side.
Torque on "C"
clamp should not
exceed 20 ft.lbs.
MA1065.eps

Outer
Rail

Figure 57

7-56
MAST

Shimming
Checking Lower Roller Clearance With
Intermediate
Rail
Inner
Rail
upright extended Approximately within 6”
of full extension
Roller

Pry Now check the roller clearance in the same manner as before.
Here
Record the number of shim needed for the outer and inner rails
Check opposite the rollers checked.
Clearance
Here

ROLLERS SHOULD BE INSTALLED

“LINE-TO-LINE”
0.020” MINIMUM CLEARANCE
Feeler
Outer Point of
Rail roller
Gauge
MA1060.eps
Contact (0.020) Refer to adjustment reference chart
when using feeler gauges.

Step Feeler Gauge will Shimmed Shim

Inner
Rail
Gauge Pass / Not Pass Correctly QTY
0.020” PASS Check with a
1 0.050” NOT PASS No, ADD 0
0.050” PASS Check with a

Pry Here
2 0.080” NOT PASS No, ADD 1
0.080” PASS Check with a
3 0.120 NOT PASS No, ADD 2
Check Clearance Here

Intermediate
Rail

Pry Here
Use "C" clamp
to force rollers
to one side.
Torque on "C"
clamp should not
exceed 20 ft.lbs.
Check Clearance Here
Outer
Rail

MA1066.eps

Figure 58

7-57
MAST

Determining the Number of Shims needed

to make roller adjustments
• Refer to step 3. Look at the three numbers
that were recorded at each roller on the rails.
The smallest of these is the total number of
shims that need to be added. “0” means DO
NOT add shims.
• If any of the rollers require adjustment, refer
to adjustment procedures on next page. # of Shims Dimension Dimension
• If the upright roller clearance was checked per Shim (in) (decimal - in)
one 0.031
with the upright mounted to the truck, and two 1/32” 0.062
roller adjustment is required, remove the three 0.093
upright from the truck as described at the
beginning of this section.
• Do not attempt to adjust roller with the
upright mounted to the truck.

Example
Step 1 of Gauge Step 3
Step 2
Readings

1
1
Inner
1 Rail

0.020 - 0.040" 0
2
1 Inner 0.040 - 0.060" 2

Rail Inner 0
Rail 0.080 - 0.100" 2
3

1
Intermediate
3
Rail

1
1

Intermediate
Rail
3

2 0
3 2
2
0
3 Intermediate 2
3
Rail

Outer
Rail

Outer Outer MA1067.eps

Rail Rail Rail extended to
Rail extended to
Rail extended to within 6 - 10" of
within 6 - 10" of
within one half of full extension.
fully retracted.
full extension. Figure 59

7-58
MAST

Shim Adjustment
With the upright laying horizontal on
blocking.
• Expose the rollers by pulling the rails
part way out of the bottom as shown.
• Pull rollers (one set at a time) from their
stubshaft. Count the number of shim(s)
currently used on each shaft. Add Right
shims as indicated in the roller
clearance check. Left
• If the check indicates that an even
number of shims are needed Upper
(2 etc..), split the number between Rollers
the right and left sides. If the check
indicates an odd number of shims
(3, etc..), place the odd shim on the
right hand side shaft. Always keep
the odd number of shims on to one
side.
• The target for adjustment is to have
the same number of shims on each
roller set (right and left per rail
assembly). An odd or extra shim
MA1068.eps
must be placed on the same side
as the one before.
• Reposition each roller on it’s shaft
using a rubber or plastic mallet.
Lower
Gently tap the roller to seat it evenly
Rollers
and snugly on the shaft.

Right

Left
Pull Rails part way out the bottom
exposing rollers at both ends.

Figure 60

7-59
MAST

Shimming
Lift Bracket & Fork Carriage Assembly 5.7
The Lift Bracket Assembly may be serviced while
installed in the upright with two exceptions:
the carriage rollers and the inner and outer arm
bushings must be serviced with the lift bracket
removed from the upright.
Preparation
• Move truck to service area.
• Park truck on a flat level surface.
• Extend and lower lift bracket.
• Turn key switch OFF.
1. Remove Load Back Rest Extension.
Remove bolts from load backrest Extension
and lift the extension free of the fork
carriage.
2. Elevate and Block Lift Bracket.
• Turn key switch ON and elevate lift
bracket approximately 3 to 4 feet.
• Place an oak block (hardwood) between MA2189.eps

lift bracket carriage and ground. Lower lift

bracket until carriage rests on 4X4
blocking as shown.
• Tilt forks forward.
• Turn key OFF and remove key.
• Disconnect truck battery. Figure 61

Disconnect
Battery

MA1035.eps

Figure 62

7-60
MAST

FORK REMOVAL WARNING

!
Refer to Figure 63
Remove fork by releasing the locking pin on the Forks are heavy. Care must be taken to
top fork hanger and sliding the fork to the center avoid personal injury.
of the carriage fork bar. Lift the fork up and
disengage the fork hanger from the carriage bar.

MA2201.eps

Figure 63

7-61
MAST

LIFT BRACKET SERVICE

Fork Carriage Removal
Upright Models Equipped with Side Shift Only
1. Remove hose hold down cap.
2. Disconnect electrical plug (1) from the main
harness connector.
3. Disconnect both hydraulic connections at the
connector fitting (2). Cap the open ports and
connections.
Pantograph

MA2192.eps

Block

1
Figure 64

MA2207.eps

Figure 65

7-62
MAST

Fork Carriage Removal

Models Equipped with Tilt Only
1. Remove both cable and hose covers (4),
Arms See below.
2. Disconnect hydraulic connection (a) from tilt
C cylinders.

C All Models
3. Install lifting straps as shown to chain hoist
equipped with
safety hook.
4
4. Remove retainer bolts and pins (C) securing
scissor arms to the fork carriage.
5. Slowly elevate carriage until free of arms.
Continue to elevate until lower scissor rollers
MA2193.eps
are free to one side.
B
Lift Straps
A &
Safety Hook

2
1

MA2218.eps

Figure 66

7-63
MAST

Lift Bracket Service

Servicing Lift Bracket Arm Rollers
Thrust Pads (Scissor Arm Roller “B” &
“C”)
When pad is worn near "flush" with carriage
roller, new pads should be installed
1. Disconnect reach arm cylinders.
See figure 66. Remove retainer bolts and
pins (item “B”) securing reach cylinder to lift
B bracket arms.
2. Lift reach arms (A) upward while pivoting
arm (B) in direction shown in figure 67. This
allows access to arm roller and thrust pad
without removing scissor assembly from
A
carriage.
3. Inspect the thrust pads for further service as
C shown in figure 78. Pads that are damaged
or worn to their wear limit should be
removed and new pads installed.
4. Remove Allen screw and pad. Install new
MA1016.eps pad. Be certain same number of shims are
installed on the shaft if they were removed.
Figure 67
Scissor Arm Roller "B and C'

Shims

To Remove Arm Roller “B” (or ”C”): Nylon Thrust Pad

Slowly move Arm “A” (up as required) while Allen Screw

rotating Arm “B” (as shown) to move arm roller
upward and out of the carriage channel.

Be extremely careful that you do When pad is worn near "flush"

not “pinch” your hands or fingers. with carriage roller, new pads
should be installed

MA1017.eps

Worn Out New Pads

3.5 mm 6.3mm
Figure 68

7-64
MAST

Lift Bracket Service

Pivot Bearing

Grease Fitting

Inner Arm Pivot Bearings Outer Arm

MA1019.eps

MA1019.eps
Snap Ring

Cup

Cone

Shield
Grease Fitting
Cylinder
Bearing
Cone

Lock Nut

Nut (*)

Cup

Shims

Grease Fitting

O-Ring
Figure 68Roller
Wear Pad
Housing Allen Screw
Snap Ring
Shims

Roller
Wear Pad
Allen Screw Figure 69

5. Disassemble the outer arm assembly. Note

6. Replace seals with new ones. If the Inner Arm Pivot Bearings need to be
7. Wash bearings (cups and Cones) in a replaced, the lift bracket carriage must be
Stoddard type solvent. Inspect parts for removed from the upright.
further serviceability. Replace any part that is 9. Reassemble to the reverse of disassembly.
nicked or having rough spots in the cones or Lubricate parts with clean chassis grease
cups. Cones and cups must be replaced prior to assembly.
together. Do not install a new cone in an old
cup.
8. Check grease fitting for damage and to
make certain none are missing.Allen Screw

Important
Prepack bearing cup and cone assemblies prior to installation

7-65
MAST

Lift Bracket Service

Tilt Cylinder Overhaul
Cylinder Removal
Remove forks.
Refer to illustration 70
Remove fork by releasing the locking pin on the
top fork hanger and sliding the fork to the center
of the carriage fork bar. Lift the fork up and
disengage the fork hanger from the carriage bar.

! WARNING

Forks are heavy. Care must be taken to

avoid personal injury.

MA2201.eps

Figure 70

7-66
MAST

ITA LIFT BRACKETS

ITA Lift Bracket With Side Shifter

Carriage Pin
Carrier Assembly Dowel Pin

Lock Washer

Shim
Capscrew
Hose Clamp
Capscrew Snap Ring
Shim

Upper Wear Pad

Bushing

Tilt Cylinder Carriage Weldment

Cap

Tilt Pivot Fitting

Bushing Seal
Fitting
Tilt Pin
Seal
Wiper
SS Rod
Retainer Tilt Pin Bushing

Capscrew
Snap Ring
Fitting Valve Assembly Lower Grease Fitting
Carriage Claw Wear Pad
Coil

Capscrew

MA2202.eps

Guard
Lockwasher
Capscrew

Carriage Bar
Assembly
Figure 71

7-67
MAST

ITA Lift Bracket without Side Shifter

Carriage Frame Assembly

Dowel Pin

Capscrew
Shim
Lockwasher
Hose Clamp
Capscrew Snap Ring
Shim

Carrier Assembly

Cap
Shaft
Bushing

Clip Ring

MA2219.eps

Figure 72

7-68
MAST

Cylinder removal: Preparation Cleaning and Inspection

Remove the fork carriage by removing the The exterior surface of a cylinder should be
lower claws and lifting the carriage bars off thoroughly washed before disassembly.
the carriage frame. A soft fiber brush should be used to remove
Refer to figure 71 and 72. debris and foreign objects from grooves and
1. Extend the tilt cylinder completely. threaded areas, etc.
2. Secure the carriage frame using an A Stoddard type cleaning solvent should be used
overhead hoist and a lifting strap. to wash the cylinder.
3. Remove snap rings from the tilt pin. See Any part unfit for further service should be
figure 71 and 72. replaced with new part.
4. Using the hoist, take the slack out of the
strap.
5. Using a brass drift, drive shaft out. See
figure 71 and 72.
6. Using the hoist, rotate the carriage section
up to gain access to the tilt cylinder from
below the carriage weldment.
7. Disconnect the hydraulic hoses from the tilt
cylinder.
8. Remove the capscrews holding the tilt
cylinder pivot caps in place.
9. Remove the tilt cylinder.

7-69
MAST

Disassembly Retainer Assembly

(Refer to Illustration Below) 1. Remove wiper ring.
Wash exterior of the tilt cylinder in a Stoddard 2. Remove rod seal from inner groove. Be
type cleaning solvent before disassembly. Use a careful that you do not nick or scratch
brush to remove grease and grime from the surface of retainer assembly.
cylinder tube, anchor and rod ends. 3. Remove outer o-ring and backup ring from
1. Place cylinder in a vise equipped with soft the retainer assembly.
jaws. Do not overtighten - distortion of the 4. Discard seals, wiper and backup rings.
shell will result.
2. Push piston rod all the way into cylinder. Piston Rod and Piston
3. Using a narrow blade screwdriver, remove 1. Separate the inner shell from the rod
the capscrew securing the pull wire / assembly.
retaining ring. 2. Remove the back rings and o-rings from the
4. Remove the pull wire by rotating the upper inner shell and discard.
section of the shell clockwise while gently 3. Remove the piston retaining ring.
prying the pull wire out of it’s groove. 4. Remove piston seal with o-ring from piston
5. Remove the upper section of the shell while and discard.
pushing the piston rod through the upper 5. Remove the piston.
shell section.
6. Discard o-ring, sealing ring and energizer.
6. Remove the piston / rod assembly. Always install new seals.

Retaining
Capscrew
Ring
Inner Shell
Back-Up
Seal Piston O-Ring
w/O-Ring

Base Rod

Retaining
Ring
Rod
O-ring Seal
Piston Wiper
Fitting
Outer Shell
Pivot Shaft
MA2209.eps

Figure 73

7-70
MAST

Cleaning and Inspection Retainer Assembly

1. Discard old seals, wiper and shear ring. 1. Lubricate new seals, wiper ring and retainer
2. Wash all parts in a Stoddard type cleaning assembly with clean hydraulic fluid.
solvent and dry with a clean lint free shop 2. Install the inner seal, with the sealing lip
rag. facing inward, into the retainer groove. Be
3. Inspect cylinder mounting bushings for careful not to nick the sealing lip upon
damage. If the bushings show signs of wear installation.
and/or damage, they should be replaced with 3. Install a new wiper into retainer.
new bushings. 4. Lubricate and install a new backup ring into
4. Examine cylinder barrel for scoring, nicks or the outer groove on the retainer.
scratches. The cylinder barrel may be 5. Lubricate and install a new o-ring in the
sanded with crocus cloth to remove minor groove next to the backup ring. Note the
scratches, etc.. Be careful not to remove the position of the backup and o-ring per figure
chrome plating when polishing the surface. 73.
Replace all damaged or unserviceable parts.
6. Push retainer as far as it will go into the
5. Inspect surfaces of the piston and piston rod housing.
to be sure they are clean, smooth and free of
damage. 7. Insert the new pull wire in the pull wire
pushing on the wire with your fingers. Rotate
the top section of the outer shell counter
clock wise while pushing the pull wire into
the groove.
Reassembly
8. Once the pull wire is installed, insert and
1. Using only new seals and o-rings, lubricate tighten the capscrew to secure the pull wire.
all parts with clean hydraulic fluid.
2. Lubricate and install the energizer o-ring into
the groove in the piston. Refer to figure 73.
3. Lubricate and install the piston seal over the
energizer. Be careful not to nick or cut the
seals.
4. Install new o-rings and back-up rings onto
the inner shell.
5. Lubricate the seals of the inner shell and
insert the inner shell into the outer shell.
6. Lubricate the piston and piston rod with
clean hydraulic fluid.
7. Start piston into cylinder tube while gently
pushing and rotating piston rod. Be careful
not to damage seal.
8. Shove the piston rod all the way into the
cylinder tube until it bottoms.

7-71
MAST

REACH CYLINDER OVERHAUL WARNING

!
Cylinder Removal
Support forks as forkbar is removed so
Remove forks. they canot fall.
Refer to Figure 74
Remove fork by releasing the locking pin on the
top fork hanger and sliding the fork to the center
of the carriage fork bar. Lift the fork up and
disengage the fork hanger from the carriage bar.

MA2201.eps

Figure 74

7-72
MAST

Cylinder removal:
Remove the fork carriage as described on
page 62.
Refer to figure 75.
1. Extend the reach cylinder completely.
2. Using an overhead crane, secure the scissor
arms (C) to keep the scissor arms from Lift Straps
falling once the reach cylinder has been &
disconnected. See figure 85. Safety Hook
3. Disconnect the hydraulic connectors and
plug all open lines.
4. Remove retainer bolt and pin (B) securing
cylinder shaft ends in position. See figure 85.
It may be necessary to use a brass drift to
gently tap the pins loose.
5. Remove the reach cylinder and place on a C
clean work bench.

C
A
Arms
MA1089.eps

Reach
Cylinder

Figure 75

7-73
MAST

Preparation, Cleaning and Inspection 4. Threaded area of piston rod should be

1. The exterior surface of a cylinder should be examined for damage, stripping or marring
thoroughly washed before disassembly. after removal of rod end and jam nut. The
bushing in rod end should be inspected for
2. A soft fiber brush should be used to remove further serviceability.
debris and foreign objects from grooves and
threaded areas, etc. 5. All foreign objects should be removed from
between threads on the piston rod, in the nut
3. A Stoddard type cleaning solvent should be and rod end.
used to wash the cylinder.
6. Any part unfit for further service should be
replaced with new part.

Bushing
(Bronze/Teflon)
NOTE
Press Bushings
Flush with
Rod End.
Rod Nut
Cylinder Piston Rod

MA1021.eps

Inspect Threads
Rod End

Figure 76

7-74
MAST

A A

Right Hand A Left Hand

Reach Cylinder Reach Cylinder A

Shear O-Ring
Retaining Ring w/ Back-up Shell Piston
Ring Nut
Rod Seal Rod Seal
Rod End Retainer Piston
Nut
Wiper

MA2197.eps

Typical Illustration

Figure 77

Disassembly Retainer Assembly

(Refer to Illustration Above) 1. Remove wiper.

Wash exterior of the reach cylinder in a Stoddard 2. Remove seal from inner groove. Be careful
type cleaning solvent before disassembly. Use a that you do not nick or scratch surface of
brush to remove grease and grime from the retainer assembly.
cylinder tube, anchor and rod ends. Remove rod 3. Remove outer o-ring and backup ring from
end and jam nut. the retainer assembly.
1. Place cylinder in a vise equipped with soft 4. Discard seals, wiper and backup rings.
jaws. Do not overtighten - distort shell.
Piston Rod and Piston
2. Push piston rod all the way into cylinder.
1. Using a 3/4” wrench, hold the rod using the
3. Using snap ring pliers, remove the snap ring “flats” provided just below threaded area of
from the cylinder retainer. piston rod. Now install a 2-2/8 in. socket onto
4. Remove o-ring. the piston rod nut.
5. Using a bronze drift, gently tap retainer 2. Remove nut from piston rod while holding
assembly into cylinder housing clear of the the piston rod.
shear ring. 3. Pull piston free of piston rod.
6. Using a screwdriver, carefully lift end of 4. Remove sealing ring and the energizer from
shear ring from it’s groove. Be careful not to piston. Use care not to nick or scratch piston
nick or scratch the piston rod. surfaces.
7. With a pair of pliers, carefully pull shear ring 5. Discard o-ring, sealing ring and energizer.
from cylinder tube. Again, be careful not to Always install new seals.
nick or scratch the piston rod.
8. Pull outward on piston rod until rod and
retainer are free of cylinder housing.
Remove retainer.

7-75
MAST

Cleaning and Inspection Bushing

1. Discard old seals, wiper and shear ring.

2. Wash all parts in a Stoddard type cleaning
solvent and dry with a clean lint free shop
rag.
3. Inspect cylinder mounting bushing for
Grease Fitting
Bushing
damage. If the bushings show signs of wear
and/or damage, they may be pressed out
and new bushing installed. A Sleeve to fit
over spherical inner bushing will be needed.
Do not press out by prying on the inner Grease Fitting

bushing. Refer to figure 89.

MA1027.eps

4. Inspect threaded parts for damage. Examine

cylinder barrel for scoring, nicks or PORT "B" Figure 78
PORT "A"
scratches. A The cylinder barrel may be 10. Start piston into cylinder tube while gently
sanded with crocus cloth to remove minor pushing and rotating piston rod until piston
scratches, etc.. Be careful not to remove the and seal have passed the shear ring groove
chrome plating when polishing the surface. in the cylinder tube. Be careful not to
Replace all damaged or unserviceable parts. damage seal.
5. Inspect surfaces of the piston and piston rod 11. Push the piston rod all the way into the
to be sure they are clean, smooth and free of cylinder tube until it bottoms.
damage.
Retainer Assembly
Reassembly
1. Lubricate new seals, wiper ring and retainer
1. Lubricate all parts with clean hydraulic fluid. assembly with clean hydraulic fluid.
2. Lubricate and install the energizer ring into 2. Install the inner seal, with the sealing lip
the groove in the piston. Refer to figure 77. facing inward, into the retainer groove. Be
3. Lubricate and install the piston seal over the careful not to nick the sealing lip upon
energizer. Be careful not to nick or cut the installation.
seals. 3. Install a new wiper into retainer.
4. Place a plastic parts bag over the threaded 4. Lubricate and install a new backup ring into
area of the piston rod (to protect seal). Slide the outer groove on the retainer.
a new o-ring over the bag and into the
5. Lubricate and install a new o-ring in the
groove in the piston rod.
groove next to the backup ring. Note the
5. Remove bag and install piston onto rod. position of the backup and o-ring per above
Carefully slide the piston over and up against diagram.
the rod shoulder.
6. Place a plastic parts bag over the threaded
6. Install nut onto piston rod finger tight against end of the rod (to protect seals) and carefully
the piston. slide the retainer over the rod and into the
7. Install the 3/4” wrench back into the “Flats” cylinder housing.
provided in the piston rod. 7. Push retainer as far as it will go into the
8. Using a torque wrench and 1-1/8 in. socket, housing.
torque nut to 115 - 132 ft. lbs. (156 - 179 8. Insert the open end of a new shear ring into
Nm). the cylinder housing while pushing on the
9. Now, lubricate the piston and piston rod with ring with your fingers. Push ring inward as
clean hydraulic fluid. far as you can.

7-76
MAST

Retainer Assembly (Continued)

1. Using a bronze punch, gently tap ring the
rest of the way into the tube and groove. Be
sure the shear ring is fully seated in it’s
groove.
2. Pull the piston rod out as far as it will come.
This will position the retainer so that the
retainer ring groove and into the housing on
top of the retainer.
3. Lubricate a new backup ring and place it
over the o-ring just installed.
4. Install the washer over the retainer and next
to the backup ring previously installed.
5. Install a new split retainer into it’s groove in
the retainer assembly. Be sure it is
completely seated in it’s groove.
6. Install jam nut and rod end to the same
location it was when removed from the
piston rod.
7. Cap cylinder ports until the cylinder is
installed on the truck.
8. Check fluid level of truck once cylinder have
been installed.
9. Purger air from hydraulic system by cycling
cylinders several times to force air from the
lines into the sump tank.

A A

Right Hand A Left Hand

Reach Cylinder Reach Cylinder A

Shear O-Ring
Retaining Ring w/ Back-up Shell Piston
Ring Nut
Rod Seal Rod Seal
Rod End Retainer Piston
Nut
Wiper

MA2197.eps

Typical Illustration

7-77
MAST

SIDE SHIFT CYLINDER OVERHAUL

Cylinder Removal
Lift Bracket Service
Remove forks.
Refer to illustration 80
1. Remove fork by releasing the locking
pin on the top fork hanger and sliding
the fork to the center of the carriage
fork bar. Lift the fork up and disengage
the fork hanger from the carriage bar.
2. Loosen fittings at the bottom of the
side shifter cylinder, catching any
oil that may escape.
3. Using a pry bar, push the side shifter
rods into the cylinder body catching
any oil be leaks from the cylinder.
4. Remove the capscrews securing the
carriage claws to the back of the lower
carriage bar.
MA2201.eps

5. Rotate the front of the carrier frame

up and remove the carriage bars.
6. Remove all wear pads and discard. Figure 80

! WARNING

Support forks as forkbar is removed so

they canot fall.

7-78
MAST

Preparation Cleaning and Inspection Retainer Assembly

1. The exterior surface of a cylinder should be 1. Remove the piston rod seal and wiper. Be
thoroughly washed before disassembly. careful that you do not nick or scratch
2. A soft fiber brush should be used to remove surface of retainer assembly.
debris and foreign objects from grooves and 2. Remove outer o-ring from the retainer
threaded areas, etc. assembly.
3. A Stoddard type cleaning solvent should be 3. Discard seals, wiper and backup rings.
used to wash the cylinder.
4. Any part unfit for further service should be
replaced with new part.

Disassembly (Refer to Figure 81)

Wash exterior of the side shift cylinder in a
Stoddard type cleaning solvent before
disassembly. Use a brush to remove grease and
grime from the cylinder tube, anchor and rod
ends.
5. Using a spanner wrench in the holes located
in the top of the retainer, rotate the retainer
assembly counter clockwise to loosen the
retainer.
6. Remove retainer and rod.
7. Remove rod from retainer.

7-79
MAST

LIFT BRACKET SERVICE

Carriage Pin
Carrier Assembly Dowel Pin

Lock Washer

Shim
Capscrew
Hose Clamp
Capscrew Snap Ring
Shim

Upper Wear Pad

Bushing

Tilt Cylinder Carriage Weldment

Cap

Tilt Pivot Fitting

Bushing Seal
Fitting
Tilt Pin
Seal
Wiper
SS Rod
Retainer Tilt Pin Bushing

Capscrew
Snap Ring
Fitting Valve Assembly Lower Grease Fitting
Carriage Claw Wear Pad
Coil

Capscrew

MA2202.eps

Guard
Lockwasher
Capscrew

Carriage Bar
Assembly

Figure 81

7-80
MAST

Cleaning and Inspection Reassembly

1. Discard old seals and wiper. 1. Lubricate new seals, wiper ring and retainer
2. Wash all rods and retainers in a Stoddard assembly with clean hydraulic fluid.
type cleaning solvent and dry with a clean 2. Install the inner seal, with the sealing lip
lint free shop rag. facing inward, into the retainer groove. Be
3. Inspect surfaces of the rod to be sure they careful not to nick the sealing lip upon
are clean, smooth and free of damage. installation.
3. Install a new wiper into retainer.
4. Lubricate and install a new o-ring in the
groove.
5. Push retainer as far as it will go into the
housing.
6. Using a spanner wrench, tighten the retainer.
7. Start rod into cylinder tube while gently
pushing and rotating the rod. Be careful not
to damage seal.
8. Push the rod all the way into the cylinder
shell until it bottoms out.
9. Purger air from hydraulic system by cycling
cylinders several times to force air from the
lines into the sump tank.
a. Reinstall new wear pads and lubricate
wear pads.
b. Reinstall front carrier on cylinder body.
c. Reinstall carriage claws and capscrews
to back face of the lower bar.

7-81
MAST

Preparation
Reach and Side Shift Selector Valve
1. Move the truck to a service area.
Disconnect
• Move truck to a flat level surface. Battery

• Extend lift bracket.

• Fully lower lift bracket.
• Tilt (if so equipped) forks forward MA1035.eps

until the fork tips touch the ground.

2. Turn key switch off.
• Remove key.
• Disconnect truck battery.

MA1069.eps

Figure 82

7-82
MAST

Figure 83

7-83
MAST

Hydraulic Schematic

Mounting Bolts

A Guard

S6
S5

To
R.H.Hand Hydraulic
Reach Supply
Cylinder To
11 12
L.H. Hand
6 7 Reach
Cylinder
To Tilt Cylinders
9 10
or
Side Shifter
Selector Valve
5 8

To Truck
Auxiliary
Switches
B
To Truck
Hydraulic
Supply
! CAUTION

The solenoid valve stem is very

fragile. Be very careful when
handling the valve that you do not
dent or bend the stem.
MA1076.eps
Over torquing the coil nut or the
valve at installation will cause
damage to the valve.
Figure 84

7-84
MAST

Illustration
Mounting Bolts

6 7

9 10
5
8

To
L.H. Reach To
Cylinder R.H. Reach
Cylinder

To Tilt Cylinder
or
Side Shifter
Selector Valve

To Truck
Auxiliary
Switches

To Truck
Hydraulic
Supply

MA1075.eps

Figure 86

7-85
MAST

Reach and Tilt Selector Valve Disassembly

• Remove nuts, coils and solenoid valves (S5)
WARNING and (S6) from the valve body.
!
Note
Be sure the lift bracket is blocked.
The valve body and valves are not serviceable. If
the unit is not functioning properly, it must be
replaced.
! WARNING

Hydraulic lines may have trapped

pressure. “Crack” the fittings to bleed
pressure before disconnecting.

! WARNING

When trapped pressure is bled, the lift

bracket may settle. Beware.

1. Loosen guard mounting bolts and remove

the guard.
2. Unplug connect (#1) from coil (S6) and
unplug connectors (#2) from coil (S5).
3. Remove fasteners (#4) from clamp (#3).
4. Tag hoses and disconnect hydraulic
connections (#5) and (#8) from valve (A).
Cap both hose ends.

! CAUTION

Residual pressure will be present when

disconnecting hydraulic lines. Use
caution when disconnecting fittings.

5. Tag tubes and disconnect fittings (#11) and

(#12) from bottom side of valve (A). Cap
both hose ends.
6. Remove both mounting fasteners from lift
bracket frame (B) and valve (A).
7. Remove valve from lift bracket. Place
components on a clean work bench.

7-86
MAST

Illustration
Mounting Bolts

A Guard

S6
S5

To
R.H.Hand Hydraulic
Reach Supply
Cylinder To
11 12
L.H. Hand
6 7 Reach
Cylinder
To Tilt Cylinders
9 10
or
Side Shifter
Selector Valve
5 8 Mounting Bolts

6 7

9 10
To Truck
5
Auxiliary 8
Switches
B
To Truck
A
Hydraulic
Supply

MA1076.eps To
L.H. Reach To
Cylinder R.H. Reach
Cylinder
Figure 87

To Tilt Cylinder
or
Side Shifter
Selector Valve

To Truck
Auxiliary
Switches

To Truck
Hydraulic
Supply

MA1075.eps

Figure 88

7-87
MAST

Mounting Selector Valve IMPORTANT

1. Position the valve to the lift bracket frame Be sure the hoses are routed correctly before
aligning holes in frame with those in the attempting to connect them to the valve.
valve. Refer to illustration on previous page. Installing clamps, connect wire, tighten nuts
2. Install mounting fasteners finger tight. Do not and bolts
tighten fasteners until after the hydraulic 7. Be sure the valve guard is located properly
hoses are installed. and securely tighten both solenoid valve
Connecting Hydraulic Plumbing mounting bolts.

3. Remove cap, hose tag and install connection 8. Install wire clamps (#3) and bolts (#4).
(#11) to the valve finger tight. 9. Connect coil plugs to their respective
4. Remove cap, hose tag and install (#12) receptacles.
connection finger tight. IMPORTANT
5. Install connections (#5) and (#8). Install All electrical plugs and their receptacles are
connections (#6, 7, 8, 9 and 10) to the reach matched labeled for easy connection. Check
cylinders finger tight. to be sure each plug and receptacle match
6. Securely tighten each hydraulic connection before attempting to make connections.
to the valve body and the reach cylinder.

! CAUTION
The system must be purged of air before
putting truck back into service or damage
to the hydraulic system may occur.

10. Install and tighten clamp bolts (#4).

7-88
MAST

Lift Bracket Service

Side Shifter Solenoid Control Valve
1. Move the truck to a service area.
• Move truck to a flat level surface.
• Extend lift bracket.
• Fully lower lift bracket.
• Tilt (if so equipped) forks forward until the
fork tips touch the ground.
2. Turn key switch off.
• Remove key.
Disconnect
Battery
• Disconnect truck battery.
3. If equipped, control circuit capacitors must
be discharged to avoid possibly being
shocked when working on the solenoid MA1035.eps

valve.
a. Remove guard lockwashers and
capscrews. Figure 89

Carriage Pin
Carrier Assembly Dowel Pin

Lock Washer

Shim
Capscrew
Hose Clamp
Capscrew Snap Ring
Shim

Upper Wear Pad

Bushing

Tilt Cylinder Carriage Weldment

Cap

Tilt Pivot Fitting

Bushing Seal
Fitting
Tilt Pin
Seal
Wiper
SS Rod
Retainer Tilt Pin Bushing

Capscrew
Snap Ring
Fitting Valve Assembly Lower Grease Fitting
Carriage Claw Wear Pad
Coil

Capscrew

MA2202.eps

Guard
Lockwasher
Capscrew

Carriage Bar
Figure 90 Assembly

7-89
MAST

Figure 90
Removal
• Unplug Connectors from (S7) coil.
• Label each hose with it’s location.
• Disconnect hydraulic connections (V1, V2,
C6, C5, C2, and C4) from the side shifter
selector valve.
• Cap each hose when disconnected.

! WARNING 1

Hydraulic lines may have trapped

pressure. “Crack” the fittings to bleed 2
pressure before disconnecting.

Note 3
There will be some fluid leakage when hydraulic
fittings are disconnected. Place a rag beneath
the fitting to be removed.
• Remove mounting bolts securing the selector
valve to the lift bracket.
• Remove valve and place on a clean work
bench.
• The valve assembly is not serviceable, if unit
is not functioning properly, it must be
replaced.
• Inspect hoses and connectors for further MA2207.eps

serviceability.
• Replace defective parts. Figure 91

7-90
MAST

Installation
Mount Selector Valve
• Line up mounting holes in selector valve with
those in the mounting bracket. Install
mounting bolts finger tight.
Install Hoses
• Wipe hose ends and connectors clean.
Remove hose caps just prior to installation.
Be certain all connections are tight.
Connect Coils
• Plug connectors to (S7) and (S8) coils.
• Tighten all mounting fasteners.
• Install guard.

Figure 93

7-91
MAST

Carriage Pin
Carrier Assembly Dowel Pin

Lock Washer

Shim
Capscrew
Hose Clamp
Capscrew Snap Ring
Shim

Upper Wear Pad

Bushing

Tilt Cylinder Carriage Weldment

Cap

Tilt Pivot Fitting

Bushing Seal
Fitting
Tilt Pin
Seal
Wiper
SS Rod
Retainer Tilt Pin Bushing

Capscrew
Snap Ring
Fitting Valve Assembly Lower Grease Fitting
Carriage Claw Wear Pad
Coil

Capscrew

MA2202.eps

Guard
Lockwasher
Capscrew

Carriage Bar
Assembly

Figure 94

7-92
MAST

Servicing a Double Reach Lift Bracket

The Double Reach Lift Bracket is serviced the
same as the Single Reach Lift Bracket with one
exception. The Double Lift Bracket has two
scissor assemblies. Follow service procedures
outlined in Section 7, Figures 95-97.

Sideshifting Models Only

Sleeve

Clamp

Solenoid Scissor Pin Capscrew

Valve Block
C2

Solenoid
Coil
Roll Pin Wire Harness
Fitting to Sideshifter
Reach
Cylinder

Fitting

Fitting
Tube

Solenoid O-Ring
Coil
Guard

Clamp

Fitting
Hose Guard
Clamp Cylinder Pin

Fitting

Wire Harness

Capscrew

Tube Assembly

Nut

CONNECT TO PLUG ON
MAST WIRE HARNESS

Figure 95

MA2313.eps

7-93
MAST

Double Reach Without Sideshifter

Inner Reach
Cylinder Hose
Tilt Cylinder Hoses

Outer Reach
Cylinder Hose

Cover

MA2310.eps
Cable Tie

Figure 96 Hose Routing

Double Reach With Sideshifter

Inner Reach
Cylinder Hose
Tilt Cylinder Hoses and Cable

Outer Reach
Cylinder Hose

Cover

MA2311.eps
Cable Tie

Figure 97 Hose Routing

7-94
TROUBLESHOOTING AND PIN BY PIN VOLTAGES

8. TROUBLESHOOTING & PIN BY PIN VOLTAGES

Display Information Example Alarm logbook information to the driver /

Warning situation, information to the driver: maintenance:

WARNING ON MOD#06 ALARM LOGBOOK 01

STEERING HAZARD CODE = 18: DRIVER EVP GR1

Alarm situation, information to the driver:ALARM NODE =9

18 ON MOD #09 DATE = 01/20/03
CALL MAINTENANCE TIME = 02:33 PM
HOURS = 0023
BATTERY = 080

Sicos Alarms and Warnings (Mod#1)

00001 ZAPI VERSIONS ALARM CLASS Alarm # SICOS (MOD #1)
00002 ACC OUT OF RANGE Alarm 1 Accelerator voltage near 0 or near 5V
Accelerator high at stand or not correctly
00057 VACC NOT OK Warning 2 programmed.
appear when pressing the buttons
UP+DOWN+ENTER at key switch on for at least
10 seconds. The EEPROM is in the re-programming
00013 CLEARING EEPROM! Warning 3 phase
00024 EEPROM KO Alarm 4 Eeprom parameters managing error
forward and backward switch closed in the same
00027 FORW + BACK Warning 5 time
00045 POT #1 NOT OK Warning 6 lifting pot high at stand or not correctly programmed
00006 CAN BUS KO EPS 7 No message from EPS to Sicos
00007 CAN BUS KO EV 8 No message from Mhyrio to Sicos
No message from module connected to Sicos with
00044 NO CAN MESSAGE Alarm 9 can bus
00008 CAN BUS KO PU #1 10 No message from pump 1 to Sicos
00009 CAN BUS KO PU #2 11 No message from pump 2 to Sicos
00010 CAN BUS KO TR 12 No message from traction to Sicos
not permitted configuration of the steering switches
00055 STEER SENSOR KO Warning 13 on the steering wheel
one of the modules connected to the sicos through
00005 CAN BUS KO Alarm 14 CAN BUS don’t communicate correctly
00012 CHECK UP NEEDED Warning 15 programmed maintenance request
pump or traction enable request at switch on or
00031 INCORRECT START Warning 16 starting sequence not correct
00046 POT #2 NOT OK Warning 17 reach pot high at stand or not correctly programmed
00049 POWER FAILURE #1 Alarm 18 Short circuit on the one of the sicos digital outputs
side shift pot high at stand or not correctly
00048 POT #4 NOT OK Warning 19 programmed
00047 POT #3 NOT OK Warning 20 tilting pot high at stand or not correctly programmed
Mhyrio Alarms and Warnings (Mod#9)
00001 ZAPI VERSIONS ALARM CLASS Alarm # MHYRIO (MOD #9)
Fault in the EEPROM. If the alarm persists after key
off/on, replace the Mhyrio. If the alarm disappears,
the parameters have been replaced with default
00024 EEPROM KO Alarm 4 values.
Flip-flop circuit, that manages valve drivers short-
circuit protection, has been set. The cause can be an
external short across the valve coil; it can be set also
00026 FF VALVES Alarm 35 by a disturb coming into Mhyrio logic.
One of the MOS (or more than one) that drives the
00019 DRIVER EVP GR1 Alarm 29 valves 1, 2 is shorted.
One of the MOS (or more than one) that drives the
00020 DRIVER EVP GR2 Alarm 30 valves 3, 4 is shorted.
One of the MOS (or more than one) that drives the
00021 DRIVER EVP GR3 Alarm 31 valves 5, 6, 7, 8 is shorted.

8-1
TROUBLESHOOTING AND PIN BY PIN VOLTAGES

00001 ZAPI VERSIONS ALARM CLASS Alarm # MHYRIO (MOD #9)

The high side switch that drive positive to valves
(used for safety related valves) is closed when it
00023 DRIVER SHORTED Alarm 33 should be opened.
The high side switch that drives positive to valves
(used for safety related valves) is opened when it
00022 DRIVER OPEN Alarm 32 should be closed.
Electric Steer Controller Alarms And Warnings (Mod #6)
00001 ZAPI VERSIONS ALARM CLASS Alarm # EPS ( MOD #6)
Cause: the Master Microprocessor (MM) has
detected a status signal coming from the supervisor
(SM) that doesn’t agree with the present command
values. When MM is reading a command value
different from the one the SM is reading, this alarm
occur. Remedy: If the alarm occurs permanently, it
00042 MICRO SLAVE KO Alarm 49 is necessary to substitute the logic.
Error in EEPROM parameters. Clearing EEPROM
00024 EEPROM KO Alarm 4 might fix the problem.
In the initial rest state at least one of the phases of
the motor voltages are high. If the alarm occurs
00063 VMN NOT OK Alarm 62 permanently, the EPS need to be replaced.
00054 STEER HAZARD Warning 55 Limit switch active
Mismatch between main microcontroller and slave
00041 MICRO SLAVE Alarm 48 microcontroller
Motor U is disconnected/broken. This can also be
caused if battery + connection is disconnected from
00049 POWER FAILURE #1 Alarm 18 EPS.
00050 POWER FAILURE #2 Alarm 51 motor V is disconnected/broken.
00051 POWER FAILURE #3 Alarm 52 motor W is disconnected/broken.
Occurs during init by CAN-bus synchronization with
00040 MAIN CONT. OPEN Warning 47 traction module if main contactor doesn’t close.
Occurs when the unit power base exceeds 76
00029 HIGH TEMPERATURE Alarm 37 celcius degrees. Let the unit cool down.
Real voltage between phases U and V are different
00036 LOGIC FAILURE #1 Alarm 43 from the desired.
Real voltage between phases U and W are different
00037 LOGIC FAILURE #2 Alarm 44 from the desired.
The rest state current signals between phases U and
00053 STBY I HIGH Alarm 54 W are not in the window 2,5+/-0,3Vdc.

00039 LOGIC FAILURE #4 Alarm 46 The rest state voltage of the phases U and W is high.
00038 LOGIC FAILURE #3 Alarm 45 The rest state voltage of the phases V and U is high.
The safety contact did not operate when the master
00032 KM CLOSED Alarm 39 controlled it. It was stuck to closed position.
The safety contact did not operate when the master
00033 KM OPEN Alarm 40 controlled it. It was stuck to open position.
The safety contact did not operate when the slave
00034 KS CLOSED Alarm 41 controlled it. It was stuck to closed position.

The safety contact did not operate when the slave

00035 KS OPEN Alarm 42 controlled it. It was stuck to open position.
This alarm occurs only when the operator turns to
level 1 the "Adjustment #1". Switching on / off the
00018 DATA ACQISITION Warning 28 key removes the alarm.
Lift Controller AC-3 (Mod #37)
00001 ZAPI VERSIONS ALARM CLASS Alarm # AC-3 (MOD #37)
A problem with the motor connections or the motor
power circuit. This can also be caused if the inverter
00061 VMN HIGH Alarm 60 is broken.
A problem with the motor connections or the motor
power circuit. This can also be caused if the inverter
00062 VMN LOW Alarm 61 is broken.
00056 THERMIC SENS. KO Warning 56 AC-3 thermal sensor out of range.
Chopper temperature is over 75 celcius degrees.
Unit stops at 100 celcius degrees. Let the unit cool
00029 HIGH TEMPERATURE Alarm 37 down.

8-2
TROUBLESHOOTING AND PIN BY PIN VOLTAGES

00001 ZAPI VERSIONS ALARM CLASS Alarm # AC-3 (MOD #37)

00003 AUX OUTPUT KO Alarm 21 Electromagnetic brake output is faulty.

00005 CAN BUS KO Alarm 14 Error at can-bus. Check wiring, if ok, replace AC-3.
Fault in the EEPROM. If the alarm persists after key
off/on, replace the AC-3. If the alarm disappears,
the parameters have been replaced with default
00024 EEPROM KO Alarm 4 values.
Fault in the hardware section of the logic board
which manages the hardware current protection.
00038 LOGIC FAILURE #3 Alarm 45 Replace the logic board.
Fault in the hardware section of the logic board
which manages the phase’ s voltage feedback.
00037 LOGIC FAILURE #2 Alarm 44 Replace the logic board.
Incorrect start sequence. If the sequence was right,
00031 INCORRECT START Warning 16 check the microswitch or wiring fault.
Motor over temperature. If this happens when the
00043 MOTOR TEMPERAT. Warning 50 motor is cold, check wiring.
00052 SAFETY Alarm 53 Security input not active
The main contactor coil has been driven by the logic
00017 CONTACTOR OPEN Alarm 27 board, but the contactor does not close.
The rest state current is not 0. Causes might be
00053 STBY I HIGH Alarm 54 current sensor failure or logic failure.
The test is carried out when the key is switched on
and in stand-by. It means there is a failure on
current feedback connectors (G, H) or in the
current transducer or in the current amplifier; check
00030 I=0 EVER Alarm 38 the connectors and the cables.
The test is made in both running and standby. It is a
self-diagnosing test within the logic. If an alarm
00060 WATCHDOG Alarm 59 should occur, replace the logic.
The truck does not start because the handbrake is
00028 HANDBRAKE Warning 36 on.
There is 10% of battery capacity left and current is
00004 BATTERY LOW Warning 22 reduced to half. Charge the battery.
This alarm is only at combi-systems, pump
configuration. Pump is OK and the CAN-bus is
working, but it can not proceed until the traction has
00059 WAITING TRACTION Alarm 58 finished it’s job.
This alarm is only at combi-systems, traction
configuration. Traction is OK and the CAN-bus is
working, but it can not proceed until the pump has
00058 WAITING PUMP 57 finished it’s job.
This alarm is signaled when a double running
request is made simultaneously. Check
00027 FORW + BACK Warning 5 microswitches and the wiring.
This is a warning. It is an information for the user
that the programmed time for maintenance is
00012 CHECK UP NEEDED Warning 15 elapsed.
00025 ENCODER ERROR Alarm 34 Too great variation in encoder signal
Undervoltage / overvoltage protection has operated.
There have been a real undervoltage situation or
00036 LOGIC FAILURE #1 Alarm 43 there is fault in the hardware section.
When the initial diagnosis is finished, the traction
logic closes the MC and checks the voltage on the
Drain of the driver. If this is not low , an alarm is
00016 CONTACTOR DRIVER Alarm 26 signaled. Replace the logic.
When the key is switched on, the inverter tries to
charge internal capacitor via resistor in certain time.
This can be caused if the charging resistance is
opened, the charging circuit has a failure or there is
00011 CAPACITOR CHARGE Alarm 23 a problem on the power modules.
When the key is switched ON the P checks the MC
driver FF SR. If it does not react in a correct way to
the P stimulus, the alarm is signaled. Replace the
logic board. The FF SR makes an hardware control
of the current in the MC coil. If this is too high, it
opens the MC and the alarm is signaled if there are
external shortcircuit and if the ohmic value of the
00014 COIL SHORTED Alarm 24 MC is correct.

8-3
TROUBLESHOOTING AND PIN BY PIN VOLTAGES

00001 ZAPI VERSIONS ALARM CLASS Alarm # AC-3 (MOD #37)

When the key is switched ON, the P checks that
the MC coil driver is not shorted; if it is, this alarm is
00023 DRIVER SHORTED Alarm 33 signaled; replace the logic board.
00064 WRONG SET BATT. Alarm 63 Wrong selection of battery type
AC-2, Traction (Mod#2), Pump (Mod#5)
00001 ZAPI VERSIONS ALARM CLASS Alarm # AC-2 (Tract. MOD#2, Pump MOD#5)
A problem with the motor connections or the motor
power circuit. This can also be caused if the inverter
00061 VMN HIGH Alarm 60 is broken.
A problem with the motor connections or the motor
power circuit. This can also be caused if the inverter
00062 VMN LOW Alarm 61 is broken.
00056 THERMIC SENS. KO Warning 56 AC-2 thermal sensor out of range.
Chopper temperature is over 75 celcius degrees.
Unit stops at 100 celcius degrees. Let the unit cool
00029 HIGH TEMPERATURE Alarm 37 down.
00003 AUX OUTPUT KO Alarm 21 Electromagnetic brake output is faulty.
00005 CAN BUS KO Alarm 14 Error at can-bus.
Fault in the EEPROM. If the alarm persists after key
off/on, replace the AC-2. If the alarm disappears,
the parameters have been replaced with default
00024 EEPROM KO Alarm 4 values.
Fault in the hardware section of the logic board
which manages the hardware current protection.
00038 LOGIC FAILURE #3 Alarm 45 Replace the logic board.
Fault in the hardware section of the logic board
which manages the phase’ s voltage feedback.
00037 LOGIC FAILURE #2 Alarm 44 Replace the logic board.
Incorrect start sequence. If the sequence was right,
00031 INCORRECT START Warning 16 check the microswitch or wiring fault.
00015 CONTACTOR CLOSED Alarm 25 Main contactor always closed
Motor over temperature. If this happens when the
00043 MOTOR TEMPERAT. Warning 50 motor is cold, check wiring.
00052 SAFETY Alarm 53 Security input not active
The main contactor coil has been driven by the logic
00017 CONTACTOR OPEN Alarm 27 board, but the contactor does not close.
The rest state current is not 0. Causes might be
00053 STBY I HIGH Alarm 54 current sensor failure or logic failure.
The test is made in both running and standby. It is a
self-diagnosing test within the logic. If an alarm
00060 WATCHDOG Alarm 59 should occur, replace the logic.
The truck does not start because the handbrake is
00028 HANDBRAKE Warning 36 on.
There is 10% of battery capacity left and current is
00004 BATTERY LOW Warning 22 reduced to half. Charge the battery.
This alarm is only at combi-systems, pump
configuration. Pump is OK and the CAN-bus is
working, but it can not proceed until the traction has
00059 WAITING TRACTION Alarm 58 finished it’s job.
This alarm is only at combi-systems, traction
configuration. Traction is OK and the CAN-bus is
working, but it can not proceed until the pump has
00058 WAITING PUMP 57 finished it’s job.
This alarm is signaled when a double running
request is made simultaneously. Check
00027 FORW + BACK Warning 5 microswitches and the wiring.
This is a warning. It is an information for the user
that the programmed time for maintenance is
00012 CHECK UP NEEDED Warning 15 elapsed.
00025 ENCODER ERROR Alarm 34 Too great variation in encoder signal
Undervoltage / overvoltage protection has operated.
There have been a real undervoltage situation or
00036 LOGIC FAILURE #1 Alarm 43 there is fault in the hardware section.
When the initial diagnosis is finished, the traction
logic closes the MC and checks the voltage on the
Drain of the driver. If this is not low , an alarm is
00016 CONTACTOR DRIVER Alarm 26 signaled.

8-4
TROUBLESHOOTING AND PIN BY PIN VOLTAGES

00001 ZAPI VERSIONS ALARM CLASS Alarm # AC-2 (Tract. MOD#2, Pump MOD#5)
When the key is switched on, the inverter tries to
charge internal capacitor via resistor in certain time.
This can be caused if the charging resistance is
opened, the charging circuit has a failure or there is
00011 CAPACITOR CHARGE Alarm 23 a problem on the power modules.

When the key is switched ON the P checks the MC

driver FF SR. If it does not react in a correct way to
the P stimulus, the alarm is signaled. Replace the
logic board. The FF SR makes an hardware control
of the current in the MC coil. If this is too high, it
opens the MC and the alarm is signaled if there are
external shortcircuit and if the ohmic value of the
00014 COIL SHORTED Alarm 24 MC is correct; otherwise replace the logic.
When the key is switched ON, the P checks that
the MC coil driver is not shorted; if it is, this alarm is
00023 DRIVER SHORTED Alarm 33 signaled; replace the logic board.
00064 WRONG SET BATT. Alarm 63 Wrong selection of battery type

8-5
Pin By Pin Voltages Worksheet
All Voltages in Refernce to Battery Nagative Example: Battery Voltage 38.49 at Rest

All Voltages in Reference to Battery Negative Example: Battery Voltage 37.49 at Rest

LABEL NAME PAGE ZONE CONTROLLER Condition Reading Example Your Test Results
MAIN
XA1F:2 3 14 Traction Key On/No Faults B+ V 37.4 V
CONT.CONTROL

XA1F:2 MAIN 3 14 Traction Key On/Faults B+ V 37.4 V

CONT.CONTROL

MAIN Key On/No Faults Pulsed 24V across coil

XA1F:8 3 14 Traction Contactor Energized 13 Volts 14.18 V
CONT.CONTROL Reading off time volts
Operator Presence Switch Closed

Key On/Faults
XA1F:8 MAIN 3 14 Traction Contactor Energized 13 Volts Pulsed 24V across coil 14.18 V
CONT.CONTROL Directional Control - not in neutral Reading off time volts
position.

XA1F:1 Key 3 15 Traction Key On B+ V 37.4 V

XA1F:4 3 15 Key On/ Operator Presence Switch 0V

(NONE) Traction 0V
(S12) Not Activated
Key On/ Operator Presence Switch
XA1F:4 (NONE) 3 15 Traction B+ V 36.76 V
(S12) Activated

8-6
XA1F:3 36V (Brake Feed) 3 16 Traction Key On B+ V 37.0 V

XA3B:1 3 18 Steer Motor

A3 Controller Key On / No Steering Faults B+ V 37.03 V

XA3B:1 A3 3 18 Steer Motor Key On /Steering Faults < 3.0 V .0 V (Alarm On)
Controller <3.0 V (No alarm)

XA3B:7 Safety B+ into Steer 3 18 Steer Motor Key On B+ V 37.04 V

Controller
TROUBLESHOOTING AND PIN BY PIN VOLTAGES

Key On / No Steering Faults/ Brake

XA1F:9 BRAKE CONTROL 3 18 Traction 2.0 V 2.166 V
Pedal Switch Not Activated
Key On / No Steering Faults/ Brake
XA1F:9 BRAKE CONTROL 3 18 Traction B+ V 36.94
Pedal Switch Activated

X13:7 Brake Pedal 3 18 S11 Key On/No Steering Faults B+ V 37.0 V

X13:8 Brake Pedal 3 18 S11 Key On / No Steering Faults/ Brake 2.0 V 2.166 V
Pedal Switch Not Activated
Key On / No Steering Faults/ Brake
X13:8 Brake Pedal 3 18 S11 B+ V 36.94
Pedal Switch Activated
Key On / No Steering Faults/ Brake
XA4B:8 (I7) 3 19 Sicos 2.0 V 2.162 V
Pedal Switch Not Activated

XA4B:8 (I7) 3 19 Sicos Key On / No Steering Faults/ Brake B+ V 36.94 V

Pedal Switch Activated
LABEL NAME PAGE ZONE CONTROLLER Condition Reading Example Your Test Results

XA4B:5 3 20 Key On/ Operator Presence Switch 0V OV

(I5) Sicos
(S12) Not Activated
XA4B:5 3 20 Key On/ Operator Presence Switch 36.69 V
(I5) Sicos B+ V
(S12) Activated
XA4B:17 36V 3 21 Sicos Key On B+ V 36.7 V

XA4D:4 5V 3 22 Sicos Key On 5.0 V 5.02 V

XA4D:5 (NONE) 3 23 Sicos Key On/Forks First Direction Request 2.5V - .5 V 2.5V - .5 V

XA4D:5 (NONE) 3 23 Sicos Key On/Forks Trailing Direction 2.5V - 4.5 V 2.5V - 4.5 V
Request

XA4D:6 0V 3 23 Sicos Key On 0V 0V

XA4C:13 3 25 Key On/ Vehicle Not Speed Limited 36.6 V

(I3) Sicos B+ V
Due To Limit Switch Status

Key On/ Vehicle Speed Limited To 1

XA4C:13 (I3) 3 25 Sicos MPH When Switch Opens Or Jumper 0V 0V
Removed.

8-7
XA4C:17 36V 3 26 Sicos Key On B+ V 36.6 V

Currently jumper between this pin and 36.69 V jumper in. 0 V

XA4B:6 (I4) 3 28 Sicos B+ V
XA4B:18 jumper removed.

XA4B:18 36V 3 29 Sicos Key On B+ V 36.71 V

X13:4 Brake Pedal 3 20 36.7 V

(Operator Presence) S12 Key On B+ V

X13:5 Brake Pedal 3 20 S12 Key On/ Operator Presence Switch 0V 0V

(Operator Presence) (S12) Not Activated

X13:5 Brake Pedal 3 20 S12 Key On/ Operator Presence Switch B+ V 36.69 V
(Operator Presence) (S12) Activated
Em. Stop
X12:1 (Emergency 3 12 S1 Battery Plugged In B+ V 37.4
Disconnect)

X12:2 Key Switch 3 12 S1,S2 Key On B+ V 37.4 V

X12:3 Key Switch 3 13 S1,S2 Key On B+ V 37.4 V

TROUBLESHOOTING AND PIN BY PIN VOLTAGES
LABEL NAME PAGE ZONE CONTROLLER Condition Reading Example Your Test Results
Feed To Cold Battery Plugged In/Emergency Stop
X12:4 3 13 B+ V 37.4
storage Raised

Battery Lock Switch

X39:1 (Option,May be 3 28 S36 (B+) Key On B+ V 36.71 V
Jumpered)

Battery Lock Switch

X39:2 (Option,May Be 3 28 S36 (I4) Key On/ Battery Lock Switch Activated B+ V 36.69
Jumpered)

Battery Lock Switch Key On/ Battery Lock Switch Not

X39:2 (Option,May Be 3 28 S36 (I4) 0V 0V
Activated
Jumpered)

Speed Reduction
X40:1 (Option May Be 3 25 S37 (B+) Key On B+ V 36.6 V
Jumpered)

Speed Reduction Key On/ Vehicle Not Speed Limited

X40:2 (Option May Be 3 25 S37 (I3) B+ V 36.6 V
Due To Limit Switch Status
Jumpered)
Speed Reduction Key On/ Vehicle Speed Limited To 1

8-8
X40:2 (Option May Be 3 25 S37 (I3) MPH When Switch Opens Or Jumper 0 Volts 0V
Jumpered) Removed.

XA3B:4 0 4 14 Steer Motor Key On 0V 0V

Controller

XA3B:9 (STEERING 4 14 Steer Motor Steering Wheel Rotated (+/-) .3 V (+/-) .13 V
REQUEST) Controller
(STEERING Steer Motor
XA3A:10 4 15 Steering Wheel Rotated (+/-) .3 V (+/-) .13 V
REQUEST) Controller
TROUBLESHOOTING AND PIN BY PIN VOLTAGES

XA3A:20 (STEERING 4 16 Steer Motor

Steering Wheel Rotated (+/-) .3 V (+/-) .13 V
REQUEST) Controller

XA3A:7 0 4 16 Steer Motor Key On 0V 0V

Controller

XA3B:3 (STEERING 4 17 Steer Motor

REQUEST) Controller Steering Wheel Rotated (+/-) .3 V (+/-) .13 V

Steering End Limit Steer Motor Drive Unit Position Not To The
XA3B:12 4 19 15.0 V 15.1 V
Sensor Controller Extreme Left Or Right

XA3B:12 Steering End Limit 4 19 Steer Motor Drive Unit Position To The Extreme 0V 0V
Sensor Controller Left Or Right

XA4B:2 (I18) 4 26 Sicos Key On S32 Not Activated 0V 0V

XA4B:2 (I18) 4 26 Sicos Key On S32 Activated B+ V 36.68 V

LABEL NAME PAGE ZONE CONTROLLER Condition Reading Example Your Test Results

XA4B:13 (I19) 4 29 Sicos Key On S33 Not Activated 0V 0V

XA4B:13 (I19) 4 29 Sicos Key On S33 Activated B+ V 36.7 V

XA4D:3 0V 5 12 Sicos Key On 0V 0V

XA4D:2 (I 8) 5 13 Sicos Key On, Vehicle Lift Requested 2.5 - 0.5 V 2.5 - 0.5 V

XA4D:2 (I 9) 5 13 Sicos Key On, Vehicle Lower Requested 2.5 - 4.5 V 2.5 - 4.5 V

XA4D:1 5V 5 13 Sicos Key On 5V 5.02 V

XA4B:4 Center Switch 5 14 Sicos Key on, Not Activated 0V 0V

XA4B:4 Center Switch 5 14 Sicos Key on, Lift or Lower Activated B+ V 36.04 V

XA4C:19 36V 5 16 Sicos Key On B+ V 36.68 V

XA4C:10 (I10) 5 17 Sicos Key On S14 (Reach) Activated B+ V 35.4 V

8-9
XA4C:10 (I10) 5 17 Sicos Key On S14 (Reach) Not Activated 0V 0V

XA4C:20 (I11) 5 18 Sicos Key On S15 (Retract) Activated B+ V 35.4 V

XA4C:20 (I11) 5 18 Sicos Key On S15 (Retract) Not Activated 0V 0V

XA4C:5 (I12) 5 19 Sicos Key On S17 (Tilt Down) Activated B+ V 33.7 V

XA4C:5 (I12) 5 19 Sicos Key On S17 (Tilt Down) Not Activated 0V 0V

XA4C:6 (I13) 5 20 Sicos Key On S16 (Tilt Up) Activated B+ V 33.7 V

XA4C:6 (I13) 5 20 Sicos Key On S16 (Tilt Up) Not Activated 0V 0V

XA4C:4 (I16) 5 21 Sicos Key On S16 (Sideshift Left) Activated B+ V 33.8 V

XA4C:4 (I16) 5 21 Sicos Key On S16 (Sideshift Left) Not 0V 0V

Activated

XA4C:7 (I20) 5 22 Sicos Key On S16 (Sideshift Right) Activated B+ V 37.49

Key On S16 (Sideshift Right) Not

XA4C:7 (I20) 5 22 Sicos 0V 37.49
Activated
XA5A:12 (DI1) 5 27 MHYRIO Key On B+ V 37.49 V
TROUBLESHOOTING AND PIN BY PIN VOLTAGES
LABEL NAME PAGE ZONE CONTROLLER Condition Reading Example Your Test Results

XA5A:15 36V 5 28 MHYRIO Key On B+ V 37.49 V

XA5G:14 36V 6 12 MHYRIO Key On/ Lower B+ V 37.49 V

37.49 V at rest, than lowers

B+ V at rest, than lowers to
XA5G:8 OUT 6 13 MHYRIO Key On/ Lower (M1) Request to 24.9 V at full lower
24.9 V at full lower position.
position.

B+ V at rest, than lowers to 37.22 V at rest, than lowers

XA5G:10 6 14 MHYRIO Key On/ Lift (M2) Request .5 V at full lift position. to .5 V at full lift position.

XA5G:7 6 15 MHYRIO Key On Lift B+ V at rest, than lowers to 37.38 V at rest, than lowers
.5 V at full lift position. to .6 V at full lift position.

XA5G:11 6 16 MHYRIO Key On B+ V 37.38 V

Key On/Retract,Tilt Up Or Sideshift B+ V at rest. Activated 36.05 V at rest. Activated

XA5G:6 6 17 MHYRIO Retract 5.0 V, Tilt Up 2.3 V. Retract 5.1 V, Tilt Up 2.3 V.
Left Request (M3)
SS Left 5.2 V. SS Left 5.2 V.

XA5G:16 6 18 MHYRIO Key On B+ V 37.49 V

8-10
B+ V at rest. Activated 36.05 V at rest. Activated
XA5G:5 6 19 Key On/Reach, Tilt Down Or Sideshift
MHYRIO Right Request (M4)
Reach 5.1 V, Tilt Down 2.3 Reach 5.1 V, Tilt Down 2.3
V. SS Right 5.2 V. V. SS Right 5.2 V.

XA5G:13 6 19 MHYRIO Key On B+ V 37.49 V

TROUBLESHOOTING AND PIN BY PIN VOLTAGES

Key On/ Reach Or Retract Request B+ V at rest. Reach or 37.38 V at rest. Reach or
XA5G:4 6 20 MHYRIO
(S5),(S6) Retract 11.0 TO 12.0 V Retract 12.2 V

XA5F:3 6 23 Key On/Sideshift Left Or Right B+ V at rest. Activated Right 37.38 V at rest. Activated
MHYRIO
Request (S7),(S8) or Left Sideshift .8 V Right or Left Sideshift .8 V

XA4A:1 7 12 Key On/Up (S21) Keyboard Switch 5.01 V

Sicos 5.0 V
Idle

XA4A:1 7 12 Sicos Key On/Up (S21) Keyboard Switch 0V 0V

Activated

XA4A:2 7 14 Key On/Down (S22) Keyboard Switch 5.01 V

Sicos 5.0 V
Idle

XA4A:2 7 14 Sicos Key On/Down (S22) Keyboard Switch 0V 0V

Activated
LABEL NAME PAGE ZONE CONTROLLER Condition Reading Example Your Test Results

Key On/Enter (S23) Keyboard Switch

XA4A:3 7 15 Sicos 5.0 V 5.01 V
Idle
Key On/Enter (S23) Keyboard Switch
XA4A:3 7 15 Sicos 0V 0V
Activated

XA4A:4 7 17 Sicos Key On/ X (S24) Keyboard Switch Idle 5.0 V 5.01 V

Key On/ X (S24) Keyboard Switch

XA4A:4 7 17 Sicos 0V 0V
Activated

XA4A:5 0V 7 19 Sicos Key On 0V 0V

XA4C:3 (I21) 7 20 Sicos Key On/ Top Limit Overide (S25) Idle 0V 0V

Key On/ Top Limit Overide (S25)

XA4C:3 (I21) 7 20 Sicos B+ V 36.67 V
Activated

XA4C:14 36V 7 21 Sicos Key On B+ V 36.67 V

XA5D:3 14V 7 22 MHYRIO Key On 14.0 V 13.73

8-11
XA5D:4 0/14 7 23 MHYRIO Key On/Mast Raising Or Lowering Pulsed 0/14 V Pulsed 0/13.8 V

XA5D:2 0/14 7 23 MHYRIO Key On/Mast Raising Or Lowering Pulsed 0/14 V Pulsed 0/13.8 V

XA5D:1 0V 7 24 MHYRIO Key On 0V 0V

XA5A:14 B+ V (Light On) 0V (Light

36V 7 25 MHYRIO Key On 37.38 V
Off)
Key On/Lifting Height Reference
XA5A:2 7 26 MHYRIO B- V Light Off 0V
Sensor (S43) Not Activated
Key On/Lifting Height Reference
XA5A:2 7 26 MHYRIO B+ V Light On 37.34 V
Sensor (S43) Activated

XA5A:21 0V 7 27 MHYRIO Key On 0V 0V

XA5C:6 14V 7 28 MHYRIO Key On 14.0 V 14.37 V

Reading Will Vary

Depending On Load,
XA5C:1 7 29 MHYRIO Key On Approximately 1 Volt With 2.96 =V (No Load)
No Load, Approximately 2.7
Volts With 4500 lbs.
TROUBLESHOOTING AND PIN BY PIN VOLTAGES
LABEL NAME PAGE ZONE CONTROLLER Condition Reading Example Your Test Results

XA5C:3 0V 7 30 MHYRIO Key On 0V 0V

XA1D:1 12V 8 12 Traction Key On 12.0 V 11.25 V

XA1D:3 8 12 10.78 V at rest to 6.0 V

Traction Key On Traction Motor Rotating Pulsed 0/10 V running. Slow 0/10 V.

10.78 V at rest to 6.0 V

XA1D:5 8 13 Traction Key On Traction Motor Rotating Pulsed 0/10 V running. Slow 0/10 V.

XA1D:2 0V 8 14 Traction Key On 0V 0V

XA1F:6 8 14 Traction Key ON 1.25 Volts at 75º 1.2 V @ 75° F

Key On/Temp Increase Voltage 0 Varies With Temperature /

XA1F:12 TEMP SENSOR 8 15 Traction .034 V @ 75° F
Volts at 75º Resistance Of Thermistor

XA2E:1 12V 8 17 Pump Motor Key On 12.0 V 11.25 V

XA2E:3 8 17 Pump Motor Key On Lift Motor Rotating Pulsed 0/10 V 10.78 V at rest to 6.0 V
running. Slow 0/10 V.

XA2E:5 8 18 10.78 V at rest to 6.0 V

Pump Motor Key On Lift Motor Rotating Pulsed 0/10 V running. Slow 0/10 V.

8-12
XA2E:2 0V 8 18 Pump Motor Key On 0V 0V

XA2B:6 8 19 Pump Motor Key On 1.15 Volts at 75º 1.22 V @ 75°F

Varies With
Key On/Temp Increase Voltage 0
XA2B:12 TEMP SENSOR 8 20 Pump Motor Temperature/Resistance Of .034 V @ 75° F
Volts at 75 º
Thermistor
TROUBLESHOOTING AND PIN BY PIN VOLTAGES

XA6D:1 12V 8 22 2nd Pump Motor Key On 12.0 V 11.3 V

XA6D:3 8 22 2nd Pump Motor Key On 2nd Lift Motor Rotating Pulsed 0/10 V 10.78 V at rest to 6.0 V
running. Slow 0/10 V.

XA6D:5 8 23 10.78 V at rest to 6.0 V

2nd Pump Motor Key On 2nd Lift Motor Rotating Pulsed 0/10 V running. Slow 0/10 V.

XA6D:2 0V 8 23 2nd Pump Motor Key On 0V 0V

XA6F:6 8 24 2nd Pump Motor Key On 1.26 Volts at 75ºF 1.28 Volts at 75ºF

Varies With
XA6F:12 TEMP SENSOR 8 25 2nd Pump Motor Key On/Temp Increase Voltage 0 Temperature/Resistance Of .034 V @ 75° F
Volts at 75 º Thermistor

XA4E:1 SUPPLY 9 11 Sicos Key On B+ V 37.39 V

LABEL NAME PAGE ZONE CONTROLLER Condition Reading Example Your Test Results

XA4E:4 SUPPLY 9 12 Sicos Key On 0V 0V

XA4B:14 SUPPLY 9 12 Sicos Key On 0V 0V

XA4B:3 SUPPLY 9 13 Sicos Key On 0V 0V

XA4F:1 PCLRXD 9 12 Sicos No Test No Test

XA4E:2 CANL 9 13 Sicos No Test No Test

XA4F:2 NCLRXD 9 13 Sicos No Test No Test

XA4F:3 PCLTXD 9 13 Sicos No Test No Test

XA4F:4 NCLTXD 9 13 Sicos No Test No Test

XA4F:5 GND 9 13 Sicos Key On 0V 0V

XA6F:1 SUPPLY 9 14 2nd Pump Motor Key On B+ V 37.38 V

XA4E:3 CANH 9 14 Sicos No Test No Test

8-13
XA4F:6 +12 9 14 Sicos Key On 12.0 V 17.27 V

XA4F:7 BOOT 9 14 Sicos No Test No Test

XA4F:8 GND 9 14 Sicos Key On 0V 0V

XA6C:1 CANL 9 15 2nd Pump Motor No Test No Test

XA6C:3 CANH 9 15 2nd Pump Motor No Test No Test

XA6F:11 9 15 2nd Pump Motor No Test No Test

XA6F:5 9 15 2nd Pump Motor No Test No Test

XA6B:1 9 16 2nd Pump Motor No Test No Test

XA6B:2 9 16 2nd Pump Motor No Test No Test

XA6C:2 CANL 9 16 2nd Pump Motor No Test No Test

XA6C:4 CANH 9 16 2nd Pump Motor No Test No Test

XA1C:1 CANL 9 16 Traction No Test No Test

TROUBLESHOOTING AND PIN BY PIN VOLTAGES
LABEL NAME PAGE ZONE CONTROLLER Condition Reading Example Your Test Results

XA1C:3 CANH 9 16 Traction No Test No Test

XA1F:11 9 16 Traction No Test No Test

XA1F:5 9 16 Traction No Test No Test

XA1C:2 CANL 9 17 Traction No Test No Test

XA1C:4 CANH 9 17 Traction No Test No Test

XA2B:1 SUPPLY 9 19 Pump Motor Key On B+ V 37.38 V

XA2B:5 9 19 Pump Motor No Test No Test

XA2B:11 9 20 Pump Motor No Test No Test

XA2C:1 CANL 9 19 Pump Motor No Test No Test

XA2C:2 CANL 9 20 Pump Motor No Test No Test

XA2C:3 CANH 9 20 Pump Motor No Test No Test

8-14
XA2D:1 9 20 Pump Motor No Test No Test

XA2D:2 9 21 Pump Motor No Test No Test

XA2C:4 CANH 9 21 Pump Motor No Test No Test

XA3B:11 SUPPLY 9 22 Steer Motor Key On B+ V 37.38 V

Controller
Steer Motor
TROUBLESHOOTING AND PIN BY PIN VOLTAGES

XA3A:13 CANL 9 23 No Test No Test

Controller
Steer Motor
XA3A:3 CANH 9 23 No Test No Test
Controller
XA3A:14 CANL 9 24 Steer Motor No Test No Test
Controller
Steer Motor
XA3A:4 CANH 9 24 No Test No Test
Controller

XA5B:2 +KEY 9 26 MHYRIO Key On B+ V 37.38 V

XA5B:6 PAUX 9 26 MHYRIO Key On B+ V 37.38 V

XA5A:9 -BATT 9 28 MHYRIO Key On 0V 0V

XA5B:5 -BATT 9 28 MHYRIO Key On 0V 0V

LABEL NAME PAGE ZONE CONTROLLER Condition Reading Example Your Test Results

XA5B:4 CANL 9 28 MHYRIO No Test No Test

XA5B:1 CANH 9 29 MHYRIO No Test No Test

XA4B:7 (I22) 10 12 Sicos Horn On B+ V 36.75 V

XA4B:7 (I22) 10 12 Sicos Horn Off 0V 0V

XA4C:12 10 16 Sicos B+ V 36.63 V

8-15
XA4C:2 10 17 Sicos Buzzer On 0V 0V

XA4C:2 10 17 Sicos Buzzer Off 24.0 V 24.94 V

XA4C:11 10 19 Sicos Relay On/Horn Request 0V 0V

XA4C:11 10 19 Sicos Relay Off 24.0 V 24.94 V

XA4C:1 10 20 Sicos Relay On/Travel Alarm 0V 0V

XA4C:1 10 20 Sicos Relay Off 24.0 V 24.94 V

TROUBLESHOOTING AND PIN BY PIN VOLTAGES
PLANNED MAINTENANCE

Maintenance Locations

6 7, 8

12, 13, 17

2 9 11

9, 18

1
15

9, 18
4

9-1
PLANNED MAINTENANCE

Maintenance Intervals

10 Service 50 Service 500 Service 1000 Service 2000 Service

Hours or Hours or Hours or 3 Hours or 6 Hours or 12
Daily Weekly months months months
whichever whichever whichever whichever whichever
Item Component Check: comes first comes first comes first comes first comes first
1 Battery Charge X
Cleanliness X
Water Level after charging X
2 Battery Connector No damage, solid electrical connections X
EPO shuts down power X
3 Battery Gates & Restraints L shaped restraints in place and secured on both sides X
Gates locked into place securely on both sides X
4 Operator Presence Pedal Smooth action, no binding, stops reach truck within specific
(Brakes) limits, disables travel function when pedal is released. X
5 Contactor Tips Pitting, burning, insufficient contact material X
6 Cables/Hoses/ Hoses and cables in good condition. Spring
Tension Springs tension adjusted properly X
7 Mast Inspect Inside upright channels for lubrication X
Lubricate inside upright channels X
Inspect lift cylinders and hydraulic hoses for damage or
leaking hydraulic fluid X
8 Lift Chains Inspect chains for lubrication and visible damage X X
Lubricate chains X
Inspect chains for proper tension and position X X
Adjust chains for proper tension and position X X X
9 Lubrication Points - - - - -
Load Wheels (4) (1 Per Wheel) Lubricate X
Casters (2) Lubricate X
Radial Gear on Drive Unit (2) Lubricate X
Pantograph - Single Reach (14) Lubricate X
Pantograph - Double Reach (16) Lubricate X
10 Drive Unit Check Fluid Level X
Change Fluid X
11 Forks Check for cracks and distortions - check welds X
p Stopper pins properly engaged X
12 Function Controls Travel, lift/lower & extend/retract control their respective X
function
13 Horn Sounds when activated X
14 All Hydraulic Connections No Leaks X
15 Hydraulic Reservoir Check Fluid Level X
Change Filter X X
Change Fluid X
16 Lights All Lights should function X
17 Switches Control assigned function X
18 Load Wheels, Drive Tires No Cracks, no flat spots or missing chunks,
no bond failure - tire surface in good condition X
19 Static Strap Check for missing and damaged straps X
(beneath reach truck) Check for wear. Keep straps clean. Replace as necessary.
20 Overhead Guard Inspect for damage and cracks X
21 Check for loose components and Check for tightness or damage X
hardware
22 Decals and Warning Labels In place and legible X
23 Fire Extinguisher (Optional) Check Charge. Replace if low. X
24 Ventilation Slots Make sure slots are free of obstructions. X
25 ***Mast Mounting Bolts (8) Torque check X
***Overhead Guard (4) Torque check X
***Motor Mounts Torque check X

***Note: Check bolt torque after the first 50 hours of operation

9-2
PLANNED MAINTENANCE

Recommended Oils

Oils Standard Class I Class II

Temperature Range +14°F (-10°C) to 104°F(40°C) +20°F (-7°C) to 70°F(21°C) +40°F (4°C) to -40°F(-40°C)
SAE EP80W90 SAE EP80W90 SAE 75W90 Synthetic
Gear Exxon GX 80W90 or Exxon GX 80W90 or Mobilube SHC 75W90 or
equivalent equivalent equivalent
SAE 10W ISO VG32 ISO VG15
Hydraulic Exxon NUTO H32 or Exxon UNIVIS N32 or Exxon UNIVIS HVI13 or
equivalent equivalent equivalent
Wheel Bearings
Grease No. 2 grade multipurpose type (lithium base) grease Exxon Ronex MP or equivalent
Chassis

• Avoid mixing lubricants. In some cases, different brands of lubricant are not compatible with each other and deteriorate when mixed. It is
best to stick with the same brand at successive service intervals.
• Brands of oil are subject to change without notice.
• When you purchase oil - select recommended brands and check specifications.

9-3
TECHNICAL PUBLICATIONS FEEDBACK

(Please Print)
Dealer Name: Submitted By:
Address: P.O. Box:
City: State:
Zip Code: Country:

The following discrepancy or omission has been discovered in:

❏ Operation & Maintenance Manual ❏ Option Bulletin

❏ Part List/Manual ❏ Special Instructions
❏ Service Manual ❏ Service Data Manual
❏ Electronic Manual ❏ Other
Publication # Engine Model #

Truck model # Issue date #

Truck serial # Page #

(Please Print)
Explanation of discrepancy or omission:

(Please fax or mail completed form to):

Mitsubishi Caterpillar Forklift America Inc. Mitsubishi Caterpillar Forklift Europe B.V.
Attn: Technical Publications Attn: Service Engineering
2121 W. Sam Houston Parkway N. P.O Box 30171
Houston, Texas 77043-2305 1303 AC, Almere, The Netherlands
Fax: 713-365-1616 Fax: 31-36-5494-695

Mitsubishi Caterpillar Forklift Asia Pte. Ltd.

Attn: Service Engineering
No. 2 Tuas Avenue 20
Singapore 638818
Republic of Singapore
Fax: 65-861-9277
Mitsubishi Caterpillar Forklift America Inc.
2121 W. Sam Houston Parkway N.
Houston, TX 77043

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