Document Outline

• Maintenance safety precautions
  • a. GENERAL
  • b. HYDRAULIC SYSTEM SAFETY
  • c. MAINTENANCE
• REVISION LOG
• TABLE OF CONTENTS
• Section 1. MACHINE specifications
  • 1.1 Capacities
    • System Voltage
    • Hydraulic System
    • Drive Motor GearBox (gear oil)
  • 1.2 Component Data
    • Hydraulic Pump/Pump Motor Assembly
    • Rear Wheel Drive Motors
    • Batteries/Battery Charger
  • 1.3 Performance Data
    • Platform Capacities
    • Platform Size
    • Machine Height (platform stowed)
    • Base Footprint
  • 1.4 Torque Requirements
  • 1.5 Lubrication
    • Hydraulic Oil
    • Lubrication Specifications
  • 1.6 Hydraulic Pressure settings and Adjustment
    • Hydraulic Pressure Gauge Connection
    • After Filter Pressure Check
  • 1.7 Cylinder Specifications
  • 1.8 Serial Number Locations
• Section 2. GENERAL
  • 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE
    • General
    • Preparation, Inspection, and Maintenance
    • Pre-Start Inspection
    • Pre-Delivery Inspection and Frequent Inspection
    • Annual Machine Inspection
    • Preventative Maintenance
  • 2.2 Preventive Maintenance and Inspection Schedule
    • Inspection and Maintenance Codes:
    • Footnotes:
  • 2.3 Servicing and Maintenance Guidelines
    • General
    • Safety and Workmanship
    • Cleanliness
    • Components Removal and Installation
    • Component Disassembly and Reassembly
    • Pressure-Fit Parts
    • Bearings
    • Gaskets
    • Bolt Usage and Torque Application
    • Hydraulic Lines and Electrical Wiring
    • Hydraulic System
    • Lubrication and Servicing
    • Batteries
    • Mast Chain Inspection Procedure
  • 2.4 Lubrication Information
    • Hydraulic System
    • Hydraulic Oil
    • Changing Hydraulic Oil
    • Lubrication Specifications
  • 2.5 Positioning Lift for Access to Components Located Under The Base Frame
• SECTION 3. BASE COMPONENTS
  • 3.1 Base Assembly Components
  • 3.2 Base Frame Covers
    • Drive Motor Cover - Installation
    • Battery Charger Cover - Installation
  • 3.3 Drive And Caster Wheels
    • Drive Motor Wheel (Std.) - Installation
    • Caster Wheels - Installation
    • Wheel Retention for Rough Terrain Drive Wheel (Option)
  • 3.4 Drive Motor component - servicing
    • Torque Limiting Clutch Maintenance
    • Diagnostics
    • Visual Inspection and Limiting Torque Checking Procedure
    • Check Clutch Torque Setting
    • Torque Limiting Clutch Adjustment
    • Drive Wheel Alignment - (Machines built prior to S/N-0130005271)
  • 3.5 Drive Motor Assembly - Servicing
    • Drive Motor Assembly - Removal
    • Drive Motor Brake Removal and Adjustment
    • Brake Operation (See Figure 3-7.)
    • Brake Assembly Removal
    • Checking/Adjusting Armature Plate Gap Setting
    • Brake Assembly Installation
    • Drive Motor Boot Assembly Installation
    • Drive Motor Brush Replacement
    • Brush Cleaning and Inspection
    • Brush Removal
    • Brush Reassembly
    • Gear Box Disassembly/Assembly
    • Gear/Pinion Shaft Assembly
    • Drive Shaft Assembly
    • Final Gear Box Assembly
  • 3.6 Pot Hole Protection System
  • 3.7 Battery/Battery Charger - Service Procedures
    • Battery Low Voltage Warning Indicators
    • Diagnostics
    • Battery Condition Testing
    • Battery Replacement
    • Battery Charger General Information
    • Battery Charger Troubleshooting
    • Battery Charge/Flash Code LED Indicator on Platform Control Console
    • Battery Charging Status Indicators Mounted on Ground Control Station Cover
    • Wet/VRLA Battery - Charging Profile Switch
    • General Component Installation Notes
    • Battery Charger Installation
    • Cover Installation
    • AC Line Fuse Installation
    • Interlock Relay Installation
    • Wet/VRLA Switch Installation
    • Shunt Assembly Installation
    • SCR Rectifier Installation (Either Side)
    • Transformer Installation
    • Printed Circuit Board Installation
    • DC Circuit Breaker/Voltage Select Switch Installation
• SECTION 4. CONTROL COMPONENTS
  • 4.1 CONTROL Components Overview
  • 4.2 Controls Cover Installation
    • Battery Cover Doors
    • Center, Left and Right Lower Covers
  • 4.3 Control Components - Installation
    • Ground Control Module
    • Traction Control Module
    • Platform Control Console Installation
    • Battery Installation
    • Horn Installation
    • Alarm Installation
    • Battery Installation (EE Spec Machines Only)
    • Fuse Box - (EE Spec Machines Only)
    • Master Disconnect Switch - (EE Spec Machines Only)
  • 4.4 Ground Control Module - Service Procedure
    • Cover Removal/Installation
    • Power Selector/EStop Switch Installation
  • 4.5 Ground Control Module - Programming
    • General
    • Programming Levels
    • Activating Programming Mode
    • Entering Password
    • Programming Mode Selection
    • Selecting Programmable Item to Adjust
    • Adjusting Programmable Setting
    • Service Programming Mode - (Level-2)
    • Operator Programming Mode - (Level-3)
  • 4.6 Platform Control Console - Service Procedures (machines s/n - 0130007616 to present)
    • General
    • Remove Platform Control Console
    • Display/Controller Module Electrical Connections
    • Mounting Bracket - Install/Remove
    • Rear Cover - Install/Remove
    • Display/Controller Module - Install/Remove
    • Drive/Lift Mode Switch - Install/Remove
    • Horn Button Switch - Install/Remove
    • Key Switch - Install/Remove
    • E-Stop/ShutDown Switch - Install/Remove
    • Joystick Assembly - Install/Remove
  • 4.7 Platform Control Console - Service Procedures (machines prior to s/n - 0130007616)
    • General
    • Remove Platform Control Console
    • Upper/Lower Shell Attach Screws
    • Emergency Stop Switch Installation
    • Upper/Lower Shell Component Connections
    • Button Pad Installation
    • Joystick Assembly Installation
    • Joystick Calibration Procedure
  • 4.8 Pump-Motor Assembly - Service Procedure
    • General
    • Inline Hydraulic Filter Installation
    • Pump/Motor/Tank Installation
    • Motor Cap/Motor Installation
    • Motor Brush Installation
    • Brush Housing Final Assembly Tips
    • Tank Installation
    • Pump Installation
    • Filter Screen Installation
    • Pressure Adjust Valve Installation
    • Pressure Check Valve Installation
  • 4.9 obstruction sensor system - service procedure (dvsp - option)
    • General
    • Transducer Sensor Check
    • OSS Component Installation
• SECTION 5. MAST COMPONENTS
  • 5.1 Mast Components Overview
  • 5.2 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT
    • Mast Chain/Cable Adjustment
    • Sequencing Cable Adjustment
  • 5.3 sequence cable replacement kit
    • Remove Old Cable
    • Replacement Cable Installation
    • Clamp Installation (Drum/Socket Type)
  • 5.4 Hydraulic Lift Cylinder - Removal, Inspection and rebuild
    • Lift Cylinder Removal
    • Cylinder Disassembly
    • Lift Cylinder Component Inspection
    • Cylinder Assembly
    • Cylinder Installation
  • 5.5 Mast Assembly Installation
    • Mast Removal
    • Mast Installation
  • 5.6 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES
    • Mast Disassembly Procedure
    • Mast Assembly - DVL/DVSP
  • 5.7 DVSP - Stockpicker Platform - Installation
  • 5.8 DVSP - Stockpicker Platform - Mid-Gate Interlock Installation
  • 5.9 mast beacon - Installation
• Section 6. troubleshooting
  • 6.1 General
  • 6.2 Troubleshooting Information
  • 6.3 Hydraulic Circuit Checks
  • 6.4 ELECTRICAL CIRCUIT CHECKS
    • General
    • Ground Control Module LCD Display
  • 6.5 TROUBLESHOOTING TABLES Index
    • SPECIFICATIONS FOR VARIOUS COMPONENTS PAGE
    • SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS
    • FAULT CODE TROUBLESHOOTING TABLES
    • MAIN POWER CIRCUIT TROUBLESHOOTING
    • MAST TROUBLESHOOTING
    • HYDRAULIC LEAK TROUBLESHOOTING
    • BASE FRAME COMPONENTS TROUBLESHOOTING
    • DRIVE SYSTEM TROUBLESHOOTING
  • 6.6 SPECIFICATIONS FOR VARIOUS COMPONENTS
  • 6.7 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS
  • 6.8 FAULT CODE TROUBLESHOOTING TABLES
    • Machine in Drive Speed Cut-Back (Turtle) Mode All The Time
    • Obstruction Sensor System - Detection
    • Battery Voltage Low - Warning Level 3 - Three (3) LED/LCDs lit
    • Code 02 - Left PHP Bar - UP
    • Code 03 - Right PHP Bar - UP
    • Code 04 - Tilt Condition
    • Code 05 - Reserved
    • Code 06 - Reserved
    • Code 07- Left Drive Motor - Disconnected
    • Code 08 - Right Drive Motor - Disconnected
    • Code 09 - Left Brake - Disconnected
    • Code 10 - Right Brake - Disconnected
    • Code 11 - Left Drive Motor - Short Circuit
    • Code 12 - Right Drive Motor - Short Circuit
    • Code 13 - Traction Module - In Fold Back
    • Code 14 - Pump Motor - Disconnected
    • Code 15 - Lift Down Valve - Disconnected
    • Code 16 - Lift Down Valve - Short Circuit
    • Code 17 - Ground Control Module - In Fold Back
    • Code 18 - Alarm - Short Circuit
    • Code 19 - Alarm - Disconnected
    • Code 20 - Beacon - Short Circuit
    • Code 21 - Beacon - Disconnected
    • Code 22 - Horn - Short Circuit
    • Code 23 - Horn - Disconnected
    • Code 24 - Auxiliary #1 Circuit - Short Circuit
    • Code 25 - Auxiliary #1 Circuit - Disconnected
    • Code 26 - Auxiliary #2 - Short Circuit
    • Code 27 - Auxiliary #2 - Disconnected
    • Code 28 - Reserved
    • Code 29 - Reserved
    • Code 30 - Traction Module - No Communication with Ground Control Module
    • Code 31 - Platform Control Console - No Communication with Ground Control Module
    • Code 32 - Pump Motor - Over Current
    • Code 33 - Both PHP Bars - UP
    • Code 38 - Battery Voltage Low - Warning Level 2 - Two (2) LED/LCDs lit
    • Code 39 - Battery Voltage Low - Warning Level 3 - One (1) LED/LCDs lit
    • Code 40 - Obstruction Sensor System - No Communication with Ground Control Module
    • Codes 41 thru 46 - OSS - Sensor 1 through 6 - Fault Condition
    • Codes (100 - 199) Ground Control Module - Fault Condition
    • Codes (200 - 299) Platform Control Console - Fault Condition
    • Codes (300 - 399) Traction Control Module - Fault Condition
  • 6.9 MAIN POWER CIRCUIT TROUBLESHOOTING
    • Machine Will Not Power Up
  • 6.10 MAST TROUBLESHOOTING
    • Platform Will Not Lower Manually
    • Platform Lift Up And Down Jerky
    • Mast Noisy When Lifting And Lowering
    • Platform (Mast) Won’t Stay Elevated
    • Platform (Mast) Descends Too Slowly
  • 6.11 HYDRAULIC LEAK TROUBLESHOOTING
    • Miscellaneous Hydraulic Leak Troubleshooting
  • 6.12 BASE FRAME COMPONENTS TROUBLESHOOTING
    • Caster Wheels Not Operating Freely
    • Pot Hole Protection (PHP) Bars will not Lower
  • 6.13 DRIVE SYSTEM TROUBLESHOOTING
    • Won’t Climb Grade
    • Machine Drives in Opposite Direction
    • Machine Won’t Drive Straight
    • Noise From Drive Assembly