YALE® ELECTRIC POWER STEERING III MAINTENANCE MANUAL OS030EAIndustrial Trucks This Maintenance Manual (1718 © July, 1997) is for the electric power steering system (EPS Ill) on the following lit truck models: (OSO30EA with EPS IIT For additional information on the OSOS0EA with WIRE GUIDANCE II see: Wire Guidance Maintenance Manual 1561. Forsteer system information on the OSO30EA with Electric Power Steering II, see: ‘0S030EA Maintenance 1528Industrial Trucks CONTENTS STEERING SYSTEM — EPS III DESCRIPTION GENERAL... DESCRIPTION : CHECKS AND ADJUSTMENTS .. GENERAL ....... LED INDIGATORS DIPSWITCHES . CHECKS ........ CHECKING THE STEERING SYSTEM FOR CORRECT OPERATION .... CHECKING SLOW TRAVEL SPEED - CHECKING HIGH LIFT TRACTION SHUT-OFF. ADJUSTMENTS TACHOMETER ADJUSTMENT .. SENSITIVITY ADJUSTMENT . FEEDBACK POTENTIOMETER ADJUSTMENT .. ‘SLOW TRAVEL ADJUSTMENT . ‘STEERING CHAIN ADJUSTMENT. REPAIR TACHOMETER REPLACEMENT... FEEDBACK POTENTIOMETER REPLACEMENT. ELECTRONIC CONTROL MODULE REPLACEMENT . ‘STEER MOTOR ASSEMBLY AND STEERING CHAIN REPLACEMENT ..... aon TYPICAL OPERATING VOLTAGES TROUBLESHOOTING . WIRING SCHEMATIC... OPTIONS SCHEMATIC ... WIRING DIAGRAM OPTIONS DIAGRAM PAGE NUMBER DODOARADOOEHDIndustrial Trucks GENERAL This manual contains procedures for adjustment, repair and troubleshooting of the Electric Power Steering (EPS 111) system. The EPS II system controls the steer motor used to turn the Master Drive Unit. The ittruckis steered by tuming the Master Drive Unit DESCRIPTION The Electric Power Steering system is comprised of the following components: Steering wheel ‘Tachometer Feedback potentiometer Steering system wire hamess Electronic Contra! Module (ECM) Lift truck battery Steer motor Steering sprocket and chain The EPS III system has a steering wheel coupled to a belt-driven tachometer, The steering wheel doos NOT ‘automatically return to the center position. The steering whee! and tachometer for the EPS IIT system are located in the ‘operator's compartment. The Electronic Control Module and teat motar ara in the motor compartment beside the master drive unit, The feedback potentiometer is connected to the steer motor below the steer sprocket. The steering chain connects the steer sprocket at the gear motor to the sprocket of ‘the master drive unit. The Electronic Control Module is also, located in the steer motor compartment. “The tachometer coupledto the steering wheel providesa signal, tothe Electronic Control Module corresponding to the operator input. The Electronic Control Module processes the signal to ascertain the steer angle selected by the operator. The feedback potentiometer is connected to the steer motor. ‘The feedback potentiometer provides a signal tothe Electronic Control Module that corresponds to the position of the master dive unit The signal from the tachometer and the signal from the feedback potentiometer are sent simultaneously to the Electronic Control Module. Ifthe master drive unitis not atthe operator-selected angle, the Electronic Control Module provides electrical output tothe steer motor. The steer motor is coupled to the master drive unit with a sprocket and chain. The electrical output to the steer motor ‘causes the motor to rotate the sprocket and chain and tur the ‘master drive unit. As the master drive unit approaches the selected angle, the signal from the feedback potentiometer changes to instruct the Electronic Control Module to stow and then stop the rotation ofthe steer motor. ‘STEERING SYSTEM — EPS IIT CHECKS AND ADJUSTMENTS. General Do not make adjustments to a properly operating steering system. WARNING: Do not operate a lft ruck that needs adjustments or repairs. Report the need for adjustments or repairs immediately. If adjustment ‘or repair is necessary, put a “DO NOT OPEFATE” tag in the ‘operator's area. Remove the key from the key switch. WARNING: Some of the checks and adjustments, are done with the battery connected. Never have any metal on your fingers, arms or neck. During ‘some checks or adjustments, the operator must move the lit truck, The person doing the adjustments must make the adjustments with the system energized. Make sure the ‘operator does not move the lit truck to cause an injury ‘Taree test points are provided for adjustment of the Electronic Control Module. TP1 Is the feedback potentiometer input adjusted by P2. TP2 is NOT used in the tachometer steering system. TPS is the analog and logic common. Light Emiting Diodes (LEDs) 1 through 5, located on the Electronic Control ‘Module circuit board, are used to indicate system fauts. LED indicators The Electronic Control Module continuously monitors the steering system. Problems detected by the Elactronic Control Module are indicated by § LEDs. Refer to Figure 1. These vehicles equipped with electric steering systems are designed to stop automatically when a fault occurs. The brake relay, located in the Electronic Control Module, applies the brake to ‘stop the vehicle if a fault condition is detected. LED 1 on (green) (with motor clicking sound) LED 2 on (red) LED 3 on (red) LED 4 on, LED 5 off Controller active Loft limit reached ight limit reached Error in sensor circuit Error in contrller or motor LED 4 off, LED 5 on. ca LED 4 on, LED 5 on. Error in controler ‘Supply contactor fault or voltage on emergency LED 4, LED 5 off, and LED | brake col (the controller 10n (with no sound from | must remain off fora mini- motor) ‘mum of 2 seconds before a ‘new startup te avoid an er- ror condition) fable 1 — LED Indicators‘STEERING SYSTEM - EPS IIT DIPSWITCHES LED's ‘est POINTS POTENTIOMETERS jl pp fag ana |o} Figure 1 — Electronic Control Module Dipawitches CAUTION: The dipswitches are factory-set and. should not need to be adjusted, IMthe Electronic Control Moduleis replaced or the settings of the dipswitches are inadvertently changed, refer to Figure 2 to set the position of the dipswitches to the factory settings. ‘An adjustment can be made to the settings of dipswitches 5, 6, ‘and 7 to alter the sensitivty ofthe tachometer input scaling, it desired. Refer to SENSITIVITY ADJUSTMENT jin the ADJUSTMENTS section following. Figure 2 — Dipswitches — Factory Settings CHECKS ‘Checking the Steering System for Correct Operation 1, Open the motor compartment door, Move the key switch to the ON position and push the foot switch, 2, Make sure the battery has a corrected specific gravity of at least 1.250. To check the system for correct operation, move the steering handle or steering whee! from afullleftturn position to. full right tum position. The master drive unt should move {85° to 95° in each direction from straight travel 8, Ifthe master drive unit moves less than 90° 5°) in either direction, the steering is incorrectly adjusted or may have a ‘mechanical problem. Refer to ADJUSTMENTS. 4. Check that the master drive unit moves through the full range of rotation in ive seconds orless. The ifttruckmustbe on smooth concrete with a fully charged battery and no load on forks 5. Ifthe master drive unit requires greater than § seconds to ‘move through the full range of rotation, check for a mechanical problem or defective Electronic Control Module. Checking Slow Travel Speed NOTE: The slow travel speed is checked during the agjustment procedure. Refer to ADJUSTMENTS,‘STEERING SYSTEM — EPS III Figure 3 - Tachometer Steering Checking High Lift Traction Shut-Off 1. _Instruct the operator to raise the platform above 3810 mm (150 in. 2. The action system should NOT operate with he operator platform above 3810 mm (150 in) unless the truck s equipped ‘with the high if travel-enable option. I the unit isso equipped, check thatthe tration system operates normally EXCEPT when the steering is set for 7° or more from center and the cporatr platform is above 3810 mm (160 in. I the steering is set for more than 7° and the operator platform is above 3810 mm (150 in), the traction system should NOT operate. ADJUSTMENTS Make sure the battery has a corrected specific gravity of atleast 1.250. Move the lift truck to an open area where itcan be driven ina straight line for a distance of atleast 9 metres (80 ft), ‘Tachometer Adjustment ‘The Tachometer is located at the steering mechanism in the. Instrument panel. Remove the screws at the top of the instrument panel. Tit the panel to the open (down) position for ‘access to the tachometer. ‘The tachometer does not require adjustment. Check the drive, belt for proper alignment and verify that the belt is not excessively worn. Replace as required. Refer to Figure 3. Sensitivity Adjustment WARNING: Changing the sensitivity setting ofthe tachometer steering system alters the amount of ‘operator effort required to steer the truck. Notily all affected operators that the truck may steer differently before ‘operation, Use caution to avoid injury. ‘The sensitivity ofthe steering system is adjusted by changing the position of dipswitches 5, 6, and. Donot change any other ipswitches. Refer tothe table below. ‘Switch 5, 6, and 7 closed ‘Switch 6 and 7 closed, switch 5 open ‘Switch § and 7 closed, switch 6 open ‘Switch 7 closed, switch 5 and 6 open ‘Switch 5 and 6 closed, switch 7 open ‘Switch 6 closed, switch 5 land 7 open ‘Switch 5 closed, switch 6 and 7 open ‘Maximum Sensitivity (Factory Setting) ‘Switch 5,6, and 7 open _| Minimum Sensitivity ‘Table 2 — Sensitivity AdjustmentYale. Feedback Potentiometer Adjustment 1. Center the drive tire for straight travel 2. Refer to Figure 4 to identity the feedback potentiometer. Unplug the connector from the feedback potentiometer. 3, Measure the resistance between wires 16 and 17. ‘Measure the resistance between wires 17 and 18, 4, Adjust the feedback potentiometer until the resistance values measured in Step 3 are equal (#50 ohms). Adjust the potentiometer by loosening the retaining nut and moving the potentiometer body to attain the desired resistance readings. Tighten the retaining nut without moving the potentiometer body. 5, Attach the plug removed in Step 2 to the feedback potentiometer. Set the key switch to the “ON" postion. 6. Measure the voltage across TP3 and TP1 on the Electronic Control Module circuit board by inserting the ‘negative probe into TP3 and the positive probe in TP1. Referto Figure 7. Adjust potentiometer P2 on the Electronic Control Module circuit board to a value of 0 Volts DC (+ 0.05 VDC). WARNING: During the following check, the ‘operator must move the lit truck. Use caution to avoid injury. 7. Operate the it truck in a straight line for at least 30 feet, ‘making corrections with the steering wheel as necessary to oop the truck traveling in a straight line. At the end of the 30 ‘eet, do not touch the steering wheel. Adjust potentiometer P2 again as described in Step 6. 8, Repeat this procedure a minimum of 3 times to insure accurate potentiometer adjustment. Slow Travel Adjustment The lift truck is designed to be speed-limited above spectfic ‘mast heights. Proceed as follows: 1, Make sure the battery has a corrected specific gravity of at least 1.250. Make sure thatthe lft truck has been operated at {ull speed for approximately 10 minutes before checking the speed. 2. Move the lit truck to an area that is smooth and level for a ‘minimum of 30 m (100 ft). Refer to Figure 5. Put a line across the floor at 10 m (33 ft) and another line across the floor at 20m (68 t), to divide the areain three equal sections. The first 10 m (G3tt) sections used for acceleration, the middle section forthe speed measurement, and the last section for deceleration. 3, Raise the operator platform just over 610 mm (24 in). ‘STEERING SYSTEM — EPS III _— MOUNTING. BRACKET ‘SPROCKET POTENTIOMETER| MOUNTING BRACKET FEEDBACK i aed POTENTIOMETER| o Fuze Figure 4 Motor Mounting Assembly WARNING: During the following check, the operator must move the lift truck. Be sure all personnelare clear ofthe testing area. Use caution to avoid injury. 4, Position an assistant to the side at the 10 metre line and another assistant o the side atthe 20 metre line. Operate thet truck at full speed through the test area to determine the elapsed time between the 10 metre line and the 20 metre line. The it ruck must travel at full speed through the entre length (of the middle 10 m (83 f) section to obtain accurate data. '5._ If the measured elapsed time is loss than 10 seconds, agjust potentiometer P3 on the Electronic Control Module Circuit board counter-clockwise to slow the truck speed to 3.5 ‘kph (¢ 0.3 kph) (2.2 mph + 0.2 mph),Industrial Trucks ‘STEERING SYSTEM — EPS IIT acceleration area 30M (100 FT) TEST AREA 40M (33 FT) LINE 20M (66 FT) LINE ‘SPEED MEASUREMENT AREA deceleration area Figure 5 - Slow Travel Adjustment Speed Test 6._ Ifthe measured elapsed time is more than 10 seconds, adjust potentiometer P3 on the Electronic Control Module circuitboard clockwise to increase the truck speedto 3.5 kph (2 0.8 kph) (2.2 mph + 0.2 mph). Steering Chain Adjustment 1. Disconnect the battery connector. Open the motor ‘compartment doors, 2. Position straight edge (e.g. a thin piece of rigid material) ‘against the steering chain between the sprockets. Make sure the chain is ight on the opposite side ofthe sprockets, 3. Push on the chain at a point approximately halfway between the sprockets with a force of 9 to 12 kg (20-25 lbs). Measure the clearance between the straight edge and the chain, The clearance shouldnot exceed3.3 mm (0.13in). Refer to Figure 6. 4, Tighton the adjustment nut at the mester drive unit sprocket to obtain a maximum clearance of 23 mm (0.13 in) between the chain and straight edge. Do NOT tighten the chain toa clearance of less than 1.3 mm (0.08 in). '5. Close and fasten the motor compartment doors. 1.310 3.3 mnv (0.05 to 0.13 in) MOTOR SPROCKET MOU: STEERING CHAIN STRAIGHT EDGE ADJUSTING BOLT ADJUSTING NUT Figure 6 ~ Steer Chain AdjustmentIndustrial Trucks REPAIR NOTE: Complete disassembly is usually not necessary. Remove only the parts necessary to replace the defective part. ‘Tachometer Replacement 1. Disconnect the battery connector. 2. Remove the screw that fastens the steering whee! to the ‘shaft of the steering mechanism. Remove the steering wheel 3. Remove the screws at the top ofthe instrument panel. Tit the instrument panel to the open position for access to the parts ‘4, Disconnect the wire hamess to the tachometer. 5, Remove the capscrews, washers and nuts retaining the tachometer to the steering wheel bracket, 6. Remove the tachometer drive bet. 7. Install the tachometer mounting bracket to the new tachometer. 8, Insert the tachometer in place and instal the tachometer drive bet. 9. Install the capscrews, washers, and nuts that retain the tachometer mounting bracket to the steering wheel bracket 10. Connect the wire harness to the tachometer. 11, Install the instrument panel and connect the battery connector. Feedback Potentiometer Replacement 1. Position the master drive unit for straight travel Disconnect the battery connector. 2. Open the motor compartment door. Disconnect the ‘electrical plug for the feedback potentiometer. 3. Loosen the setscrew that fastens the shaft of the Potentiometer to the motor assembly. Remove the nut that fastens the potentiometer to the bracket. Remove the potentiometer. 4. Set the new feedback potentiometer for mid-range. Install the new potentiometer on the bracket. Install the nut to fasten the potentiometer, but do not tighten the nut or setscrew. 5. Adjust the feedback potentiometer. Refer to ADJUSTMENTS. Tighton the nut and setscrew without moving the potentiometer body or shaft to avoid changing the setting Connect the plug. 6. Close the motor compartment doors. Connect the battery 6 ‘STEERING SYSTEM — EPS III Electronic Control Module Replacement 1, Disconnect the battery connector and open the motor compartment door. 2. Disconnect the wire hamess plugs to the Electronic Control Module. 3. Prevent the Electronic Control Module trom falling white removing the mounting capscrews, washers and ruts 4, Use caution when handling the Electronic Cortrol Module toavoid spreading the heat-transfer grease from the underside of the module to the surrounding areas. 5. Install heattransfer grease on the underside of the replacement module and the frame. Install the module on the frame panel using the four capscrews, washers ard nuls. Connect the wire harness plugs. 7. Refer to ADJUSTMENTS to adjust the potentiometers on the circuit board for proper operation. 8 Check the position of the dipswitches to be sure the ‘switches are set correctly. Refer to DIPSWITCHES. ‘Steer Motor Assembly and Steering Chain Replacement 1. Disconnect the battery and open the motor compartment doors. 2. Disconnect the wire hamess plug to the feedback potentiometer. Remove the nuts that fasten the feedback potentiometer bracket tothe frame. 3. Hold the motor assembly and remove the capsorews, nuts ‘and washers that fasten the motor assembly o the frame panel, 4. Carefully tip the top of the assembly away fromthe panelto remove the motor and feedback potentiometer bracket out of the truck. Do NOT bend the bracket. Remove the steering chain {rom the sprocket and remove the motor assembly 5. Remove the steering chain from the master drive ur sprocket as required by pulling the chain anchor pins outof the holes in the sprocket. Clean and lubricate the chain using ‘multi-purpose grease. 6. Make sure the master drive unit is aligned for straight travel. Install the steering chain on the master drive unit sprocket. Install the pin of the chain anchor in the frst hole before the axle centerline 7. Install the new motor, sprocket, and feedback potentiometer assembly. Tighten the capscrews and nuts to 31 Nem (23 ff ft) torque. 8. Adjust the feedback potentiometer. Refer to ADJUSTMENTS.Industrial Trucks ‘STEERING SYSTEM - EPS III TYPICAL OPERATING VOLTAGES: The following table lists typical operating voltages for a ‘measured between the designated test point and TPS correctly adjusted steering system. Measured voltages should (ground). Refer to Figure 7. be within 10% of the values listed in the table. Voltages are Test between | To check ECM input TP3 and from ‘Measured voltage (+ 10%) Mast below 24”, should be battery voltage. K3-7 24" Proximity Switch Mast above 24", should be approximately 0 volts. Mast below 150°, should be battery voltage. K3-6 150" Proximity Switch Mast above 150", should be approximately O volt. Steering full et, should be +2.1 volts. K13 Feedback Potentiometer | Steering ful right, should be +6.1 volts. ‘Steering centered, should be +4.3 volts. Kit Key Switch ‘Should be battery voltage. ‘Table 3 - Operating Voltages: eens ‘8: Aggonn YE Figure 7 ~ Test Point and Connector ReferenceIndustrial Trucks ‘TROUBLESHOOTING ‘STEERING SYSTEM — EPS III PROBLEM POSSIBLE CAUSE Truck will not move or steer. Battery disconnected ‘Shut-off has occurred; set key to off position, wait two seconds, then set key to start, then to on position. Dipswitch in wrong position. Check dipswitches. 'No action when st ‘Open circuit in wiring between tachometer and Electronic Control Module or between feedback potentiometer and Electronic Control Module. Tachometer defective. 'No output from Electronic Control Module to steer motor. Replace Electronic. Control Module. Power leads defective between Electronic Control Module and steer motor. Check all power connections. Feedback potentiometer defective, (Check tachometer input. Test for voltage between K1-4 and TP when tachometer is spun. Test for voltage between K1-6 and TPS when tachometer 's spun. If vollage Is present, Electronic Control Module defective. Master drive unit out of normal operating range. Jack truck and manvally turn ‘master drive unit within range. Steer motor defective. Ste ing is loose. ‘Steering chain loose. Adjust chain for proper tension. Truck turns in direction opposite to direction stoored. ‘Stuer motor leads reversed. Tachometer leads reversed. Feedback potentiometer leads reversed.Industrial Trucks ELECTRICAL SYSTEM NOTESIndustrial Trucks ELECTRICAL SYSTEM Figure 8 - Wiring Schematic - EPS IIT Revision 0ELECTRICAL SYSTEM PPTL TE 5052447-00 Sheet 2 0f7 Revicion 0 Figure 8 - Wiring Schematic - EPS IIT (Continued)ELECTRICAL SYSTEM Yale. Sheet 3 of 7 Revision 0 Figure 9 ~ Option: 2ELECTRICAL SYSTEM 1505244700 ‘Sheet 4 of7 Figure 10 - Wiring Diagram - EPS IIT Revision 0 13Yale. EPS III (Continued) Figure 10 - Wiring Diagram ~|ELECTRICAL SYSTEM 5052447-00 7 Revision 0 16 Figure 10 - Wiring Diagram - EPS III (Continued)Industrial Trucks ELECTRICAL SYSTEM 8052447-00 Sheet 7 of 7 Figure 11 — Options Diagram - EPS IIT Revision 0Yale Industrial Trucks Keep The Yale Quality In Your Lift Truck Use Only Yale Approved Replacement Parts