MT60UX (A7S7) Sit-Drive Electric Tow Tractor Service and Maintenance Manual

MT60UX (A7S7)
Sit-drive electric tow tractor

Service and maintenance manual
PART NO. 550234251 REVISION 00 (03/2020)

Contents
Description of symbols .......................................................................................................... 4
Maintenance ........................................................................................................................... 5
Precautions during maintenance ............................................................................................ 5
Places for maintenance ...................................................................................................... 5
Precautions before repair and maintenance ......................................................................... 5
Setting up a new truck.......................................................................................................... 6
Initial charge .................................................................................................................... 6
Battery use and maintenance ................................................................................................ 7
Common charge ............................................................................................................... 7
Balancing charge .............................................................................................................. 7
Equalizing charge .............................................................................................................. 8
Battery storage ................................................................................................................. 8
Maintenance of electrolyte ................................................................................................. 8
Operation of storage batteries during the final stage of their lifetime...................................... 8
Emergency treatment ........................................................................................................ 9
Charger............................................................................................................................ 9
Daily inspection .................................................................................................................... 9
Periodic inspection and maintenance .................................................................................... 10
Inspection and maintenance every day (8 hours) ............................................................... 10
Inspection and maintenance every 350 hours .................................................................... 10
Inspection and maintenance every 1000 hours .................................................................. 11
Recommended fluids ....................................................................................................... 11
Repair .................................................................................................................................. 12
Driving system ................................................................................................................... 12
Principles of operation ..................................................................................................... 12
Driving axle structure ...................................................................................................... 12
Wheel hub structure ........................................................................................................ 13
Drive axle description ...................................................................................................... 14
Installation, adjustment, and maintenance ........................................................................ 15
Steering system ................................................................................................................. 24
Steering system structure ................................................................................................ 24
Steer wheel structure ...................................................................................................... 25
Steer wheel description ................................................................................................... 25
Installation, adjustment, and maintenance ........................................................................ 25
Brake system ..................................................................................................................... 40
Service brake system structure ......................................................................................... 40
Service brake description ................................................................................................. 41
2
Park brake description ..................................................................................................... 41
Brake maintenance ......................................................................................................... 41
Electrical system ................................................................................................................ 42
Electrical schematic – manual steering trucks..................................................................... 43
Electrical schematic – power assist steering trucks ............................................................. 44
Electrical component identification .................................................................................... 45
Electrical controller panel access ....................................................................................... 46
Controller panel identification ........................................................................................... 47
Traction controller 1236E – description.............................................................................. 48
Steer controller 1222 (power assist steering only) – description ........................................... 50
Troubleshooting .................................................................................................................... 52
Mechanical breakdowns ...................................................................................................... 52
Fault codes ........................................................................................................................ 53
Fault codes for traction controller 1236E ........................................................................... 53
Fault codes for steer controller 1222 (power assist steering only) ........................................ 61
Truck storage and transportation ............................................................................................ 67
Loading and unloading........................................................................................................ 67
Transportation of truck ....................................................................................................... 68
Storing the truck ................................................................................................................ 68
3
Foreword
 Please read the manual carefully before servicing.
 This manual is a common manual. We reserve the right to modify technology of the electric
truck. If there is anything in the manual that is not consistent with the actual truck, the
actual truck should be considered correct and the manual is only for reference.
 The instruction manual shall accompany the truck in case of truck leasing or transfer.
 Please contact our sales department in case of any problem.
Warning
Operator of the truck must strictly follow ISO 3691 “Safety Specification for Industrial
Vehicles” and it is prohibited for untrained people to operate the truck.
Description of symbols
The following symbols are of great importance to your safety and others.
Indicates an impending danger. Deaths or severe injuries

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

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

Caution without any precaution or avoidance. You must observe
those requirements.
You shall pay attention to statements that are in direct or

Notice indirect relation with personal security and truck
maintenance.
4
Maintenance
Comprehensive checks of the truck can avoid malfunction and ensure the service life. The hours
listed in maintenance procedures assume that the truck works for 8 hours per day and 200 hours
per month. For the sake of safety, maintenance shall be carried out according to maintenance
procedure.
Notice
All the repair work shall be carried out by professional personnel.

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

Notice
The components for replacement shall be produced completely by our company. When
replacing components of the truck, the components with the same safety requirement with the
original design shall be used.
The lubricating oil and hydraulic oil in use shall be recommended by our company.
Places for maintenance

Notice
Designated places for maintenance shall be appointed that can provide other services such
as hoisting and safety protection facility.
The places shall have level ground and good ventilation.
The places shall be equipped with fire-extinguishing devices.
Precautions before repair and maintenance

Notice
No smoking.
Use all required safety gear.
Clean up leaks or spilled fluids quickly.
Before adding lubricating oil, clean up the dirty oil or dust on the joint with brush or cloth.
Unless otherwise instructed, turn off the key switch and pull off the power socket.
Ensure no goods are on the truck during service or maintenance.
Discharge capacitors before performing any electrical work.
Clean the electric section with compressed air. Never flush with water.
When the truck requires working at height, fall protection must be provided for the repairing and
maintenance personnel.
5
Setting up a new truck
In order to follow the industry related regulations and ensure the absolute security to the truck in
the transportation, a new lift truck may arrive onsite with no electrolyte in the battery.
The electrolyte of storage battery is prepared before the truck leave the factory, and must be
poured into the storage battery by the professional personnel before the first use.
1. Place the truck to the site with good ventilation.
2. Open the lid of storage battery box.
3. Open all the top plastic lids of storage battery.
4. Use a plastic funnel and pour electrolyte into storage battery slowly and carefully.
5. Add electrolyte until it can be seen through the fill ports in the plastic lids of storage battery.
6. After all the storage battery is filled, conduct initial charge.
Initial charge
There are some special tasks that must be completed when charging a new battery for the first
time.
The initial charging and supplementary charging of the battery group must be conducted strictly
according to the regulations stipulated in the battery specification manual.
1. Clean up the surface of the battery before the initial charge, and then check for damage to
ensure reliable connection.
2. Open gas cap.
3. When the charging equipment is able to operate normally, pour the sulfuric acid electrolyte
with a density of 1.260±0.005 (25℃) at a temperature below 30℃ (86°F) into the batteries.
The electrolyte level should be 15-25mm (.5-1 in) higher than the protective board. In order
to reduce the temperature rise caused by chemical reaction of the electrolyte and to let the
electrolyte fully penetrate into the pores of the polar plates and the baffles, let the batteries
sit still for 3-4 hours but not exceeding 8 hours. The initial charging can only be conducted
when the electrolyte temperature reduces to below 35℃ (95°F). When necessary, the
batteries can be put into cold water for temperature reduction. After this cooling period, if
the electrolyte level reduces, electrolyte should be added.
4. The sulfuric acid electrolyte is prepared with battery sulfuric acid complying with the state
standard GB4554-84 and distilled water. Never use industrial sulfuric acid and running water.
The standard temperature of 25℃ (77°F) and density of the electrolytic solution can be
converted as follows:
D25 = Dt+ 0.0007 (t-25)
Where: D25: the density of the electrolytic solution at 25℃ (77°F)
Dt: the actual density of the electrolytic solution at t ℃.
t: temperature of the electrolytic solution when testing the density.
5. Dry up the electrolyte spilled on the surface of battery.
6. Connect the positive and negative poles of batteries with those of the charger and then turn
on the charger power. Charge with the current of 30A (the current of the first stage). After
the charge voltage achieves 28.8V (12×2.4V=28.8V), switch to the 15A current of the
second stage. When charging, the temperature of electrolyte shall never exceed 45℃
(113°F). When the temperature raising up nearly to 45℃ (113°F), reduce the current by half
6
or stop charging temporarily. After the electrolyte temperature reduce below 35℃ (95°F),
continue charging. The charge time needs to be extended in this case.
7. Fully charged basis: When the voltage during the second stage charging reaches 31.2V (12
×2.6V = 31.2V), the variation of the voltage is no greater than 0.005 (V). The density of the
electrolytic solution reaches 1.280 ±0.005 (25℃). If there are no apparent density changes
in 2 hours and fine air bubbles appear violently, it can be deemed that the batteries are fully
charged. The charged power capacity is 4-5 times of the rated capacity and the charging
time is about 70 hours
8. In order to accurately control the sulfuric acid content of the electrolytic solution, the
electrolytic solution density of the batteries should be examined during the last period of
charging. If needed, adjust with distilled water or sulfuric acid with a density of 1.40. The
electrolytic solution density and the liquid surface should be adjusted to the stipulated value
within two hours in the charging state.
9. After the initial charging is completed, the surface of the batteries should be cleaned. Close
the gas cap and then the batteries can be used.
Battery use and maintenance

In order to guarantee the service life of the batteries, the batteries in use should be fully charged.
Insufficiently charged batteries must not be used. During the process of use, close attention should
be paid to the discharge extent. Over-discharge is prohibited; do not continue to use the battery if
the voltage reduces to 1.7V per cell (when the total voltage reduces to 1.7V×12 = 20.4V ). When
the density of the electrolytic solution reduces to 1.17, discharging should be stopped and charging
should be conducted at once. The batteries should not be placed idle for a long period of time.
Common charge
Common charge describes charging of batteries during normal working conditions. The first stage
current of common charge is 30A and that of the second stage is 15A. The charging method is the
same as that of initial charge. The charged volume is 130-140 % of the discharged volume and the
charging time is about 12 hours.
Balancing charge
Do not over-charge batteries in normal use, but conduct a balancing charge as described below
when required.
1. “Lag-behind” cells: Cells with a voltage lower than that of the other batteries in the
discharging process, and cells having been repaired for failure may require a balancing
charge.
2. When balance charge is conducted, the positive and negative poles of the “lag-behind” cells
should be connected with the positive and negative ends of the charger (the DC power
supply) and the charge should be conducted independently.
3. Balancing charge should be conducted for the batteries in normal use every 2-3 months.
4. Balancing charge should be conducted for the batteries that have not been used for a long
period of time before use.
7
Equalizing charge
1. Charge with a 4A current.
2. When the charge voltage reaches 31.2V (12 ×2.6V = 31.2V) and air bubbles occur in the
electrolyte, the current should be reduced by 50% (2A) and continue to charge.
3. When the batteries are fully charged, stop charging for 0.5 hour and charge again with a 1A
current for one more hour.
4. Stop charging for another 0.5 hour and charge with a 1A current for another one hour.
5. Repeat step 4 until air bubbles occur violently in the batteries when the charger is switched
on.
Battery storage
The storage battery shall be kept in clean, dry and ventilated warehouse within the temperature
range of 5 to 40℃ (41 to 104°F). The valid storage period is 2 years. Safekeeping shall be made
within storage period according to the following requirements:
 Avoid direct sunlight. The distance from heat source shall not less than 2m (6.5 ft).
 Avoid contact with any harmful substance. No metal impurity shall fall inside the battery.
 No inversion, mechanical collision, or heavy weight on top of the battery is permitted.
 Storage with electrolyte is forbidden. Under special cases that the storage with electrolyte is
necessary, the density and solution level of electrolyte shall be adjusted to the specified
value.
 Every month, perform a common charge.
Maintenance of electrolyte
Density check
The suction-type densimeter shall be used to check density. During operation, avoid spilling out the
electrolyte, and wear protective gear.
Operation besides check

Consult professional personnel (a service technician), especially when complementing electrolyte
(dilute sulfuric acid).
Electrolyte leakage
As for the electrolyte leakage resulting from storage battery tilting and damage, emergency
treatment shall be made at once. See Emergency treatment.
Operation of storage batteries during the final stage of their

lifetime
When the lifetime of storage battery is about to terminate, the electrolyte in single battery reduces
very fast. If electrolyte has to be added very often, even every day, the battery is at the end of its
useful life.
8
Treatment of waste battery
As for the waste battery, draw out the electrolyte. Recycle the battery as recommended by the
battery manufacturer. The waste electrolyte can be disposed according to relevant local rules and
regulations.
Emergency treatment
1. If the electrolyte spills on skin, wash with large amount of water
2. If the electrolyte spills into eyes, wash with large amount of water, and then seek help from
specialized doctor.
3. If the electrolyte spills on clothes, take off clothes right away, wash with water, and then
flush with weak basic soap solution.
4. If the electrolyte spills or leaks from the battery neutralize it with lime or strong carbonic
acid, and then flush with large amount of water.
Charger
If the charger you use is full automatic type, it must meet the following 2 requirements:
 The output voltage of charger: 24V
 The output current of charger: 20-30A
If the charger you use is semi-automatic or manually adjustable, please charge the battery pack
according to the requirements of use and maintenance in Battery use and maintenance.
Daily inspection
1. Check that all the connecting points and plugs of the electric system are in good condition.
2. Clean the surface of the battery.
3. Check whether the voltage of the battery, the proportion of electrolyte and the electrolyte
level is appropriate.
4. Release the parking brake. Turn the steering wheel to check that the steering system is in
normal condition. Drive the tractor truck slowly and step down the brake pedal to check that
the brake system is in normal condition.
5. Check that the tire is in good condition and that the wheel bolts are fastened tightly.
9
Periodic inspection and maintenance
Inspection and maintenance every day (8 hours)
Clean dust and grease from exterior of the truck.
Whole truck Ensure all hardware is tight and undamaged.
Make sure the tow pin is undamaged.
Braking system Check brake fluid level and fill if required.
Make sure all lights are working properly.
Electrical
Make sure the horn works properly.
system
Make sure all operation switches work properly.
Inspection and maintenance every 350 hours

Every 350 hours, in addition to the daily inspections, the following maintenance should be carried
out. When the parts must be adjusted and replaced, please contact with maintenance personnel.
Keep a monthly maintenance record.
Thoroughly clean the truck, including inside the battery compartment and the
Whole truck
undercarriage.
Check all switches for wear.
Make sure the battery box has no excessive corrosion, and that the battery posts
Electrical are properly connected and undamaged.
system Check all wiring to make sure the wires, connectors, and insulations are all in good
condition.
Tighten the hardware fastening the electrical components.
Check the clearance between the brake drum and brake shoe and adjust if
necessary.
Brake system Check the brake pedal movement and adjust if necessary.
Check the brake shoes for wear and replace if necessary.
10
Inspection and maintenance every 1000 hours
Every three months, in addition to the 350-hour maintenance, the following maintenance should be
carried out. When the parts must be adjusted and replaced, please contact with maintenance
personnel.
Drive motor Clean and inspect internal components of the motor.
Electrical
Check the main electrical contactor for damage and tighten the fastening hardware.
system
Drive axle Check the gearing inside the drive axle and adjust gear clearance if necessary.
Brake system Check all internal components of the brake for wear and damage.
Replace the brake seals.
Drain and release the brake fluid.
Steering
Clean and inspect internal components of the steering system.
system
Adjust the clearance between the steering gear and the steer column.
Whole truck Grease the chassis.
Recommended fluids
Name Specification
Quantity
China Rest of world
Gear oil GL-5 85W/90 gear oil 2L
Lubricant grease 2# lithium lubricating JISK2220/2＃
Brake fluid grease DOT3 synthetic brake fluid 1L
Notice
Always recycle or dispose of all fluids according to local regulations.
11
Repair
Driving system
Principles of operation
The running of the tractor relies on the storage battery as its power source and the DC motor as its
driving force to drive the truck through the two-speed transmission. The travel direction (forward or
backward) is achieved through changing the rotation direction of the driving motor. When the truck
turns , this driving axle controls the rotating speed of the right and left drive wheels by symmetrical
taper planetary gear differential to achieve the coordinated turning of the two wheels so as to meet
the requirements of driving kinematics.
Driving axle structure

26 27 28 29 30 31 32 33
34, 35
36
37
38
39 1
40
41
42 2,3
43
44 4
6
7
25 24 23 22 2120 8
9
19 18 15 14 13 12 11
10
16,
17
1 Wheel 23 Major semi-axis

2 Wheel bolt 24 Shaft bush
3 Wheel nut 25 Motor bracket
4 Brake drum 26 Mechanical brake
5 Nut 27 Motor hoop
6 Rolling bearing 28 Motor 3KW
7 Bearing 6011 29 Motor flange
8 Shaft sleeve 30 O-type ring 47x2.65
9 Framework oil seal FB70x90x10 31 Gear box housing
10 Brake 32 Coupling band
11 Shaft tube 33 Bearing 6204
12 Minor semi-axis 34 Seal screw M10
12
13 Bearing 6208 35 Combined washer 10
14 Hoop 1 36 Gear 17
15 Differential 462 37 Washer 20x30x3
16 Seal screw M16 38 Bearing gland
17 Combined washer 16 39 Thin flat key 5x8x20
18 Gear 83 40 Washer 20x30x5.5
19 Oil tank cover 41 Gear 18
20 Hoop 2 42 Gear 46
21 Framework oil seal FB28x47x7 43 End cap
22 Circlip for hole 44 Nut sleeve
Wheel hub structure
1 Brake branch pump assembly 8 Pin

2 Hand brake push rod 9 Clearance adjuster assembly
Brake shoe with friction plate
3 Spring 10
assembly (rear)
Brake shoe with friction plate
4 11 Brake base plate assembly
assembly (rear)
5 Spring 2 12 Pressing spring
6 Return spring 13 Hand brake pull rod
7 Pawl
13
Drive axle description
Motor 3KW (item 28) is connected to gear box housing (item 31) through motor flange (item 29)
with bolts.
The male spline at the output shaft of motor is linked to male spline at gear 17 (item 36) shaft
through female spline of coupling band (item 32).
When motor 3KW (item 28) turns, it rotates gear 17 (item 36). Gear 17 (item 36) and gear 46 (item
42) makes up high speed gear transmission. Gear 46 (item 42) is connected to gear 18 (item 41)
shaft through flat keys.
When the gear 17 (item 36) shaft turns, it rotates gear 46 (item 42) through small gears. Because
gear 46 (item 42) is connected to gear 18 (item 41) shaft by a flat key, when the gear 46 (item 42)
rotates, it rotates gear 18 (item 41) shaft to achieve the first deceleration of the high speed gear
transmission.
The small gears at gear 18 (item 41) shaft and gear 83 (item 18) make up the second gear
transmission. Because the gear 83 (item 18) is connected together with differential 462 (item 15)
through bolts, the gear 18 (item 41) shaft turns, it rotates gear 83 (item 18) through small gear.
Because gear 83 (item 18) is connected to differential housing (item 15) through bolts, it rotates
differential 462 (item 15) when gear 83 (item 18) turns to achieve the second gear deceleration.
The rotation of gear 83 (item 18) passes to wheels through differential 462 (item 15), the minor
semi-axis (item 12) and the major semi-axis (item 23). Differential 462 (item 15) is connected to the
semi-axis through splines, while the semi-axis is linked to brake drum (item 4) with bolts. When
gear 83 (item 18) turns with differential 462 (item 15), it rotates the semi-axis and brake drum
(item 4). The wheel (item 1) is connected to brake drum (item 4) through wheel bolts (item 2) so as
to realize the rotation of wheel.
The differential 462 (item 15) of the driving axle is the symmetrical taper planetary differential. The
differential is installed on the reduction gearbox through the bearings on the two ends. The
differential housing is divided into the right and left parts and has two differential gears and four
planetary gears.
The drive axle includes reduction gearbox and two shaft tubes which are connected through flange.
The hub brake drum at the wheel is supported by two tapered roller bearings on the axle. The
power is transmitted onto the half shaft through differential. The hub brake drum is driven by the
half shaft and takes the rotation of driving wheel. The half shaft only bears the torque transmitted
to the hub. There is an oil seal inside the hub to prevent water and dust entering or oil leakage.
This drive axle is installed with double shoe brake at two sides of the wheel.
The wheel brake is a double shoe brake which is composed of two groups of brake shoes with
friction plate, brake branch pump, clearance adjuster assembly, hand brake pull rod, spring, base
plate and other components. When the brake oil flows into the brake branch pump, the push rods
on two sides open the brake shoe with equal pressure to press the friction plate of the brake shoe
onto the brake drum so that the brake drum stops rotation. Because the brake drum and wheel shell
are fixed together, wheel braking is realized when the wheel stops running.
14
Installation, adjustment, and maintenance
Installation
 The drive axle has the functions of driving the truck as well as supporting weight of the
truck. The drive axle and truck body are fixed together with bolts.
1
2
1 Chassis 3 Washer
2 Screw 4 Drive axle
Adjustment of bearing clearance on transmission shaft

 Bearing glands (item 38) are installed at the ends of gear 17 (item 36) shaft and gear 18
(item 41) shaft which are mounted with end cap (item 43) and which are used to press the
bearing gland. Two adjusting screws are mounted at the end cap against bearing gland
(item 38). Axial internal clearance of deep groove ball bearings is adjusted through adjusting
the tightness of the adjusting screws. After the axial internal clearance is adjusted, fix the
screws with locknuts.
 When the taper roller bearings at the driving axle wheel wear out, the axial internal
clearance becomes large and the truck wheel will swing. Then the axial internal clearance
can be eliminated through adjusting the nut (item 5) to make the internal ring of tapered
roller bearing contact with rollers.
Maintenance
 When driving the truck, try to avoid pits and depressions on the road surface as far as
possible, and also try to avoid sharp objects stabbing the tires.
 Conduct regular checks for tightness of wheel nuts. If they are not tight, screw them down.
 Check if the wheel brake is in proper working condition and if not, adjust it or repair.
15
Drive axle – remove
1. Support the rear part of the chassis
with a block or stand (item1) rated to
hold the weight of the truck.
2. Remove 6 M14x1.5 hub nuts (item 2)

from each wheel and remove the drive
wheels (item 3).
3. Remove 24 M8x30 hex screws (item

4) that fasten the semi-shaft and
remove the semi shaft (item 5).
16
4. Remove 2 M5x12 screws (item 6), and
remove check ring (item 7) and nut
(item 8).
8
7
5. Remove the hub (item 9).
6. Remove the bearing 32011 (item 10)

and bearing 32910 (item 11).
10
11
17
7. Remove the seal ring (item 12) and
bearing check ring (item 13).
13
12
8. Remove 4 M8×18 screws (item 14)

and take out the brake (item 15).
Remove the left brake in same way.
15
14
9. Remove 4 M14×45 screws, then take

out the drive axle.
18
Drive axle – disassemble
1. Remove 2 M14×1.5 nuts (item 1),
then remove the brake and the brake
wire.
2. Remove the traction motor from the

gear box.
3. Remove 6 M12×30 screw (item 2)

from the long shaft on the reduction
gear box, and remove long shaft
assembly. Remove the left short shaft
(item 3) in same way.
3
19
from the gearbox cover and remove
the cover.

from the inner cover.
20
6. Remove the differential device and
gear assembly.
7. Remove the gear assembly.
21
8. Remove 1 M12 nut (item 6) and 8
M8x25 screws (item 7) from the end
cover.
9. Remove the gear shaft assembly from

the gearbox.
22
10. Remove the nuts (item 8), circlip for
hole 20 (item 9) and seal ring (item
10) from the long shaft assembly.
11. Remove the circlip for hole 20 and
seal ring in the short shaft assembly in
same way.
8 9 10
23
Steering system
The steering system consists of the steering device, transmission gear device, front wheel and other
components.
The steering device consists of the steering wheel, steering column assembly, universal joints and
other components. Its role is to control the tractor driving direction.
The transmission gear device consists of large gears, pinions, bearings, slewing bracket, bolts and
other components. Its role is to reduce the steering force.
The steering wheel not only has the function of steering, but also supports the weight of the truck.
The steering of the wheel slows down through the two-stage gear transmission, which increases the
steering torque to the steering wheel to achieve the steering of the truck.
Steering system structure
1 Steering device
2 Transmission gear device
3 Front (steer) wheel
24
Steer wheel structure
2
3
4
5
7
6
1 Tire 5 Hub cap

2 Rim 6 Bearing
3 Screw and nut 7 Front axle
4 Steer wheel housing
Steer wheel description

One steer tire (item 1) is installed in the middle of the two steel rings by the screw and nuts (item 3)
to form the steer tire wheel assembly.
The steering wheel housing is supported by two bearings 32206 (item 6), and mounted on the front
axle (item 7).
During the assembly of steering wheel housing, add lubricant grease at the bearing. The quantity of
lubricant grease should be enough to fill the bearing raceway.
Installation, adjustment, and maintenance

Maintenance
Check the tightness of hub and wheel tire daily.
25
Mechanical steer wheel – remove
1. Remove 16 M6×12 screws from the
three covers (item 1) in the operator
compartment, and remove the 3
covers.

that fix the steer wheel to the steer
column. Secure the steer wheel, then
lift the truck chassis with hoisting
equipment and take out the steer
wheel from the bottom of the truck.
26
Mechanical steer wheel – disassemble
1. Unthread and remove bearing 6004
1 gland (item 1), then remove 4 M5×16
screws (item 2) and remove bearing
2 6004 cover (item 3).
2. Remove circlip for shaft 20 (item 4), ball

bearing 6004 (item 5) and circlip for hole
40 (item 6).
27
3. Remove the circlip for shaft 20 (item 7),
then remove ball bearing 6004 (item 8).
4. Remove 8 M6×20 screws (item 9) from

the gearbox cover and remove the gear
box cover.
28
5. Remove the bearing spacer bushing
(item 10), ball bearing 6004 (item 11),
bearing spacer bushing (item 12), gear
(item 13) and steering gear shaft (item
14).
10
11
12
13
14
6. Remove 4 M6×16 screws (item 15),

bearing 6008 gland (item 16) and ball
bearing 6008 (item 17).
15
16
17
29
7. Remove gear (item 18).
18
8. Remove steering wheel housing (item

19).
19
30
9. Remove the bearing (item 20).
20
10. Remove the ball bearing 51208 (item

21), gear (item 22) and ball bearing
61912 (item 23).
21
22
23
31
Power assist steer wheel – remove
1. Remove 5 M6 x 12 screws (item 1) from
the steer wheel cover plate.
2. Remove 6 M8×25 screws (item 2) that

fix the steer wheel. Secure the steer
wheel, then lift the truck chassis with
hoisting equipment and take out the
steer wheel from the bottom of the
truck.
32
Power assist steer wheel – disassemble
3. Remove 4 M6×12 screws (item 3) on
the steer wheel closing plate.
4. Remove closing plate (item 4),

bearing (item 5), collar (item 6),
bearing (item 7), O-ring (item 8) and
bearing (item 9) from the steer
wheel.
4
33
5. Remove 8 M8×30 screws (10) that
fix the steer wheel fluted gear, and
remove the steer wheel gear.
10
6. Remove 6 M14×1.5 hub nuts (11)

that fix the steer tire.
11
34
7. Release the air from the steer tire
(item 12), then remove the steer
tire.
12
8. Remove the steer wheel hub cover

(item 13).
13
35
9. Remove the cotter pin (item 14)
from the steer wheel shaft.
14
10. Remove the M24 x 2 nut (item 15)

from the steer wheel shaft.
15
36
11. Remove the steer wheel hub
assembly (item 16).
16
12. Remove the bearings (items 17 and

18) from each side of the steer
wheel hub.
17
18
37
Power assist steer motor – remove
1. Lift the truck and remove the gear (item
1) under the steer motor from the
bottom of the truck.
2. Remove 4 screws (item 2) that hold the

steer motor.
38
3. Remove the steer motor from the truck.
39
Brake system
The brake system consists of the service brake assembly, the foot pedal assembly, the park brake
assembly, brake lines, hand brake shaft, brake oil reservoir, and other components.
Service brake system structure

Service brake structure
4
3
2
1
1 Electromagnetic (park) brake 4 Foot pedal assembly

2 Brake line 5 Brake oil reservoir
3 Brake line
Foot pedal structure
1 Foot pedal 6 Brake pump

2 Spring 7 Cotter pin
3 Foot pedal support 8 Pin
4 Pin 9 Adjustment screw
5 Brake support
40
Service brake description
When braking, step on brake pedal (item 1) to make the brake pedal rotate around pin (item 4).
The sway arm together with the brake pedal will turn together.
The rod pushes on the brake pump (item 6) and the sway arm on the brake pedal is connected
together with pin (part 8). The push rod passes the pressure to the piston in the brake pump. The
piston passes the pressure to the brake oil which is fed into brake pump from brake oil reservoir.
The brake pedal changes the mechanical force into brake oil pressure through the push rod and
brake general. The pressurized oil is transmitted to the cylinder on each side of the wheel through
the two outlets on the brake pump so that the brake pump presses the brake shoe with friction pad
presses on the brake drum to actuate the brake. When brake is released, the tension spring (item 2)
will make the brake pedal and push rod on brake pump return to position.
Park brake description

The electromagnetic brake is used as a park brake, to prevent movement of the truck when parked.
Brake maintenance
Every day before driving, check if the braking system stops the truck as expected and the return
spring on the foot pedal assembly returns the brake to neutral position. If the brake does not stop
the truck properly or if the foot pedal does not return to position, they must be adjusted.
It is also necessary to check these items:
 Connection of the hand brake lever and brake hoop at the driving motor
 Tightness of rivets and other hardware of brake components
 Flexibility of hand brake lever protection sleeve and steel wire rope
 Smooth movement of the foot pedal
 Park brake hold
Only operate the truck when the brake system is in good working condition.
Brake pedal adjustment

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

When the park brake is set, the struck should hold on a 6% slope without moving.
To adjust hand brake turn the adjusting screws on the electromagnetic brake, then adjust the
position of the cable. Pull out the cable to increase braking force.
41
Electrical system
Start-up
The truck is energized when both the emergency power disconnect SA1 and the keyswitch are
turned on.
Travelling
 When the seat is occupied and the seat belt is work, seat switch T9 is energized.
 When the hand brake is released, the hand brake switch T10 is energized.
 When the directional switch is pushed forward, forward switch T22 is energized, or when the
direction switch is pulled back, reverse switch T33 is energized.
 When the accelerator pedal is pressed, a variable signal of 0-5V will be on T16. Lower
accelerator voltage means a slower traction speed, and higher accelerator voltage means a
faster traction speed.
Acousto-optic
 When the turn signal lever is pulled back, left steering switch 131 is energized with 12V
voltage and the left turn signal turns on.
 When the turn signal lever is pushed forward, the right steering switch 132 is energized
with 12V and the right turn signal turns on.
 When the width light switch 141 is turned on, the width light receives 12V power and turns
on.
 When the headlight switch 142 is turned on, the headlight receives 12V power and turns on.
 The headlight switch and width light are on at the same time.
Steering controller – power assist steering only

The steering controller 1222 (T13) is energized with 48V after the drive controller 1236E is
energized. The controller will adjust the position of the steer wheel back and forth to find the zero
position.
When the steering wheel is rotated, two sets AB-phase steering encoders output a square wave.
The high speed counter in the steering controller 1222 sends signal to the steer motor according to
the number of square waves.
42
Electrical schematic – manual steering trucks
43
Electrical schematic – power assist steering trucks
44
Electrical component identification
1 Controller panel 15 Nut M8

3 Washer 8 16 Horn
4 Washer 8 17 Combined switch JK804
5 AC motor 18 Blue light
6 Micro switch TM-1308 (solenoid brake) 19 Turn signal
7 Rear light 20 Headlight
8 Nut M5 21 Screw M5 x 12
9 Main circuit chart 22 DC power switch ZDK31/250A
10 Control circuit chart 23 Warning ring yellow
11 Lead-acid battery 24 Mushroom head JD12-01C
12 Brake light switch JK231 26 Instrument panel
13 Accelerator 27 Strobe light LTD152/12V-24V
14 Screw M8 x 30
45
Electrical controller panel access
1 Rear cover plate 2 Controller panel
46
Controller panel identification
1 Base plate 17 Screw M6 x 30

2 Fixed seat THD-AD18.5 Black 18 Screw M4 x 12
3 Screw M4 x 8 19 Fuse seat
4 Screw M8 x 16 20 Buzzer
5 Washer 8 21 Washer 5
6 Washer 8 22 Washer 5
7 Reverse buzzer 23 Screw M5 x 12
8 DC converter 24 Mounting plate 1 (SW180)
9 Screw M6 x 10 25 Contactor
10 Washer 6 26 Connecting stripe
11 Washer 6 27 Fuse
12 Screw M6 x 16 28 Screw M5 x 20
13 DC/DC support plate 29 Fuse seat
14 Reverse relay DCJ-01/48V 30 Screw M5 x 8
15 Electronic flasher SG152-12V 31 Screw M3 x 12
16 AC controller
47
Traction controller 1236E – description
Terminal Description
B+ Battery positive to controller
B- Battery negative to controller
U Motor phase U
V Motor phase V
W Motor phase W
Battery cables
These two cables should be routed near each other between the controller and the battery. Use high
quality copper lugs and observe any specified torque ratings. For the best electrical noise reduction,
do not rout cables across the center of the controller. When using multiple high-current controllers,
use a star ground from the B- terminal.
Motor wiring
The three phase cables should be close to the same length and routed together between the
controller and motor. Keep the cable lengths as short as possible. Use high quality copper lugs and
observe any specified torque ratings. F or the best electrical noise reduction, do not rout cables
across the center of the controller. Do not rout low current signal wires parallel to motor cables.
48
Traction controller connector pinout
All low power connections are made through a single 35-pin AMPSEAL connector. The mated plug
housing is AMP part number 776164-1, and the contact pins are AMP part number 770520-3. The
connector will accept 20 to 16 AWG wire with 1.7-2.7mm (.067-106 in) thin wall insulation.
49
Steer controller 1222 (power assist steering only) – description
Terminal Description
B+ Battery positive to controller
B- Battery negative to controller
U Motor phase U
V Motor phase V
W Motor phase W
Battery cables
These two cables should be routed near each other between the controller and the battery. Use high
quality copper lugs and observe any specified torque ratings. For the best electrical noise reduction,
do not rout cables across the center of the controller. When using multiple high-current controllers,
use a star ground from the B- terminal.
Motor wiring
The three phase cables should be close to the same length and routed together between the
controller and motor. Keep the cable lengths as short as possible. Use high quality copper lugs and
observe any specified torque ratings. F or the best electrical noise reduction, do not rout cables
across the center of the controller. Do not rout low current signal wires parallel to motor cables.
50
Steer controller connector pinout
All low power connections are made through a single 35-pin AMPSEAL connector. The mated plug
housing is AMP part number 776164-1, and the contact pins are AMP part number 770520-3. The
connector will accept 20 to 16 AWG wire with 1.7-2.7mm (.067-106 in) thin wall insulation.
Pin Name Description

number
1 Keyswitch Provides logic power for the controller and power to
the coil drivers
2 Contactor driver Driver for steer connector
3 [reserved] Not used
7 Ground Ground
8 Command analog 1 Primary steer command pot
9 Interlock input 1 Primary interlock switch pot
10 Home input 2 Primary home switch input
11 Interlock input 3 Redundant interlock switch input
12 Home input 4 Redundant home switch input
13 Coil return Coil return pin for all contactor coils
14 Command encoder 1A Steer command encoder 1 input phase A
15 +10V Regulated low power +10V output
16 Position analog 5 Primary position feedback pot
17 Position analog 6 Redundant position feedback pot
18 Ground Ground
19 Command analog 3 Redundant steer command pot
20 Command encoder 2B Steer command encoder 2 input phase B
22 Motor temperature sensor Motor temperature sensor
23 CAN high CANbus high
24 Fault output Steer fault output
25 Command encoder 1B Steer command encoder 1 input phase B
26 Steer motor encoder 4A Steer motor encoder 4 input phase A
27 Steer motor encoder 4B Steer motor encoder 4 input phase B
28 TX Serial transmit line
29 RX Serial receive line
30 Ground Ground
31 Steer motor encoder 3A Steer motor encoder 3 input phase A
32 Steer motor encoder 3B Steer motor encoder 3 input phase B
33 Command encoder 2A Steer command encoder 2 input phase A
35 CAN low CANbus low
51
Troubleshooting
Mechanical breakdowns
Fault Possible cause Possible repair
1. Leaking in brake system
2. Clearance between brake shoe is not well
1. Repair
adjusted
2. Adjust the adjuster
3. Brake is overheated
3. Check the return spring
Improper 4. Improper contact between brake drum and
4. Readjust
braking friction pad
5. Repair or change
5. Impurity on friction plate
6. Check the brake liquid
6. Impurity in brake liquid
7. Adjust
7. Micro adjust valve on brake pedal is not well
adjusted
1. Friction plate surface is hardened or has
impurity 1. Repair or change
2. Base plate is deformed or screws are loosened 2. Repair or change
Noise in brake 3. Brake shoe is deformed or is not mounted 3. Repair or change
correctly 4. Change
4. Friction plate is worn out 5. Repair
5. Wheel bearing is loosened
1. Oil stain on the friction plate surface
1. Repair or change
adjusted
Uneven brake 3. Repair or change
3. Branch pump doesn’t work
4. Change
4. Return spring on the brake shoe is damaged
5. Repair or change
5. Brake drum is slanting
1. Oil leaking in brake system
1. Repair or change
Improper brake adjusted
3. Release the air
3. Air in brake system
4. Readjust
4. Brake pedal is not well adjusted
52
Fault codes
Fault codes for traction controller 1236E
The traction controller detects a wide variety of faults or error conditions. Faults can be detected by
the operating system or by the VCL code.
Faults detected by VCL code (51-67) vary from application to application.
Diagnostics
Diagnostics information can be obtained in either of two ways.
If a 1313 handheld device or a 1314 PC Programmer is available, the fault log in these devices
displays faults that are currently set and faults that have been set since the fault log was last
cleared. Faults are displayed by name in these devices.
Without a handheld device or a PC Programmer, the fault codes are communicated by the status
LEDs on the controller itself.
The controller has one red LED and one yellow LED. The patterns of these LEDs communicate the
status of the controller (including a fault code number if there are faults present).
LED illumination Controller status
Neither LED is illuminated Controller is not powered on, battery is dead, or
truck is severely damaged
Yellow LED is flashing continuously Controller is operating normally
Yellow and red LEDs are both on and solid Controller is in programming mode
Red LED is on and solid No software is loaded to the controller or an
internal hardware fault is detected; cycle the
keyswitch, reload software, or replace the
controller to resolve
Red LED and yellow LED flash alternately in The controller has detected a fault; see Fault
different patterns code identification with LEDs
Fault code identification with LEDs

The red LED will flash once to indicate that the first digit of the code will follow, and the yellow LED
will then flash to indicate the value of that digit. Then, the red LED will flash twice to indicate the
second digit of the code will follow, and again the yellow LED flashes to indicate the value of that
digit.
For example, if the fault code 23 (B+ Battery Undervoltage Cutback) is set, the red LED will flash
once to indicate the first digit of the fault code is coming. Then, the yellow LED will flash twice to
indicate that the first digit of the fault code is 2. The red LED will then flash twice to indicate that
the second digit of the code is coming, and the yellow LED will flash three times to indicate the
second digit of the fault code is 3.
53
Troubleshooting chart – traction controller 1236E
Use this chart to identify fault names, potential causes, and conditions to set and clear the fault.
Before troubleshooting, cycle the keyswitch to see if the fault clears. If the fault does not clear, turn
off the keyswitch and disconnect the 35 pin connector from the controller, inspect the connector for
damage or corrosion, clean and replace if necessary, and reconnect. If the fault persists, use the
troubleshooting chart.
Code Name Possible cause Set/clear conditions
12 Controller Overcurrent 1. External short of U, V, or W motor Set: Phase current exceeded the
connections. current measurement limit.
2. Motor parameters are mistuned Clear: Cycle keyswitch.
3. Controller defective.
4. Speed encoder noise problems.
13 Current Sensor Fault 1. Leakage to vehicle frame from Set: Controller current sensors have
phase U, V, or W (short in motor invalid offset reading.
stator). Clear: Cycle keyswitch.
14 Precharge Failed 1. See Monitor menu>>Battery: Set: Precharge failed to charge the
Capacitor Voltage. capacitor bank to the keyswitch
2. External load on capacitor bank (B+ voltage.
connection terminal) that prevents Clear: Cycle Interlock input or use
capacitor bank from charging. VCL function Enable_Precharge().
15 Controller Severe 1. See Monitor menu>>Controller: Set: Heatsink temperature below -
Undertemp Temperature. 40°C (-40°F).
2. Controller is operating in an extreme Clear: Bring heatsink temperature
environment. above -40°C (-40°F) and cycle
interlock or keyswitch.
16 Controller Severe 1. See Monitor menu>>Controller: Set: Heatsink temperature above
Overtemp Temperature. 95°C (203°F).
2. Controller is operating in an extreme Clear: Bring heatsink temperature
environment. below 95°C (203°F) and cycle
3. Excessive load on vehicle. interlock or keyswitch.
17 Severe B+ Undervoltage 1. Battery Menu parameters Set: Capacitor band dropped below
misadjusted. the Severe Undervoltage limit with
2. Non-controller system drain on FET bridge enabled.
battery. Clear: Bring capacitor voltage
3. Battery resistance too high. above Severe Undervoltage limit.
4. Battery disconnected while driving.
5. See Monitor menu>>Battery:
Capacitor Voltage.
6. Blown B+ fuse or main contactor did
not close.
17 Severe KSI Undervoltage 1. See Monitor menu>>Battery: Set: Keyswitch voltage dropped
Keyswitch Voltage. below 8.4V (Brownout voltage is
2. Non-controller system drain on 8.0V).
battery. Clear: Bring keyswitch voltage
3. Resistance in low power circuit too above 8.4V.
high.
4. Low power circuit power source
disconnected while driving.
5. Blown fuse.
54
18 Severe B+ Overvoltage 1. See Monitor menu>>Battery: Set: Capacitor bank voltage
Capacitor Voltage. exceeded the Severe Overvoltage
2. Battery menu parameters are Limit with FET bridge enabled.
misadjusted. Clear: Bring capacitor voltage
3. Battery resistance too high for given below Severe Overvoltage Limit.
regen current.
4. Battery disconnected while regen
braking.
22 Controller Overtemp 1. See Monitor menu>>Controller: Set: Heatsink temperature
Cutback Temperature. exceeded by 85°C (153°F).
2. Controller is performance-limited at Clear: Bring heatsink temperature
this temperature. below 85°C (153°F).
3. Controller is operating in an extreme
environment.
4. Excessive load on vehicle.
5. Improper mounting of controller.
23 B+ Undervoltage 1. Normal operation; fault shows that Set: Capacitor bank voltage
Cutback batteries need recharging (controller dropped below the Undervoltage
is performance-limited at this limit with the FET bridge enabled.
voltage). Clear: Bring capacitor voltage
2. Battery parameters are misadjusted. above the Undervoltage limit.
3. Non-controller system drain on
battery.
4. Battery resistance too high.
5. Battery disconnected while driving.
6. See monitor menu>>Battery:
Capacitor Voltage.
7. Blown B+ fuse or main contactor did
not close.
24 B+ Overvoltage Cutback 1. Normal operation; fault shows that Set: Capacitor bank voltage
regen braking currents elevated the exceeded the Overvoltage limit with
battery voltage during regen braking the FET bridge enabled.
(controller is performance-limited at Clear: Bring the capacitor voltage
this voltage). below the Overvoltage limit.
2. Battery parameters are misadjusted.
3. Battery resistance too high for given
regen current.
4. Battery disconnected while regen
braking.
5. See Monitor menu>>Battery:
Capacitor Voltage.
25 +5V Supply Failure 1. External load impedance on the +5V Set: +5V supply (pin 26) outside
supply (pin 26) is too low. the +5V+/-10% range.
2. See Monitor menu>>Outputs: 5 Clear: Bring voltage within range.
Volts and Ext Supply Circuit.
26 Digital Out 6 Open/Short 1. External load impedance on digital Set: Digital Output 6 (pin 19)
output 6 driver (pin 19) is too low. current exceeded 15 mA.
Clear: Remedy the overcurrent
cause and use the VCL function
Set_DigOut() to turn the driver on
again.
27 Digital Out 7 Open/Short 1. External load impedance on digital Set: Digital Output 7 (pin 20)
output 7 driver (pin 20) is too low. current exceeded 15 mA.
Clear: Remedy the overcurrent
cause and use the VCL function
Set_DigOut() to turn the driver on
again.
55
28 Motor Temp Hot Cutback 1. Motor temperature is at or above Set: Motor temperature is at or
the programmed temperature hot above the Temperature Hot
setting and current is being cut parameter setting.
back. Clear: Bering the motor
2. Motor temperature control menu temperature within range.
parameters are mistuned.
3. See Monitor menu>> Motor:
Temperature and Inputs: Analog 2.
4. If the application does not use a
motor thermistor, Temp
Compensation and Temp Cutback
should be programmed to Off.
29 Motor Temp Sensor Fault 1. Motor thermistor is not connected Set: Motor thermistor input (pin 8)
properly. is at the voltage rail (0 or 10V).
2. If the application does not use a Clear: Bring the motor thermistor
motor thermistor, Motor Temp input within range.
sensor Enable should be
programmed Off.
3. See Monitor menu>> Motor:
Temperature and Inputs: Analog 2.
31 Coil1 Driver Open/Short 1. Open or short on driver load. Set: Driver 1 (pin 6) is either open
2. Dirty connector pins. or shorted. This fault can be set
3. Bad crimps or faulty wiring. only when Main Enable = Off.
Clear: Correct open or short, and
cycle driver.
31 Main Open/Short 1. Open or short on driver load. Set: Main contactor driver (pin 6) is
2. Dirty connector pins. either open or shorted. This fault
3. Bad crimps or faulty wiring. can be set only when Main Enable
= On.
cycle driver.
2. Dirty connector pins. or shorted. This fault can be set
3. Bad crimps or faulty wiring. only when EM Brake Type = 0.
cycle driver.
32 EMBrake Open/Short 1. Open or short on driver load. Set: Electromagnetic brake driver
2. Dirty connector pins. (pin 5) is either open or shorted.
3. Bad crimps or faulty wiring. This fault can be set only when EM
Brake Type > 0.
cycle driver.
2. Dirty connector pins. or shorted.
3. Bad crimps or faulty wiring. Clear: Correct open or short, and
cycle driver.
2. Dirty connector pins. or shorted.
cycle driver.
35 PD Open/Short 1. Open or short on driver load. Set: Proportional driver (pin 2) is
2. Dirty connector pins. either open or shorted.
cycle driver.
36 Encoder Fault 1. Motor encoder failure. Set: Motor encoder phase failure
2. Bad crimps or faulty wiring. detected.
3. See Monitor menu>>Motor: Motor Clear: Cycle keyswitch.
RPM.
56
36 Sin/Cos Sensor Fault 1. Sin/cos sensor failure. Set: Motor Sin/Cos sensor failure
2. Bad crimps or faulty wiring. detected.
3. See Monitor menu>>Motor: Motor Clear: Cycle keyswitch.
RPM.
37 Motor Open 1. Motor phase is open. Set: Motor phase U, V, or W
2. Bad crimps or faulty wiring. detected open.
Clear: Cycle keyswitch.
38 Main Contactor Welded 1. Main contactor tips are welded Set: Just prior to the main
closed. contactor closing, the capacitor
2. Motor phase U or V is disconnected bank voltage (B+ connection
or open. terminal) was loaded for a short
3. An alternate voltage path (such as time and the voltage did not
an external precharge resistor) is discharge.
providing current to the capacitor Clear: Cycle keyswitch.
bank (B+ connection terminal).
39 Main Contactor Did Not 1. Main contactor did not close. Set: With the main contactor
Close 2. Main contactor tips are oxidized, commanded closed, the capacitor
burned, or not making good contact. bank voltage (B+ connection
3. Eternal load on capacitor bank (B+ terminal) did not change to B+.
connection terminal) that prevents Clear: Cycle keyswitch.
capacitor bank from charging.
4. Blown B+ fuse.
41 Throttle Wiper High 1. See Monitor menu>>Inputs: Set: Throttle pot wiper (pin 16)
Throttle Pot. volage is higher than the high fault
2. Throttle pot wiper voltage too high. threshold (can be changed with the
VCL function Setup_Pot_Faults()).
Clear: Bring the throttle pot wiper
voltage below the fault threshold.
42 Throttle Wiper Low 1. See Monitor menu>>Inputs: Set: Throttle pot wiper (pin 16)
Throttle Pot. volage is lower than the low fault
2. Throttle pot wiper voltage too low. threshold (can be changed with the
VCL function Setup_Pot_Faults()).
Clear: Bring the throttle pot wiper
voltage above the fault threshold.
43 Pot2 Wiper High 1. See Monitor menu>>Inputs: Pot2 Set: Pot2 wiper (pin 17) volage is
Raw. higher than the high fault threshold
2. Pot2 wiper voltage too high. (can be changed with the VCL
function Setup_Pot_Faults()).
Clear: Bring the Pot2 wiper voltage
below the fault threshold.
44 Pot2 Wiper Low 1. See Monitor menu>>Inputs: Pot2 Set: Pot2 wiper (pin 17) volage is
Raw. lower than the low fault threshold
2. Pot2 wiper voltage too low. (can be changed with the VCL
function Setup_Pot_Faults()).
Clear: Bring the Pot2 wiper voltage
above the fault threshold.
45 Pot Low OverCurrent 1. See Monitor menu>>Outputs: Pot Set: Pot low (pin 18) current
Low. exceeds 10mA.
2. Combined pot resistance connected Clear: Clear pot low overcurrent
to pot low is too low. condition and cycle keyswitch.
46 EEPROM Failure 1. Failure to write to EEPROM memory. Set: Controller operating system
This can be caused by EEPROM tried to write to EEPROM memory
memory writes initiated by VCL, by and failed.
the CAN bus, by adjusting Clear: Download the correct
parameters with the programmer, or software 9OS) and matching
by loading software into the parameter default settings into the
controller. controller and cycle keyswitch.
57
47 HPD/Sequencing Fault 1. Keyswitch, interlock, direction, and Set: HPD (High Pedal Disable) or
throttle inputs applied in incorrect sequencing fault caused by
sequence. incorrect sequence of keyswitch,
2. Faulty wiring, crimps, or switches at direction, and throttle inputs.
keyswitch, interlock, direction, or Clear: Reapply inputs in the correct
throttle inputs. sequence.
3. See Monitor menu>>Inputs.
47 Emer Rev HPD 1. Emergency Reverse operation has Set: At the conclusion of
concluded, but the throttle, forward Emergency Reverse, the fault was
and reverse inputs, and interlock set because various inputs were not
have not been returned to neutral. returned to normal.
Clear: If EMR_Interlock = On, clear
the interlock, throttle, and direction
inputs. If EMR_Interlock = Off,
clear the throttle and direction
inputs.
48 Following Error Fault 1. The Following Error Limit has been Set: The Following Error Limit has
exceeded for the Following Error been exceeded for the Following
Time. Error Time.
2. Incorrect or overly restrictive Clear: Cycle keyswitch.
Following Error Limit and Following
Error Time parameter settings.
3. Motor or drivetrain rotation
obstruction or degradation.
49 Parameter Change Fault 1. This is a safety fault caused by a Set: Adjustment of a parameter
change in certain parameter settings setting requires cycling of
so that the vehicle will not operate keyswitch.
until keyswitch is cycled. For Clear: Cycle keyswitch.
example, if a user changes the
Throttle Type this fault will appear
and require cycling keyswitch before
the vehicle can operate.
68 VCL Runtime Error 1. VCL code encountered a runtime Set: Runtime VCL code error
VCL error. condition.
2. See Monitor menu>>Controller: VCL Clear: Edit VCL application software
Error Module and VCL Error. This to fix this error condition; flash the
error can then be compared to the new compiled software and
runtime VCL module ID and error matching parameter defaults; cycle
code definitions found in the specific keyswitch.
OS system information file.
69 External Supply Out of 1. External load on the 5V and 12V Set: The external supply current
Range supplies draws either too much or (combined current used by the 5V
too little current. supply [pin 26] and 12V supply [pin
2. Fault checking menu Ext Supply Max 25]) is either greater than the
and Ext Supply Min parameters are upper current threshold or lower
mistuned. than the lower current threshold.
The two thresholds are defined by
the External Supply Max and
External Supply Min parameter
settings.
Clear: Bring the external supply
current within range.
71 OS General 1. Internal controller fault. Set: Internal controller fault
detected.
58
72 PDO Timeout 1. Time between CAN PDO messages Set: Time between CAN PDO
exceeded the PDO Timeout Period. messages received exceeded the
PDO Timeout Period.
Clear: Cycle keyswitch or receive
CAN NMT message.
73 Stall Detected 1. Stalled motor. Set: No motor encoder movement
2. Motor encoder failure. detected.
3. Bad crimps or faulty wiring. Clear: Either cycle keyswitch, or
4. Problems with power supply for the detect valid motor signals while
motor encoder. operating in LOS mode and return
5. See Monitor menu>>Motor: Motor Throttle Command = 0 and Motor
RPM. RPM = 0.
77 Supervisor Fault 1. The Supervisor has detected a Set: Mismatched redundant
mismatch in redundant readings. readings; damaged Supervisor;
2. Internal damage to Supervisor illegal switch inputs.
microprocessor. Clear: Check for noise or voltage
3. Switch inputs allowed to be within drift in all switch inputs; check
upper and lower thresholds for over connections; cycle keyswitch.
100 milliseconds.
78 Supervisor Incompatible 1. The main OS is not compatible with Set: Incompatible software.
the Supervisor OS. Clear: Load properly matched OS
code or update the Supervisor
code; cycle keyswitch.
82 Bad Calibrations 1. Internal controller fault. Set: Internal controller fault
detection.
83 Driver Supply 1. Internal controller fault in the Set: Internal controller fault
voltage supply for the driver circuits. detection.
87 Motor Characterization 1. Motor characterization failed during Set: Motor characterization failed
Fault characterization process. See during the motor characterization
Monitor menu>>Controller Motor process.
Characterization Error for cause: Clear: Correct fault, cycle
0=none keyswitch.
1=encoder signal seen, but step size
not determined; set Encoder Step
Size manually
2=motor temp sensor fault
3=motor temp hot cutback fault
4=controller overtemp cutback fault
5=controller undertemp cutback
fault
6=undervoltage cutback fault
7=severe overvoltage fault
8=encoder signal not seen, or one
or both channels missing
9=motor parameters out of
characterization range
88 Encoder Pulse Count 1. Encoder Steps parameter does not Set: Motor lost IFO control and
Fault match the actual motor encoder. accelerated without throttle
command.
Clear: Ensure the Encoder Steps
parameter matches the actual
encoder, cycle keyswitch.
89 Motor type fault 1. The Motor_Type parameter value is Set: Motor_Type parameter is set
out of range. to an illegal value.
Clear: Set Motor_Type to correct
value and cycle keyswitch.
59
91 VCL/OS Mismatch 1. The VCL software in the controller Set: VCL and OS software do not
does not match the OS software in match; when keyswitch cycles, a
the controller. check is made to verify that they
match and a fault is issued when
they do not.
Clear: Download the correct VCL
and OS software into the controller.
92 EM Brake Failed to Set 1. Vehicle movement sensed after the Set: After the EM Brake was
EM Brake has been commanded to commanded to set and time has
set. elapsed to allow the brake to fully
2. EM Brake will not hold the motor engage, vehicle movement has
from rotating. been sensed.
Clear: Activate the throttle.
93 Encoder LOS (Limited 1. Limited Operating Strategy (LOS) Set: Encoder Fault (Code 36) or
Operating Strategy) control mode has been activated, as Stall Detect Fault (Code 73) was
a result of either an Encoder Fault activated, and Brake or Interlock
(code 36) or a Stall Detect Fault has been applied to activate LOS
(code 73). control mode, allowing limited
2. Motor encoder failure. motor control.
3. Bad crimps of faulty wiring. Clear: Cycle keyswitch or, if LOS
4. Vehicle is stalled. mode was activated by Stall Fault,
clear by ensuring encoder senses
proper operation, Motor RPM = 0,
and Throttle Command = 0.
94 EMR Rev Timeout 1. Emergency Reverse was activated Set: Emergency Reverse was
because the EMR Timeout timer has activated and ran until the EMR
expired. Timeout timer expired.
2. The emergency reverse input is Clear: Turn the emergency reverse
stuck On. input Off.
98 Illegal Model Number 1. Model_Number variable contains Set: Illegal Model_Number variable;
illegal value. when keyswitch cycles, a check is
2. Software and hardware do not made to confirm a legal
match. Model_Number, and a fault is
3. Controller defective. issued if one is not found.
Clear: Download appropriate
software for your controller model.
99 Parameter Mismatch 1. Dual Motor Enable parameter is set Set: When the Dual Drive software
On and Control Mode Select is enabled, the controller must be
parameter not set to 1 (Speed Mode set to either Speed Mode Express
Express) or 2 (Speed Mode) or Speed Mode; otherwise fault is
2. Motor Technology and Feedback set. Motor Technology=0 must be
Type parameters do not match. paired with Feedback Type=1, and
Motor Technology=1 must be
paired with Feedback Type=2;
otherwise this fault is set.
Clear: Adjust parameters to
appropriate values and cycle
keyswitch.
60
Fault codes for steer controller 1222 (power assist steering only)
The steer controller detects a wide variety of faults or error conditions. Faults can be detected by
the operating system or by the VCL code.
Diagnostics
Diagnostics information can be obtained in either of two ways.
If a 1313 handheld device is available, the fault log in these devices displays faults that are currently
set and faults that have been set since the fault log was last cleared. Faults are displayed by name
in these devices.
Without a handheld device, the fault codes are communicated by the status LEDs on the controller
itself.
The controller has one red LED and one yellow LED. The patterns of these LEDs communicate the
status of the controller (including a fault code number if there are faults present).
LED illumination Controller status
Neither LED is illuminated Controller is not powered on, battery is dead, or
truck is severely damaged
Yellow LED is flashing continuously Controller is operating normally
Yellow and red LEDs are both on and solid Controller is in programming mode
Red LED is on and solid No software is loaded to the controller or an
internal hardware fault is detected; cycle the
keyswitch, reload software, or replace the
controller to resolve
Red LED and yellow LED flash alternately in The controller has detected a fault; see Fault
different patterns code identification with LEDs
Fault code identification with LEDs

The red LED will flash once to indicate that the first digit of the code will follow, and the yellow LED
will then flash to indicate the value of that digit. Then, the red LED will flash twice to indicate the
second digit of the code will follow, and again the yellow LED flashes to indicate the value of that
digit.
For example, if the fault code 25 (5V Supply Failure) is set, the red LED will flash once to indicate
the first digit of the fault code is coming. Then, the yellow LED will flash twice to indicate that the
first digit of the fault code is 2. The red LED will then flash twice to indicate that the second digit of
the code is coming, and the yellow LED will flash five times to indicate the second digit of the fault
code is 5.
61
Troubleshooting chart – steer controller 1222 (power assist steering only)
Use this chart to identify fault names, potential causes, and conditions to set and clear the fault.
Before troubleshooting, cycle the keyswitch to see if the fault clears. If the fault does not clear, turn
off the keyswitch and disconnect the 35 pin connector from the controller, inspect the connector for
damage or corrosion, clean and replace if necessary, and reconnect. If the fault persists, use the
troubleshooting chart.
Unless indicated as a Warning in the Name column, all faults in this table cause the truck to shut
down.
Code Sub Name Possible cause Set/clear conditions
Code
11 1 Hardware Fault 1. Hardware error: an Set: a)System starting with an indication
unexpected HW Reset, one of of HW Reset, b) CORE supply voltage is
the internal supply voltages is not within +/-5% of 3.75V on main or
out of range, or one of the within +/-5% of 2.5V on supervisor, or
RAM tests failed. c) a RAM test failed.
12 1 Controller 1. External short of phase U, V, Set: BridgeEnabled and TrapBar = Off
Overcurrent 1 or W motor connection. for twenty consecutive samples in the
2. Motor parameters are interrupt.
mistuned. Clear: Cycle keyswitch.
12 2 Controller 1. Rail check or calibrated Set: a) Irms > 120% max base current
Overcurrent 2 current greater than 120% of for 1.2 msec, b) I-U or I-V (current
base current. sensor raw ADC) or I-W (-((I-U –
UOffset) + (I-V – VOffset) + 2.5 V)) is
greater than 950 (4.65V) or less than 41
(0.2V) for five consecutive samples at
240 μs.
13 1 Current 1. Leakage to vehicle frame from Set: a) UOffset or VOffset is outside the
phase U, V, or W (short in ADC range of 450 92.2V) to 573 (2.8V)
motor stator) or, b) UOffset or VOffset functions did
2. Controller defective. not compute.
14 1 Precharge 1. See Monitor menu>>Battery & Set: Capacitor Voltage does not reach ¾
Supply>>Capacitor Voltage. Keyswitch Voltage or 2/3 Nominal
2. External load on capacitor Voltage within 3 sec.
bank (B+ connection terminal) Clear: Cycle keyswitch.
that prevents the capacitor
bank from charging.
15 1 Controller Severe 1. See Monitor Set: Controller heatsink Temperature
Undertemp menu>>Controller>>Tempera equal to or below -40°C (-40°F).
(Warning) ture. Clear: Bring heatsink temp above -35°C
2. Controller is operating in an (-31°F).
extreme environment.
16 1 Controller Severe 1. See Monitor Set: Controller heatsink Temperature
Overtemp menu>>Controller>>Tempera equal to or above 95°C (203°F).
ture. Clear: Bring heatsink temp below 95°C
2. Controller is operating in an (203°F) and cycle keyswitch.
extreme environment.
3. Excessive load on vehicle.
4. Improper mounting of
controller.
62
Code
17 1 Severe 1. Battery parameters are Set: a) Capacitor Voltage < 12V and
Undervoltage misadjusted. Interlock = On and (Contactor Control
2. Non-controller system drain on Type = 1 and Contactor State = 2), or
battery. b) Contactor Control Type <>1 for 60
3. Battery resistance too high. msec.
4. Battery disconnected while Clear: Bring capacitor voltage above
driving. Severe Undervoltage limit and cycle
5. See Monitor menu>>Battery & keyswitch.
Supply>>Capacitor Voltage.
6. Blown B+ fuse or main
contactor did not close.
18 1 Severe 1. See Monitor menu>>Battery & Set: a) Keyswitch Voltage > 65V, or b)
Overvoltage Supply>>Capacitor Voltage. Capacitor Voltage > 65V for 30 msec.
2. Battery parameters are Clear: Bring capacitor voltage below
misadjusted. Severe Overvltage limit and cycle
keyswitch.
22 1 Controller 1. See Monitor Set: Controller heatsink Temperature >
Overtemp menu>>Controller>>Tempera 85°C (185°F).
(Warning) ture. Clear: Brink heatsink temp below 85°C
2. Controller is performance- (185°F).
limited at this temperature.
25 1 5V Supply Failure 1. External load impedance on Set: a) 5v Out < 4.5V for 80 msec, or b)
the +5V supply (pin 21 or 34) 5v Out >5.5V for 80 msec.
is too low. Clear: Bring voltage within range and
2. See Monitor menu>>Battery & cycle keyswitch.
Supply>>5V Out
26 1 10V Supply Failure 1. External load impedance on Set: a) 10v Out < 9.0V for 80 msec, or
the +10V supply (pin 15) is b) 10v Out > 11.0V for 80 msec.
too low. Clear: Bring voltage within range and
2. See Monitor menu>>Battery & cycle keyswitch.
Supply>>10V Out.
27 1 Severe Motor 1. Motor temperature is at or Set: Sensor Enable = On and Steer
Overtemp above the programmed Motor Temperature > programmed
Temperature Max setting. Temperature Max.
2. Motor Temperature Control Clear: Bring voltage within range and
parameters are mistuned. cycle keyswitch.
3. See Monitor menu>>Steer
Motor>>Temperature.
28 1 Severe Motor Hot 1. Motor temperature is at or Set: Sensor Enable = On and Steer
Cutback above the programmed Motor Temperature > programmed
Temperature Hot setting, and Temperature Hot.
the requested current is being Clear: Bring temp within range.
cut back.
2. Motor Temperature control
parameers are mistuned.
Motor>>Temperature.
29 1 Motor Temp 1. Motor thermistor is not Set: Sensor Enable = On and Motor-
Sensor Fault connected properly. Temp (raw A/D) is > 1003 (4.9V) or
(Warning) 2. If the application does not use <20 (0.1V) for 80 msec.
a motor thermistor, parameter Clear: Sensor Enable = On and Motor-
Motor>>Temperature Temp (raw A/D) is < 1003 (4.9V) or
Control>>Sensor Enable <20 (0.1V) for 80 msec.
should be programmed Off.
Motor>>Temperature Sensor
Voltage.
63
Code
31 1 Contactor 1. Open or short on driver load. Set: Contactor Control Type = 1 and
Open/Short 2. Dirty connector pins. Checks Enable = On and Contactor
3. Bad crimps or faulty wiring. Driver = 0% and DrainOut1 = Off for 60
msec.
Clear: Correct open or short, and cycle
keyswitch.
35 1 Fault Output - Set: Fault output = On and ABS (KSI –
Open/Short FaultOutputVoltage) < 2.0V for 80 msec,
or b) Fault Output = On and
FaultOutputVoltage < 4.0V for 80 msec.
Clear: Correct open or short, and cycle
keyswitch.
37 1 Motor Open 1. Motor phase is open. Set: No current on phase V or phase W
2. Bad crimps or faulty wiring. when 10A DC current is run out of phase
U after the contactor is closed before
operation begins.
38 1 Contactor Welded 1. Main contactor tips are welded Set: Contactor Control Type = 1 and
closed. Checks Enable = On and Contactor
2. Motor phase U or V is State = 3 and Weld Check = On and
disconnected or open. ABD (Keyswitch Voltage – Capacitor
3. An alternative voltage path Voltage) is 1.0V for 100 msec.
(such as an external Clear: Cycle keyswitch.
precharge resistor) is
providing a current to the
capacitor bank (B+ connection
terminal).
39 1 Contactor Opened 1. 1222 contactor was closed but Set: Contactor Control Type = 1 and
is no longer closed. Checks Enable = On and Contactor
State = 2 and ABS (Keyswitch Voltage –
Capacitor Voltage) is > 5.0V for 1 sec.
39 2 Contactor Did Not 1. Main contactor did not close. Set: Contactor Control Type = 1 and
Close 2. Main contactor tips are Checks Enable = On and Contactor
oxidized, burned, or not State = 1 and ABS (Keyswitch Voltage –
making good contact. Capacitor Voltage) is > 5.0V for 1 sec.
3. External load on capacitor Clear: Cycle keyswitch.
bank (B+ connection terminal)
that prevents capacitor bank
from charging.
4. Blown B+ fuse.
41 1 Command - Set: (Command Input Device = 0 or 2)
Analog1 Out of and (Analog 1 > Analog 1 Fault Max or
Range Analog 1 < Analog 1 Fault Min) for 60
msec.
42 1 Command - Set: (Command Input Device = 0 or 2)
Analog3 out of and (Analog 3 > Analog 3 Fault Max or
Range Analog 3 < Analog 3 Fault Min) for 60
msec.
43 1 Feedback Analog5 - Set: (Command Input Device = 0 or 2)
Out of Range and (Analog 5 > Analog 5 Fault Max or
Analog 5 < Analog 5 Fault Min) for 60
msec.
64
Code
44 1 Feedback Analog6 - Set: (Command Input Device = 0 or 2)
Out of Range and (Analog 6 > Analog 6 Fault Max or
Analog 6 < Analog 6 Fault Min) for 60
msec.
46 1 EEPROM Failure 1. Failure to write to EEPROM Set: EEPROM CRC does not match after
memory. This can be caused four attempts to read.
by EEPROM memory writes Clear: Cycle keyswitch.
initiated by the CAN bus, by
adjusting parameters with the
programmer, or by loading
new software into the
controller.
47 1 Sin/Cos Command - Set: Analog 1 and Analog 3 inputs are
Sensor not within the parameter Command
Device >>2 – Sin/Cos Sensor>>Fault
Volts of the ideal waveform as defined
by the Gain and Offset parameters.
48 1 Sin/Cos Feedback - Set: Analog 5 and Analog 6 inputs are
Sensor not within the parameter Command
Device >>2 – Sin/Cos Sensor>>Fault
Volts of the ideal waveform as defined
by the Gain and Offset parameters.
49 1 Parameter Change 1. A parameter value was Set: a) A parameter is changed using
Fault changed that requires a power CAN or ESP that requires a power cycle,
cycle or must be changed b) an application is loaded and started
prior to first interlock. that has a parameter interlock key
2. A new software application different from the old application (an
was loaded that does not automatic reset of the parameters
match the existing parameters occurs when the keys do not match; the
and the parameters were fault is set to indicate that the
overwritten with the defaults parameter settings need review), or c) a
from FLASH. parameter change is requested when
3. A device (such as the 1313) using ESP that is out of range.
using the serial interface is Clear: Cycle keyswitch.
requesting a change to a
parameter that is outside
allowable range.
51 1 Interlock Switch - Set: Interlock Type = 2 and Switch1 =
Supervision Switch3 for 60 msec.
(Sets Clear: Interlock Input 1 <> Interlock
Interlock=Off) Input 3 for 60 msec.
52 1 Home Switch - Set: a) Input Type = 1 and Switch2 =
Supervision Switch4 and Wheel Position > 5° from
last position where they did not match
for more than 60 msec., or b) Input
Type = 2 and Switch2 <> Switch4 and
Wheel Position > 5° from last position
where they matched for 60 msec.
53 1 Home Position Not - Set: Steer Command State = 2 and
Found Wheel Position changes by more than
180° without a change in the monitor
variable Home Reference>>Home.
65
Code
54 1 Home Reference 1. During steering (Steer Set: Steer Command State = 4 and ABS
Tolerance Fault Command State = 4), the (Encoder 3 Degrees from Home at the
wheel position at which the home transition) >Home Reference
Home variable changes is Tolerance for 60 msec.
farther than the allowed Clear: Cycle keyswitch.
tolerance from the original
position found during homing
(Steer Command State = 2).
55 1 Steer Command 1. Steer Command differs from Set: Device State = 4 and ABS (Steer
Supervision Steer Command 2 by more Command (deg) – Steer Command 2
than the allowed tolerance. (deg)) > Wheel Position Tolerance for
80 msec.
56 1 Wheel Position 1. Wheel Position differs from Set: Device State = 4 and ABS (Steer
Supervision Wheel Position 2 by more than Command (deg) – Steer Command 2
the allowed tolerance. (deg)) > Steer Command Tolerance for
80 msec.
69 1 5V Current Out of 1. The monitor variable 5V Out is Set: a) 5v Out < 5V Current Min for 80
Range less than the programmed 5V msec, or b) 5v Out > 5V Current Max for
Current Min or greater than 80 msec.
the programmed 5V Current Clear: Cycle keyswitch.
Max.
71 1 Software Fault 1 - Set: a) Watchdog reset, or b)
unexpected re-entry from the Start
Manager.
71 2 Software Fault 2 - Set: a) ENUM out of range, or b) an
improperly calculated value (assert).
71 3 Software Fault 3 - Set: a) out of range calculated value or
parameter, or b) common parameters
CRC for main and supervisor do not
match.
71 4 Software Fault 4 - Set: A fault occurred in the supervisor
micro that can only occur in the main
micro.
71 5 Software Fault 5 - Set: a) An internal CAN PDO was not
received from the other micro within 100
msec, or b) the internal PDO sequence
number is not in sequence.
72 1 PDO1 Timeout - Set: CAN NMT State = 5, and time since
the last PDO1 message is greater than
PDO1 TimeoutTime.
73 1 Following Error - Set: Steer Command State = 4 and ABS
(Steer Command 2 (deg) – Wheel
Position 2 (deg)) > Following Error
Tolerance for Following Error Time.
66
Code
74 1 Hardware 1. Software not compatible with Set: a) The hardware product code
Software controller hardware (3300000x, where x = 1, 2, 3, 4, 5, 6)
Mismatch configuration. does not match the application product
2. Application software loaded code, or b) the controller rated voltage
into one or both micro (g_profile.controllerRatedVoltage) does
controllers is loaded into the not conform with the hardware product
wrong micro. code.
3. Different versions of the Clear: Download appropriate software
application software are and cycle keyswitch.
loaded into the two micro
controllers.
75 1 Parameter Conflict 1. Using quadrature encoder 1 Set: Command Device>>Command
for steering command and for Input Device =1 and Vehicle
traction motor feedback. Configuration>> Traction Speed Input
>>Input Type=1.
Clear: Resolve conflict and cycle
keyswitch.
Truck storage and transportation

Loading and unloading
Before loading the truck, check the nameplate for the total weight of truck to choose appropriate
hoisting handling equipment.
When hoisting the truck, connect the lifting gear to three points on the truck. Use the two lift points
under the front of the truck, one on each side, and the tow pin.
When hoisting the truck, keep it level and lower it slowly and carefully. The personnel around shall
watch for safety. Assign one person to guide the truck and watch for correct placement. If another
lift truck is used for loading and unloading, please watch the bottom of the truck. Take care to insert
the fork arms to the bottom, to avoid damaging the drive wheel, casters, and load wheels.
67
Transportation of truck
During transportation of the truck, please pay attention to the following items:
 Set the parking brake of the tractor.
 Fix the front wheel and rear driving axle with steel wire and block the front and back wheel.
Make sure that the tractor truck is tied down to the transport truck securely.
 During hoisting of the tractor, lift the tractor truck only according to the “hoisting marks” on
the covers.
 Trucks used to load and transport the tractor should not run too fast and should avoid sharp
turning and sudden braking to prevent damaging the tractor truck and avoid accidents.
Storing the truck

 Shut off the electric lock and unplug the battery.
 Set the parking brake of the tractor truck.
 Block the front and rear wheel.
 If the tractor truck is not used for a long time, place blocks under the truck so that the
wheels are suspended. Conduct complementary charge to the storage battery every month.
68

MT60UX (A7S7) Sit-Drive Electric Tow Tractor Service and Maintenance Manual

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MT60UX (A7S7) Sit-Drive Electric Tow Tractor Service and Maintenance Manual

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MT60UX (A7S7)

Sit-drive electric tow tractor

PART NO. 550234251 REVISION 00 (03/2020)

Indicates an impending danger. Deaths or severe injuries

Indicates a potential danger. Deaths or severe injuries

Indicates a potential danger. Moderate injuries may result

You shall pay attention to statements that are in direct or

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

Precautions during maintenance

Places for maintenance

Precautions before repair and maintenance

Battery use and maintenance

Operation besides check

Operation of storage batteries during the final stage of their

Whole truck Ensure all hardware is tight and undamaged.

Make sure the tow pin is undamaged.

Braking system Check brake fluid level and fill if required.

Make sure all lights are working properly.

Make sure all operation switches work properly.

Inspection and maintenance every 350 hours

Check the brake shoes for wear and replace if necessary.

Drive motor Clean and inspect internal components of the motor.

Replace the brake seals.

Drain and release the brake fluid.

Whole truck Grease the chassis.

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

Driving axle structure

1 Wheel 23 Major semi-axis

Wheel hub structure

1 Brake branch pump assembly 8 Pin

Adjustment of bearing clearance on transmission shaft

2. Remove 6 M14x1.5 hub nuts (item 2)

3. Remove 24 M8x30 hex screws (item

5. Remove the hub (item 9).

6. Remove the bearing 32011 (item 10)

8. Remove 4 M8×18 screws (item 14)

9. Remove 4 M14×45 screws, then take

2. Remove the traction motor from the

3. Remove 6 M12×30 screw (item 2)

5. Remove 8 M10×50 screws (item 5)

7. Remove the gear assembly.

9. Remove the gear shaft assembly from

Steering system structure

1 Tire 5 Hub cap

Steer wheel description

Installation, adjustment, and maintenance

2. Remove 4 M12×25 screws (item 2)

2. Remove circlip for shaft 20 (item 4), ball

4. Remove 8 M6×20 screws (item 9) from

6. Remove 4 M6×16 screws (item 15),

8. Remove steering wheel housing (item

10. Remove the ball bearing 51208 (item

2. Remove 6 M8×25 screws (item 2) that

4. Remove closing plate (item 4),

6. Remove 6 M14×1.5 hub nuts (11)

8. Remove the steer wheel hub cover

10. Remove the M24 x 2 nut (item 15)

12. Remove the bearings (items 17 and

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

Service brake system structure

1 Electromagnetic (park) brake 4 Foot pedal assembly

Foot pedal structure