Maintenance

32:(5 67((5,1*
OS030EB [B801];
OS030EC [C801];
OS/SS030BD [C826];
OS/SS030BE [D826]

PART NO. 524163981 1600 YRM 691

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, and that the load being lifted is balanced. Make sure the crane, cables, and chains
have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on

electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE
LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using
force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or
if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels
and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away
from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Power Steering Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
EPS III ............................................................................................................................................................. 1
APS ................................................................................................................................................................. 1
Description .......................................................................................................................................................... 1
EPS III ............................................................................................................................................................. 1
APS System .................................................................................................................................................... 2
Checks and Adjustments..................................................................................................................................... 2
General ........................................................................................................................................................... 2
Checks ............................................................................................................................................................ 2
Check Steering System for Correct Operation............................................................................................ 2
Check Slow Travel Speed ........................................................................................................................... 3
Check High Lift Traction Shutoff.................................................................................................................. 3
Dipswitches, EPS III.................................................................................................................................... 3
LED Indicators, EPS III ............................................................................................................................... 3
Checks, APS ................................................................................................................................................... 4
Checks Prior to Powerup, APS ................................................................................................................... 4
Dipswitches, APS........................................................................................................................................ 5
LED Indicators, APS ................................................................................................................................... 5
Adjustments .................................................................................................................................................... 5
General ....................................................................................................................................................... 5
Steer Motor With Steering Chain Replacement, EPS III............................................................................. 5
Steer Motor With Steering Gear Replacement, APS .................................................................................. 5
Return-to-Center Steering System ............................................................................................................. 5
Command Potentiometer Adjustment, EPS III........................................................................................ 5
Feedback Potentiometer Adjustment (Earlier Models Only) ................................................................... 7
Tach Generator Steering System, EPS III................................................................................................... 10
Tach Generator Adjustment, EPS III....................................................................................................... 10
Sensitivity Adjustment, EPS III ............................................................................................................... 10
Feedback Potentiometer Adjustment, EPS III......................................................................................... 11
Slow Travel Adjustment, EPS III.................................................................................................................. 11
Return-to-Center and Multiturn System, APS............................................................................................. 12
Encoder Replacement, APS................................................................................................................... 12
Steering Chain Adjustment, EPS III............................................................................................................ 12
Repairs ................................................................................................................................................................ 13
RTC Steering System, EPS III ........................................................................................................................ 13
Command Potentiometer Replacement, EPS III......................................................................................... 13
TGS System, EPS III....................................................................................................................................... 14
Tach Generator Replacement, EPS III........................................................................................................ 14
Feedback Potentiometer Replacement, EPS III .............................................................................................. 14
ECM Replacement, EPS III............................................................................................................................. 14
Steer Motor Assembly and Steering Chain Replacement, EPS III.................................................................. 14
Typical Operating Voltages, EPS III ..................................................................................................................... 15
Steering Proximity Switch and Centering Proximity Switch, APS........................................................................ 16
Advanced Power Steering System Replacement............................................................................................ 16
Troubleshooting ................................................................................................................................................... 16
EPS III ............................................................................................................................................................. 16
APS ................................................................................................................................................................. 17

©2002 Yale Materials Handling Corp. i

Table of Contents Power Steering

TABLE OF CONTENTS (Continued)

This section is for the following models:

OS030EB [B801];
OS030EC [C801];
OS/SS030BD [C826];
OS/SS030BE [D826]

ii
1600 YRM 691
General
This manual contains procedures for adjustment, re-
pair, and troubleshooting of the Electric Power Steering
(EPS III) System and Advanced Power Steering (APS)
System. These systems control the steer motor that
is used to turn the master drive unit. The lift truck is
steered by turning the master drive unit.
EPS III
EPS III is only applicable to the C826 and B801 trucks.
There are three types of EPS III systems available: the
standard system, called the Return-to-Center (RTC)
Steering System, the optional Tach Generator Steering
(TGS) System, and the optional Wire Guidance Steer-
ing System. This section pertains to the RTC and TGS
Systems only.
Description
EPS III
The EPS System is comprised of the following compo-
nents:
• Steering handle (RTC System) or steering wheel
(TGS System)
• Command potentiometer (RTC System) or the tach
generator (TGS System)
• Feedback potentiometer
• Steer system wire harness
• Electronic Control Module (ECM)
• Lift truck battery
• Steer motor
• Steering sprocket and chain
WARNING
The Master Drive Unit (MDU) will automatically cen-
ter when the key is ON. Keep hands, arms, and other
appendages and tools clear.
The RTC System has a steering handle that returns to
the center position when released. The handle moves
100 degrees each side of center for the full range of
steering control. The TGS System has a steering wheel
coupled to a belt-driven tach generator. The steering
wheel does NOT automatically return to the center po-
sition.
The steering handle and command potentiometer for
the RTC System are located in the operator’s compart-
ment. Similarly, the steering wheel and tach generator
Description
NOTE: This manual is NOT applicable to lift trucks with
the optional Wire Guidance Steering System. See the
section Wire Guidance - Description 2200 YRM 421
for checks and adjustments and the section Wire Guid-
ance - Repair 2200 YRM 422 for repairs to the steer-
ing system of trucks equipped with the Wire Guidance
Steering System.
APS
APS is only applicable to the D826 and C801 trucks.
There are two steering input devices used with the
APS: the standard system, called the Multiturn Steer-
ing (MTS) System and the optional Return-to-Center
(RTC) System.
for the TGS System are located in the operator’s com-
partment. The ECM and steer motor are in the motor
compartment beside the master drive unit. The feed-
back potentiometer is connected to the steer motor be-
low the steer sprocket. The steering chain connects the
steer sprocket at the gear motor to the sprocket of the
master drive unit. The ECM is also located in the steer
motor compartment.
The command potentiometer attached to the steering
handle provides a signal to the ECM corresponding to
the operator input. Similarly, the tach generator coupled
to the steering wheel on the optional TGS System pro-
vides a signal to the ECM corresponding to the operator
input. The ECM processes the signal to determine the
steer angle selected by the operator.
The feedback potentiometer is connected to the steer
motor. The feedback potentiometer provides a signal to
the ECM that corresponds to the position of the master
drive unit.
The signal from the command potentiometer (or tach
generator) and the signal from the feedback poten-
tiometer are sent simultaneously to the ECM. If the
master drive unit is not at the operator-selected angle,
the ECM provides electrical output to the 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 turn the master drive unit. As the master drive
unit approaches the selected angle, the signal from the
1
Checks and Adjustments
feedback potentiometer changes to instruct the ECM to
slow and then stop the rotation of the steer motor.
APS SYSTEM
The APS System is comprised of the following compo-
nents:
• APS controller
• Steering handle (RTC) or steering wheel (MTS)
mechanisms
• Steering encoder for both systems
• Steering proximity switch (RTC only)
• MDU centering proximity switch (MTS and RTC)
• Steer motor with built-in position encoder
• Steering sprocket and chain or gear
The MTS System has a steering wheel that does NOT
automatically return to the center position. It has no
stops.
The RTC System has a steering handle that returns to
the center position when released. The handle moves
100 degrees each side of center for the full range of
steering control.
The steering wheel and encoder for the MTS System
are located in the operator’s compartment. The steer-
ing handle, steering proximity switch, and steering en-
coder for the RTC System are located in the operator’s
Checks and Adjustments
GENERAL
WARNING
Do not operate a lift truck that needs adjustments or
repairs. Report the need for adjustments or repairs
immediately. If adjustment or repair is necessary,
put a DO NOT OPERATE 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 lift truck.
The person doing the adjustments must make the
adjustments with the system energized. Make sure
the operator does not move the lift truck and cause
a personal injury.
Do not make adjustments to a properly operating steer-
ing system.
2
1600 YRM 691
compartment. The APS controller, steer motor, and
MDU centering proximity switch are in the motor com-
partment beside the master drive unit.
The steering encoder is attached to the steering wheel,
which provides a signal to the Master Control Unit
(MCU) corresponding to the operator input. Similarly,
the steering handle on the optional RTC system
provides a signal to the MCU corresponding to the
operator input. The MCU processes the signal to the
steer angle selected by the operator, and steering
commands are sent to the APS controller via the CAN
bus communication wires. The APS provides electrical
output to the steer motor.
The steer motor is coupled to the master drive unit with
a sprocket and chain or a gear. The steering chain
connects the steer sprocket at the gear motor to the
sprocket of the master drive unit. The electrical out-
put to the steer motor causes the motor to rotate the
sprocket and chain or pinion gear and turn the master
drive unit. On lift trucks that have gear steering, the
pinion gear on the steering actuator directly drives the
ring gear on the master drive unit. As the master drive
unit approaches the selected angle, the signal from the
steering encoder changes to instruct the APS controller
to slow and then stop the rotation of the steer motor.
CHECKS
Check Steering System for Correct
Operation
The ECM check includes checks for the command po-
tentiometer and the feedback potentiometer.
1. Open the motor compartment door. Move the key
switch to the ON position and push the foot switch.
Make sure the battery has a corrected specific grav-
ity of at least 1.250.
2. Check the system for correct operation: Move the
steering handle or steering wheel from a full left turn
position to a full right turn position. The master drive
unit should move 85 to 95 degrees in each direction
from straight travel.
3. If the master drive unit moves less than 90 degrees
(±5 degrees) in either direction, the steering is in-
correctly adjusted or may have a mechanical prob-
lem. Refer to Adjustments.
1600 YRM 691 Checks and Adjustments

4. Check that the master drive unit moves through the Dipswitches, EPS III
full range of rotation in 5 seconds or less. The
lift truck must be on smooth concrete with a fully NOTE: The dipswitches are factory-set and should not
charged battery and no load. need to be adjusted.

5. If the master drive unit requires greater than 5 sec- If the ECM is replaced, or the settings of the dipswitches
onds to move through the full range of rotation, are inadvertently changed, refer to Figure 1 to set the
check for a mechanical problem or defective ECM. position of the dipswitches to the factory settings.

On trucks equipped with the optional TGS System, an

Check Slow Travel Speed
NOTE: The slow travel speed is checked during the ad-
justment procedure. Refer to Adjustments.
Check High Lift Traction Shutoff
adjustment can be made to the settings of dipswitches
5, 6, and 7 to alter the sensitivity of the tach generator
input scaling if desired. Refer to Tach Generator Steer-
ing System, EPS III, Sensitivity Adjustment, EPS III in
the Adjustments section following.

1. Instruct the operator to raise the platform above
3810 mm (150 in.).
2. The traction system should NOT operate with the
operator platform above 3810 mm (150 in.) unless
the truck is equipped with the high lift travel-enable
option. Note that the standard travel cut-out for
the C826 is 5384.8 mm (212 in.). If the unit is so
equipped, check that the traction system operates
normally EXCEPT when the steering is set for 10
degrees or more from center and the operator plat-
form is above 3810 mm (150 in.). If the steering
is set for more than 10 degrees and the operator
platform is above 3810 mm (150 in.), the traction
system should NOT operate.
LED Indicators, EPS III
Three test points are provided for adjustment of the
ECM. TP1 is the feedback potentiometer input adjusted
by P2. TP2 is the command potentiometer input ad-
justed by P1. TP3 is the analog and logic common.
Light-Emitting Diodes (LEDs) 1 through 5, located on
the ECM circuit board, are used to indicate steer sys-
tem faults. Refer to Figure 2 and Table 1. The vehicles
equipped with electric steering systems are designed
to stop automatically when a fault occurs. The brake
relay, located in the ECM, applies the brake to stop the
vehicle if a fault condition is detected.
Table 1. LED Indicators

LED 1 on (green) (with Controller active

motor clicking sound)
LED 2 on (red) Left limit reached
LED 3 on (red) Right limit reached
LED 4 on, LED 5 off Error in sensor circuit
LED 4 off, LED 5 on Error in controller or
motor circuit
LED 4 on, LED 5 on Error in controller
LED 4 off, LED 5 off, and Supply contactor fault or
LED 1 on (with no sound voltage on emergency
from motor) brake coil (the controller
must remain off for a
minimum of 2 seconds
A. SET SWITCH 8 FOR RTC STEER before a new startup to
B. SET SWITCH 8 FOR TACH STEER avoid an error condition)
Figure 1. Dipswitches - Factory Setting

3
Checks and Adjustments 1600 YRM 691

1. DIPSWITCHES 3. TEST POINTS

2. LED’S 4. POTENTIOMETERS

Figure 2. Electronic Control Module (ECM) - EPS III

CHECKS, APS 6. The truck controller is functional. See Figure 3.

Checks Prior to Powerup, APS

NOTE: There are no adjustments for the 1243 Con-
troller Module for APS System.

The initial startup and verification of an APS in a new ap-

plication or new design requires additional procedures
for the first time powerup.

Verify the following before applying power to an APS for

the first time.

1. The proper APS number for the application has

been installed.

2. The vehicle battery voltage matches the nominal

DC voltage listed on the product indentification
lable.

3. All power and signal wires are correct.

4. The APS is correctly fused for the application.
5. All steering input and feedback transducers are cor-
rectly installed.
Figure 3. Master Control Unit (MCU)
NOTE: If the MCU or APS is replaced, the Steering Off-
set Adjustment procedure in Setup of Electrical Sys-
tem 2200 YRM 933 or 2200 YRM 956 MUST be per-
formed before the lift truck can be operated.

4
1600 YRM 691
Dipswitches, APS
Their are no dipswitches on the APS System.
LED Indicators, APS
Their are no LED indicators on the APS System.
ADJUSTMENTS
General
NOTE: This manual is NOT applicable to lift trucks
with the optional Wire Guidance Steering System. See
Wire Guidance - Description EPS III 2200 YRM 421
or Wire Guidance - Description APS 2200 YRM
957 for checks and adjustments to the Wire Guidance
Steering System.
NOTE: Do not make adjustments to a properly operat-
ing steering system. The following adjustments must be
done in the order specified. Do not move the steering
wheel or handle after it has been accurately centered
unless instructed to move it in the following procedures.
NOTE: The steer motor has no internal serviceable
parts. Do not disassemble the steer motor.
NOTE: The steer motor gearbox does not have any
serviceable parts, nor does the gearbox oil need to be
checked, refilled, or replaced.
Make sure the battery has a corrected specific gravity
of at least 1.250. Move the lift truck to an open area
where it can be driven in a straight line for a distance of
at least 9 m (30 ft).
Steer Motor With Steering Chain
Replacement, EPS III
Refer to Figure 6 and Figure 7 for the following instruc-
tions.
1. Turn key switch OFF, disconnect battery, and open
the motor compartment door.
2. Hold the steer motor assembly and remove the cap-
screws, nuts, and washers that fasten the motor as-
sembly to the frame.
3. Carefully tip the top of the assembly away from the
panel to remove the motor from the truck. Remove
the steering chain from the sprocket.
Checks and Adjustments
4. Remove the steering chain from the master drive
unit sprocket as required by pulling the chain an-
chor pins out of the holes in the sprocket. Clean
and lubricate the chain using multipurpose grease.
5. 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 first hole before the axle cen-
terline.
6. Install the new motor and sprocket assembly.
Tighten the capscrews and nuts to 31 N•m
(23 lbf ft).
Steer Motor With Steering Gear
Replacement, APS
Refer to Figure 8 for the following instructions.
1. Turn key switch OFF, disconnect battery, and open
the motor compartment door.
2. Remove the three bolts holding the steer motor as-
sembly to the frame and lift out the steer motor and
pinion gear.
3. Install steer motor onto the frame by aligning the
teeth of the pinion gear with the teeth of the steering
gear and installing the three bolts.
NOTE: There are no adjustments between the steering
gear motor and the steering gear.
4. Torque the three bolts holding the steer motor as-
sembly to the frame to 23 N•m (17 lbf ft). Lubricate
the pinion gear and ring gears using multipurpose
grease.
Return-to-Center Steering System
Command Potentiometer Adjustment, EPS III
WARNING
The MDU will automatically center when key is ON.
Keep hands, arms, and other appendages and tools
clear.
The Return-to-Center (RTC) command potentiometer
is located at the steering mechanism in the instrument
panel. Refer to Figure 4 and Figure 5. Remove the
screws at the top of the instrument panel. Tilt the panel
to the open (down) position for access to the poten-
tiometer.
5
Checks and Adjustments 1600 YRM 691

Legend for Figure 4

1. RTC STEERING HANDLE
2. INSTRUMENT PANEL
3. COMMAND POTENTIOMETER
4. RETAINING NUT
5. COWL CAPSCREWS

Figure 4. Return-to-Center (RTC) Steering, EPS III

1. LOCKWASHER 8. BELLEVILLE WASHER 15. WASHER

2. NUT 9. SPRING - TORSION 16. PROXIMITY SWITCH
3. CAPSCREW 10. ENCODER 17. STANDOFF
4. CAPSCREW 11. BRACKET - ENCODER 18. CAPSCREW
5. SETSCREW 12. GROMMET - RUBBER 19. HANDLE
6. NUT 13. PLATE WELDMENT 20. SCREW
7. BUSHING 14. SHAFT

Figure 5. Return-to-Center (RTC) Steering, APS (Exploded View)

6
1600 YRM 691 Checks and Adjustments

1. Set the key switch in the OFF position.

2. Unplug the connector from the command poten-

tiometer. Refer to Figure 4.

3. Use an ohmmeter to measure the resistance be-

tween wires 19 (black) and 20 (green). Measure
the resistance between wires 20 (green) and 21
(white).

4. Adjust the command potentiometer until the resis-

tance 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 command

potentiometer.

6. Set the key switch to the ON position.

7. Measure the voltage across TP3 and TP2 on the

ECM circuit board by inserting the negative probe
into TP3 and the positive probe in TP2. Refer to
Figure 2. Adjust potentiometer P1 on the ECM cir-
cuit board to a value of 0 VDC (+0.05 VDC).

Feedback Potentiometer Adjustment (Earlier

Models Only)

CAUTION
Make sure the RTC command potentiometer is
properly adjusted before adjusting the feedback
potentiometer.

1. Center the drive tire and steer handle for straight

travel. After the drive tire and handle are centered,
do not adjust the steer handle again until specifi-
cally instructed to do so in this procedure.

2. Refer to Figure 6 and Figure 7 to identify the feed-

back potentiometer. Unplug the connector from the
feedback potentiometer.

3. Measure the resistance between wires 16 and 17.

1. MOTOR
Measure the resistance between wires 17 and 18. 2. MOTOR MOUNTING BRACKET
3. CHAIN
4. Adjust the feedback potentiometer until the re- 4. SPROCKET
sistance values measured in Step 3 are equal 5. POTENTIOMETER MOUNTING BRACKET
(+50 ohms). Adjust the potentiometer by loosening 6. FEEDBACK POTENTIOMETER
the retaining nut and moving the potentiometer
body to attain the desired resistance readings. Figure 6. Motor Mounting Assembly (EPS III)
Tighten the retaining nut without moving the po-
tentiometer body.

7
Checks and Adjustments 1600 YRM 691

Figure 7. Motor Mounting Assembly - APS

8
1600 YRM 691 Checks and Adjustments

Legend for Figure 7

1. STEERING ACTUATOR 9. CAPSCREW 17. FLAT WASHER
2. MOTOR 10. BRACKET - STEER MOTOR 18. STEERING CONTROLLER,
3. COUPLING, 11. SPROCKET WIRE GUIDANCE
MOTOR/GEARBOX 12. FLAT WASHER 19. NUT
4. GEARBOX 13. CAPSCREW 20. CAPSCREW
5. CAPSCREW 14. CHAIN - ROLLER 21. LOCKWASHER
6. OUTPUT SHAFT KEY 15. STEERING CONTROLLER 22. FLAT WASHER
7. CAPSCREW (APS)
8. LOCKWASHER 16. CAPSCREW

Figure 8. Motor Mounting - Gear Steering

9
Checks and Adjustments 1600 YRM 691

Legend for Figure 8

1. MASTER DRIVE 8. STOP BOLT 15. WASHER 22. CAPSCREW
UNIT 9. LOCKWASHER 16. STEERING 23. LOCKWASHER
2. TRACTION MOTOR 10. PROXIMITY SENSOR ACTUATOR 24. WASHER
3. BRAKE 11. PLATE PROXIMITY 17. STEERING MOTOR 25. LOCTITE
4. CAPSCREW TARGET 18. COUPLING 26. WASHER
5. LOCKWASHER 12. LOCKWASHER 19. GEARBOX 27. WASHER
6. CAPSCREW 13. CAPSCREW 20. KEY
7. LOCKWASHER 14. CAPSCREW 21. CAPSCREW

5. Attach the plug removed in Step 2 to the feedback is NOT within the specification, adjust P2 until the
potentiometer. trial is successful.

6. Set the key switch to the ON position.
NOTE: If there are no steering changes within a 10-sec-
ond period, the ECM removes power to the steer mo-
tor. To restore power to the steer motor, step on the foot
switch.
7. Measure the voltage across TP3 and TP1 on the
ECM circuit board by inserting the negative probe
into TP3 and the positive probe into TP1. Refer to
Figure 2. Ensure that the ECM has not removed
power to the steer motor. Adjust potentiometer
P2 on the ECM circuit board to a value of 0 VDC
(+0.05 VDC).
Tach Generator Steering System, EPS III
Tach Generator Adjustment, EPS III
The tach generator is located at the steering mecha-
nism in the instrument panel. Remove the screws at
the top of the instrument panel. Tilt the panel to the
open (down) position for access to the tach generator.
The tach generator does not require adjustment. Check
the drive belt for proper alignment and verify that the belt
is not excessively worn. Replace as required.
Sensitivity Adjustment, EPS III

WARNING WARNING
During the following check, the operator must move Changing the sensitivity setting of the TGS Sys-
the lift truck. Use caution to avoid a personal injury. tem alters the amount of operator effort required to
steer the truck. Notify all affected operators that the
8. Operate the lift truck in a straight line for at least 9 m truck may steer differently before operation. Use
(30 ft) without touching the steer handle. Adjust po- caution to avoid a personal injury.
tentiometer P2 again as necessary to ensure the lift
truck travels in a straight line within 152 mm (6 in.) The sensitivity of the TGS System is adjusted by chang-
in 9 m (30 ft). ing the position of dipswitches 5, 6, and 7. Do not
change any other dipswitches. Refer to Table 2.
9. To verify that the lift truck is traveling in a straight
line, install a pointer at the center of the front (mas- Table 2. Sensitivity Adjustment
ter drive unit end) of the lift truck. Make a mark on
the floor under the point of the pointer. Switches 5, 6, and 7 Maximum Sensitivity
closed
10. Operate the lift truck straight forward 5 m (16 ft).
Switches 6 and 7 closed,
Make a mark on the floor under the point of the
switch 5 open
pointer.
Switches 5 and 7 closed,
11. Operate the lift truck straight forward 5 m (16 ft) switch 6 open
more. Make another mark on the floor under the
point of the pointer. Switch 7 closed, switches (Factory Setting)
5 and 6 open
12. Draw a straight line between the first and last Switches 5 and 6 closed,
marks. The center mark must be within 76 mm switch 7 open
(3 in.) of the line. If the center mark is within this
specification, P2 is correctly adjusted. If the mark Switch 6 closed, switches
5 and 7 open

10
1600 YRM 691
Table 2. Sensitivity Adjustment (Continued)
Switch 5 closed, switches
6 and 7 open
Switches 5, 6, and 7 Minimum Sensitivity
open
Feedback Potentiometer Adjustment, EPS III
1. Center the drive tire for straight travel.
2. Refer to Figure 6 to identify the feedback poten-
tiometer. 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 re-
sistance 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 po-
tentiometer body.
5. Attach the plug removed in Step 2 to the feedback
potentiometer.
6. Set the key switch to the ON position.
7. Measure the voltage across TP3 and TP1 on the
ECM circuit board by inserting the negative probe
into TP3 and the positive probe in TP1. Refer to
Figure 2. Adjust potentiometer P2 on the ECM cir-
cuit board to a value of 0 VDC (+0.05 VDC).
1. 30 m (100 ft) TEST AREA
2. 10 m (33 ft) LINE
Figure 9. Slow Travel Adjustment Speed Test
Checks and Adjustments
WARNING
During the following check, the operator must move
the lift truck. Use caution to avoid injury.
8. Operate the lift truck in a straight line for at least 9 m
(30 ft), making corrections with the steering wheel
as necessary to keep the truck traveling in a straight
line. At the end of the 9 m (30 ft), do not touch the
steering wheel. Adjust potentiometer P2 again as
described in Step 7.
9. Repeat this procedure a minimum of three times to
ensure accurate potentiometer adjustment.
Slow Travel Adjustment, EPS III
The lift truck is designed to be speed-limited above spe-
cific mast heights. Proceed as follows:
1. Make sure the battery has a corrected specific grav-
ity of at least 1.250. Make sure that the lift truck
has been operated at full speed for approximately
10 minutes before checking the speed.
2. Move the lift truck to an area that is smooth and level
for a minimum of 30 m (100 ft). Refer to Figure 9.
Put a line across the floor at 10 m (33 ft) and another
line across the floor at 20 m (66 ft) to divide the
area in three equal sections. The first 10 m (33 ft)
section is used for acceleration, the middle section
for the speed measurement, and the last section for
deceleration.
3. Raise the operator platform slightly over 610 mm
(24 in.).
3. 20 m (66 ft) LINE
4. SPEED MEASUREMENT AREA
11
Checks and Adjustments
WARNING
During the following check, the operator must move
the lift truck. Be sure all personnel are clear of the
testing area. Use caution to avoid injury.
4. Position an assistant to the side at the 10 m (33 ft)
line and another assistant to the side at the 20 m
(66 ft) line. Operate the lift truck at full speed
through the test area to determine the elapsed
time between the 10 m (33 ft) line and the 20 m
(66 ft) line. The lift truck must travel at full speed
through the entire length of the middle 10 m (33 ft)
section to obtain accurate data.
5. If the measured elapsed time is less than 10 sec-
onds, adjust potentiometer P3 on the ECM circuit
board counterclockwise to slow the truck speed to
3.5 +0.3 km/h (2.2 +0.2 mph).
6. If the measured elapsed time is more than 10 sec-
onds, adjust potentiometer P3 on the ECM circuit
board clockwise to increase the truck speed to 3.5
+0.3 km/h (2.2 +0.2 mph).
Return-to-Center and Multiturn System,
APS
Encoder Replacement, APS
1. Disconnect the battery connector.
2. Remove the screw that fastens the steering handle
to the shaft of the steering mechanism. Remove
the steering handle (RTC only).
3. Remove the screws at the top of the instrument
panel cover to gain access to the instrument panel.
4. Remove the capscrews that fasten the steering
mechanism bracket to the back of the instrument
panel.
5. Remove the setscrew that fastens the shaft of the
encoder to the steering shaft. Remove the cap-
screw and nut that fasten the bracket for the en-
coder. Remove the bracket and encoder. Remove
12
1600 YRM 691
the encoder from the bracket. Label the encoder
connector for correct connections during installa-
tion.
6. Install the new encoder, as required. Connect the
connector of the encoder.
7. Install the steering mechanism bracket to the back
of the instrument panel.
8. Connect all wires disconnected during removal.
9. Tighten the two setscrews that fasten the encoder
to the steering shaft. One of the setscrews should
be aligned with the flat area on the encoder shaft.
10. Close the instrument panel and tighten the screws.
Install the steering handle on the shaft of the steer-
ing mechanism and tighten the screw.
11. Connect the battery connector.
Steering Chain Adjustment, EPS III
1. Disconnect the battery connector. Open the motor
compartment doors.
2. Position a straight edge (e.g., a thin piece of rigid
material) against the steering chain between the
sprockets. Make sure the chain is tight on the op-
posite side of the sprockets.
3. Push on the chain at a point approximately halfway
between the sprockets with a force of 9 to 12 kg
(20 to 26 lb). Measure the clearance between the
straight edge and the chain. The clearance should
not exceed 3.3 mm (0.13 in.). Refer to Figure 10.
4. Tighten the adjustment nut at the master drive unit
sprocket to obtain a maximum clearance of 3.3 mm
(0.13 in.) between the chain and straight edge. Do
NOT tighten the chain to a clearance of less than
1.3 mm (0.05 in.).
5. Close and fasten the motor compartment doors.
1600 YRM 691 Repairs

1. MOTOR SPROCKET 4. STRAIGHT EDGE

2. MDU 5. ADJUSTING BOLT
3. STEERING CHAIN 6. ADJUSTING NUT

Figure 10. Steer Chain Adjustment

Repairs
RTC STEERING SYSTEM, EPS III
Command Potentiometer Replacement,
EPS III
WARNING
The MDU will automatically center when key is ON.
Keep hands, arms, and other appendages and tools
clear.
1. Disconnect the battery connector.
2. Remove the screw that fastens the steering handle
to the shaft of the steering mechanism. Remove
the steering handle.
3. Remove the screws at the top of the instrument
panel. Tilt the instrument panel to the open posi-
tion for access.
4. Remove the capscrews that fasten the steering
mechanism bracket to the back of the instrument
panel.
5. Remove the setscrew that fastens the shaft of
the command potentiometer to the steering shaft.
Remove the capscrew and nut that fasten the
bracket for the command potentiometer. Remove
the bracket and potentiometer. Remove the poten-
tiometer from the bracket. Label the potentiometer
wires for correct connections during installation.
6. Install the new command potentiometer as re-
quired. Connect the wires of the command
potentiometer.
7. Install the steering mechanism bracket to the back
of the instrument panel.
8. Connect all wires disconnected during removal.

13
Repairs
9. If the command potentiometer was replaced, or the
setting was changed, adjust the command poten-
tiometer. Refer to Adjustments. Tighten the screw
that fastens the potentiometer to the steering shaft.
10. Close the instrument panel and tighten the screws.
Install the steering handle on the shaft of the steer-
ing mechanism. Tighten the screw.
TGS SYSTEM, EPS III
Tach Generator Replacement, EPS III
1. Disconnect the battery connector.
2. Remove the screw that fastens the steering wheel
to the shaft of the steering mechanism. Remove
the steering wheel.
3. Remove the screws at the top of the instrument
panel. Tilt the instrument panel to the open posi-
tion for access.
4. Disconnect the wire harness to the tach generator.
5. Remove the capscrews, washers, and nuts retain-
ing the tach generator to the steering wheel bracket.
6. Remove the tach generator drive belt.
7. Install the tach generator mounting bracket to the
new tach generator.
8. Insert the tach generator in place and install the
tach generator drive belt.
9. Install the capscrews, washers, and nuts that retain
the tach generator mounting bracket to the steering
wheel bracket.
10. Connect the wire harness to the tach generator.
11. Install the instrument panel and connect the battery
connector.
FEEDBACK POTENTIOMETER
REPLACEMENT, EPS III
1. Position the master drive unit for straight travel. Dis-
connect 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.
14
1600 YRM 691
4. Set the new feedback potentiometer for midrange.
Install the new potentiometer on the bracket. Install
the nut to fasten the potentiometer. Do not tighten
the nut or setscrew.
5. Adjust the feedback potentiometer. Refer to Adjust-
ments. Tighten the nut and setscrew without mov-
ing the potentiometer body or shaft to avoid chang-
ing the setting. Connect the plug.
6. Close the motor compartment doors and connect
the battery.
ECM REPLACEMENT, EPS III
1. Disconnect the battery connector.
2. Open the motor compartment door.
3. Disconnect the wire harness plugs to the ECM.
4. Prevent the ECM from falling while removing the
mounting capscrews, washers, and nuts.
5. Use caution when handling the ECM to avoid
spreading the heat-transfer grease from the under-
side of the module to surrounding areas.
6. Install heat-transfer grease on the underside of
the replacement module and the frame. Install
the module on the frame panel using the four
capscrews, washers, and nuts.
7. Connect the wire harness plugs.
8. Refer to Adjustments to adjust the potentiometers
on the circuit board for proper operation.
9. Check the position of the dipswitches to be sure the
switches are set correctly. Refer to Dipswitches,
EPS III.
STEER MOTOR ASSEMBLY AND
STEERING CHAIN REPLACEMENT, EPS III
1. Disconnect the battery and open the motor com-
partment doors.
2. Disconnect the wire harness plug to the feedback
potentiometer. Remove the nuts that fasten the
feedback potentiometer bracket to the frame.
3. Hold the motor assembly and remove the cap-
screws, nuts, and washers that fasten the motor
assembly to the frame panel.
1600 YRM 691
4. Carefully tip the top of the assembly away from the
panel to remove the motor and feedback poten-
tiometer bracket out of the truck. Do NOT bend
the bracket. Remove the steering chain from the
sprocket and remove the motor assembly.
NOTE: See the section DC Motor 620 YRM 145 or DC
Motor Maintenance 620 YRM 294 to repair the motor.
5. Remove the steering chain from the master drive
unit sprocket as required by pulling the chain an-
chor pins out of the holes in the sprocket. Clean
and lubricate the chain using multipurpose grease.
Typical Operating Voltages, EPS III
Table 3 lists typical operating voltages for a correctly ad-
justed steering system. Measured voltages should be
within 10 percent of the values listed in the table. Volt-
ages are measured between the designated test point
and TP3 (ground). Refer to Figure 11.
Table 3. Typical Operating Voltages
Test Between TP3 To Check ECM Input
and: From:
K3-7 24" Proximity Switch
K3-6 150" Proximity Switch
K3-9 Command Potentiometer
K1-3 Feedback Potentiometer
K1-1 Key Switch
Figure 11. Test Point and Connector Reference
Typical Operating Voltages, EPS III
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 first hole before the axle cen-
terline.
7. Install the new motor, sprocket, and feedback po-
tentiometer assembly. Tighten the capscrews and
nuts to 31 N•m (23 lbf ft).
8. Adjust the feedback potentiometer. Refer to Adjust-
ments.
NOTE: Steering full left or right refers to the operator’s
perspective standing on the truck facing the steer wheel
(with forks trailing).
Measured Voltage (±10%)
Mast below 24", should be battery voltage.
Mast above 24", should be approximately 0 volts.
Mast below 150", should be battery voltage.
Mast above 150", should be approximately 0 volts.
Steering full left, should be +1.7 volts.
Steering full right, should be +6.3 volts.
Steering centered, should be +4.1 volts.
Steering full left, should be +2.1 volts.
Steering full right, should be +6.1 volts.
Steering centered, should be +4.3 volts.
Should be battery voltage.
15
Troubleshooting
Steering Proximity Switch and Centering Proximity Switch, APS
CAUTION
The electrical system on this truck utilizes many
control-level circuits (low voltage and current),
which may be disturbed by contamination, wear,
or damage at the electrical connections. When
investigating problems or fault codes, it may be
beneficial to check and clean/repair all connections
in the affected circuit first. The use of dielectric
grease is recommended for all AMP™ and Molex™
electrical connectors when operating in adverse
environments (freezers or dirty areas).
CAUTION
The fault detection software and circuits of the trac-
tion controller (Curtis 1243) are sensitive to dras-
tic changes in currents and voltages. Traction con-
troller fault codes may not necessarily indicate a de-
fective controller. Fault codes may be generated in
response to extreme operating conditions, such as
potholes or very low battery levels.
These switches send an electronic signal to their
respective units. If voltages between the designated
points are bad, you must check for wires that are bro-
ken, cracked, or bare. If the wires are good, then you
must replace the switches. There are no adjustments
to the switches.
Troubleshooting
EPS III
PROBLEM POSSIBLE CAUSE
Truck will not move or steer. Battery disconnected.
Shutoff has occurred.
Dipswitch 8 in wrong position.
One or both 15-amp fuses that supply
current to the steering controller.
16
1600 YRM 691
ADVANCED POWER STEERING SYSTEM
REPLACEMENT
NOTE: If the MCU or APS is replaced, the Steering Off-
set Adjustment procedure in Setup of Electrical Sys-
tem 2200 SRM 933 or 2200 SRM 956 MUST be per-
formed before the lift truck can be operated.
1. Disconnect the battery and open the motor com-
partment door.
2. Wait 2 minutes for internal filter to self-discharge.
3. Disconnect the wire harness connectors to the
APS.
4. Prevent the APS from falling while removing the
mounting capscrews, washers, and nuts.
5. Install the replacement module on the frame panel
using the four capscrews, washers, and nuts.
6. Connect the wire harness connectors.
7. Connect the battery and close the motor compart-
ment doors.
PROCEDURE OR ACTION
Connect battery.
Set key to OFF position, wait 2 sec-
onds, then set key to START, then to
ON position.
Dipswitch 8 should be open for tach
generator steering or closed for RTC
steering.
Replace fuse(s).
1600 YRM 691 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

No action when steering Command potentiometer defective. Replace command potentiometer.

wheel is turned.

No output from ECM to steer motor. Replace ECM.

Power leads defective between ECM Check and repair all power leads or
and steer motor. connections.

Feedback potentiometer defective. Replace feedback potentiometer.

No input to tach generator. When tach generator is spun, check for

voltage between K-14 and TP-3, and
K1-6 and TP-3. If voltage is present,
replace ECM.

MDU out of normal operating range. Raise truck and manually turn MDU
within range.

Steer motor defective. Repair or replace steer motor.

Steering is loose. Steering chain loose. Adjust chain for proper tension.

Truck turns in direction oppo- Gear motor leads reversed. Connect gear motor leads correctly.
site to direction steered.

Command potentiometer leads re- Connect leads correctly.

versed.

Feedback potentiometer leads re- Connect leads correctly.

versed.

APS

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Truck will not move or steer. Battery disconnected. Connect battery.

Shutoff has occurred. Set key to OFF position, wait 2 sec-

onds, then set key to START, then to
ON position.

17
Troubleshooting 1600 YRM 691

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

No action when steering Open circuit in wiring between encoder Check and repair wiring.
wheel/handle is turned. and APS.

Encoder defective. Replace encoder.

No encoder input. Test for voltage change at encoder. If

no voltage change, replace encoder.
If voltage changes, check wiring.
If wiring is good, replace encoder.

No output from APS to steer motor. Replace APS.

Power leads defective between APS Check all power connections.

and steer motor.

Steering proximity switch defective. Replace proximity switch.

Steering proximity switch gap too large Adjust gap to 5 mm (0.2 in.).
(Self-Centering Steering only).

MDU out of normal operating range. Raise truck and manually turn MDU
within range.

Centering proximity switch defective Replace proximity switch.

(Self-Centering Steering only).

Built-in encoder defective. Replace encoder.

Steer motor defective. Replace steer motor.

Steering is loose (Chain Steer Steering chain loose. Adjust chain for proper tension.
trucks only).

Truck turns in direction oppo- Steer motor leads reversed. Connect steer motor leads correctly.
site to direction steered.

Encoder channel reversed in wiring. Correct encoder channel wiring.

18
 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

1600 YRM 691 7/02 Printed in U.S.A.