Crown Forklift TSP 6000 Series Maintenance Manual – PDF DOWNLOAD

Description

Crown Forklift TSP 6000 Series Maintenance Manual – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift TSP 6000 Series Maintenance Manual – PDF DOWNLOAD

Language : English
Pages :586
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift TSP 6000 Series Maintenance Manual – PDF DOWNLOAD

TSP 6000 SERIES 1
Table of Contents 3
Introduction page serial no cut Rev 5
Introduction 3 5
Operator Instructions 3 5
Operator Training 3 5
Service Training 3 5
Replacement Parts 3 5
Safety page serial no cut Rev 5
General Maintenance Instructions 7 5
Cleaning of Material Handling Equipment 9 5
Cleaning Methods 9 5
Control of Hazardous Energy 10 5
Lockout/Tagout 10 5
Battery 10 5
Capacitance 12 5
Brake 13 5
Hydraulic 14 5
Towing Truck 15 5
Lifting and Blocking 18 5
Main Mast, Auxiliary Mast and Platform 19 5
Height Sensor 22 5
Auxiliary Mast and Platform Lifting 24 5
Planned Maintenance – Lubricants 25 5
Lubrication & Adjustment page serial no cut Rev 5
Lubrication and Adjustment 31 5
General 31 5
Component Accessibility 31 5
Componentry 42 5
Introduction 42 5
Audible Indicators 43 6
ALM1 43 6
ALM2 43 6
HN 43 6
Battery 44 6
BATT 44 6
Contactors 45 6
ED1, ED2 45 6
K2 45 6
Encoders 47 6
ECR1 47 6
ECR2 47 6
ECR3 47 6
ECR4 47 6
ECR5 49 6
ECR6 49 6
ECR7 49 6
ECR8 49 6
Fuses 51 6
FU1 51 6
FU2 51 6
FU3 51 6
FU4 51 6
FU5 51 6
FU6 52 6
FU7 52 6
FU8 52 6
FU9 53 6
FU10 53 6
FU11 54 6
FU12 54 6
FU13 54 6
FU14 54 6
FU15 54 6
FU16 54 6
FU17 56 6
FU18 56 6
FU19 56 6
FU20 56 6
FU21 56 6
Lights 58 6
LGT1 58 6
LGT2 58 6
LGT3 58 6
LGT4 58 6
LGT5 58 6
LGT 6 60 6
LGT 7 60 6
LGT8 60 6
LGT9 60 6
Miscellaneous 62 7
BRK 62 7
EAC Distribution Panel 62 7
FAN1 62 7
FAN3 62 7
FSB1 62 7
FSB2 62 7
JC 64 7
P1 64 7
PS1 64 7
PS2 64 7
HYDRAULIC RESERVOIR 64 7
Modules 66 7
ACCESS 1 66 7
ACCESS 2 66 7
ACCESS 3 66 7
ACCESS 4 66 7
ACCESS 5 68 7
ACCESS 6 68 7
ACCESS 8 68 7
Motors 70 7
M1 70 7
M2 70 7
M3 70 7
Potentiometers 72 7
POT1 72 7
POT2 72 7
POT3 72 7
POT4 72 7
POT5 72 7
Relays 74 7
K1 74 7
Resistors 74 7
RES1 74 7
RES2 74 7
RES3 74 7
RES4 74 7
RES5 74 7
Sensors 76 7
CS1 76 7
EACA1 76 7
EACA2 76 7
EACB1 76 7
EACB2 76 7
GS1 78 7
GS2 78 7
LS 78 7
PDS 78 7
TS1 78 7
TS2 78 7
Solenoid Valves 80 8
EML 80 8
MVL 80 8
PCML 80 8
PVAL 80 8
PVAR 80 8
PVF1 82 8
PVF2 82 8
PVLH 82 8
PVML 84 8
PVMR 84 8
PVP1 84 8
PVP2 84 8
PVT1 84 8
PVT2 84 8
SP1 86 8
SVAL 86 8
SVML 86 8
Suppressor Blocks 88 8
SB11 88 8
SB31 88 8
SB41 88 8
Switches 90 8
APS 90 8
BRES 90 8
BRS1 90 8
BRS2 90 8
BRS3 90 8
BRS4 90 8
CHS1 92 8
CHS2 92 8
CHS3 92 8
CHS4 92 8
CHS5 92 8
CHS6 92 8
CHS7 94 8
CHS8 94 8
CTS (TF Mast Only) 94 8
DTS 94 8
EDS 94 8
EMS1 94 8
EMS2 96 8
FHSL 96 8
FHSR 96 8
FNS 96 8
FPS1 96 8
FPS2 96 8
FPS3 98 8
FPS4 98 8
FPS5 98 8
FPS6 98 8
FPS7 98 8
FPS8 98 8
FPS9 100 8
FS 100 9
GTSL 100 9
GTSR 100 9
GUS 100 9
HCS 100 9
HGTRS1 102 9
HGTRS2 102 9
HNS 102 9
HPSL 102 9
HPSR 102 9
KYS 102 9
LGS1 104 9
LGS2 104 9
LGS3 104 9
ORS1 104 9
PLS 104 9
PRS 104 9
RGSL 106 9
RGSR 106 9
RS 106 9
RSS 106 9
SES 106 9
SLS 106 9
SPS 108 9
TBS 108 9
TDS 108 9
TVRS 108 9
ZSS 108 9
Metric Torque Values 110 9
Grade 110 9
Torque Values 113 9
Grade 113 9
Hydraulic System page serial no cut Rev 9
General Information 117 9
Hydraulic Lines and Fittings 117 9
Reservoir 117 9
Filter 118 9
Drift Test 118 9
Lift Drift Test 118 9
Freezer Preparation 119 9
Hydraulic Circuits 120 9
Main Lift Circuit 120 9
Main Lower Circuit 121 9
Main Lower Circuit (MVL) 122 9
Load Handler Circuit through Main Frame Manifold 123 9
Auxiliary Lift Circuit 124 9
Auxiliary Lower Circuit 125 9
Traverse Left Circuit 126 9
Traverse Right Circuit 128 9
Fork Extend Circuit 130 9
Fork Retract Circuit 132 9
Pivot Right Circuit 134 9
Pivot Left Circuit 136 9
Hydraulic Schematic Symbols 138 10
Hydraulic Pump 142 10
Pump Replacement 142 10
Initial Start Up Procedure 143 10
Manifold 144 10
Relief Valve (RV1) 144 10
Proportional Valves 144 10
Manifold Block O-Ring Replacement 145 10
Hydraulic Motor 147 10
Preparation Before Disassembly 147 10
Tools and Materials Required for Servicing 147 10
Disassembly and Inspection 149 10
Reassembly 156 10
Final Checks 163 10
Drive Unit page serial no cut Rev 10
Drive Unit 167 10
Drive Tire Replacement 167 10
Lathe Cutting 168 10
Drive Unit Lubrication 169 10
Drive Unit Removal 169 10
Drive Unit Installation 170 10
Drive Motor Removal 170 10
Drive Motor Installation 170 10
Electrical System page serial no cut Rev 10
ACCESS 123® 173 10
When a Malfunction Occurs 173 10
Power Cable Connections 173 10
Software Package Version Level 173 10
Main Menu 176 10
Analyzer Menus 177 10
Input Menus 178 10
Platform Menu 180 10
Seat Controls Menu 181 10
Power Unit Menu 182 10
Outputs Menu 185 10
Load Handler Menu 186 10
Platform Menu or Seat Controls Menu 189 10
Power Unit Menu 190 10
Test Outputs Menu 194 10
Load Handler Menu 195 10
Platform Menu or Seat Controls Menu 196 10
Power Unit Menu 197 10
Calibration Menu 200 10
Handles Menu 201 10
Hydraulics Menu 202 10
Pivot Sense Menu 203 10
Main R Valve Menu 204 10
Main L Valve 205 10
Main HGT Sense Menu 206 10
Aux Flow Valve Menu 207 10
Traverse Valve Menu or Pivot Valve Menu 208 10
Extend Valve 209 11
Aux R Valve Menu 210 11
Weight Sense Menu 211 11
Aux Valve Menu 212 11
Aux HGT Sense Menu 213 11
Tilt Valve Menu 214 11
Height Cutouts Menu 215 11
Steer Encoder Menu 216 11
Wire Guide Menu 217 11
Calibrate Menu 218 11
Adjust X-Offset Menu 221 11
Features Menu 222 11
Mast Type, Measurement, Collapsed Height , Lift Height or Traverse Frame Menu 223 11
Fork Type Menu 224 11
Fork Length, Pallet Width, Pallet Length or Battery Compartment Menu 226 11
Truck Weight, Max Load or Lift Motor Menu 227 11
Capacity Data Monitor Menu 228 11
Wire Guidance or Manual Wire Sense Menu 229 11
End Aisle, Battery Retainer SW or Travel Alarm Menu 230 11
Language or User Performance Menu 231 11
User Codes or Cold Condition Menu 232 11
Options Menu 233 11
Front Rail, Zone Switch, Aux Mast, Screen Setup or Save Menu 235 11
Hour Meters Menu 236 11
Event Codes Menu 237 11
Performance Menu 238 11
P1 Setup P1 Menu 239 11
P2 Setup P2 Menu 241 11
P3 Setup P3 Menu 243 11
Plug, Coast, Braking or Free Range Speeds Menu 245 11
Guided Speeds Menu 246 11
EAC Setup Menu 247 11
Main Hoist R or L Menu 249 11
Aux Hoist R or L Menu 250 11
PDS Setup Menu 250 11
Utilities Menu 252 11
Active Tow Mode, Shipping Mode, Truck lockout or Traverse Valve Menu 253 11
Wire Guidance 254 11
Operation Modes 255 11
Sensors 256 11
Line Driver Output 256 11
Calibration 257 11
Troubleshooting 258 11
End Aisle Control (EAC) 259 11
Wire Guidance Calibration Speeds 260 11
Troubleshooting 260 11
Termination Point Locations 261 11
Contactor 262 12
Inspection 262 12
Component Replacement 263 12
Battery 264 12
Safety Rules 264 12
Battery Care 264 12
Charging 265 12
Battery Removal 265 12
Battery Installation 265 12
Checking 265 12
Charging 266 12
Cleaning 267 12
Troubleshooting 268 12
Motor 269 12
Event Codes 270 12
ACCESS Module Listing: 270 12
Event Codes – ACCESS 1 272 12
Event Code 101 272 12
Event Code 104 273 12
Event Code 105 273 12
Event Code 106 274 12
Event Code 107 275 12
Event Code 108 276 12
Event Code 112 277 12
Event Code 113 277 12
Event Code 114 277 12
Event Code 115 277 12
Event Code 116 277 12
Event Code 117 277 12
Event Code 118 277 12
Event Codes – ACCESS 2 278 12
Event Code 212 278 12
Event Code 213 278 12
Event Code 214 278 12
Event Code 215 278 12
Event Code 216 278 12
Event Code 217 279 12
Event Code 218 279 12
Event Code 221 279 12
Event Code 222 279 12
Event Code 223 280 12
Event Code 224 280 12
Event Code 225 280 12
Event Code 228 281 12
Event Code 229 281 13
Event Code 231 282 13
Event Code 232 283 13
Event Code 233 283 13
Event Code 234 285 13
Event Code 235 286 13
Event Code 236 287 13
Event Code 237 287 13
Event Code 246 288 13
Event Code 247 288 13
Event Code 249 288 13
Event Code 251 288 13
Event Code 255 288 13
Event Code 256 288 13
Event Code 268 289 13
Event Code 269 289 13
Event Code 272 289 13
Event Code 273 290 13
Event Code 278 290 13
Event Codes – ACCESS 3 291 13
Event Code 300 291 13
Event Code 312 291 13
Event Code 313 291 13
Event Code 315 291 13
Event Code 317 and 318 291 13
Event Code 321 293 13
Event Code 322 293 13
Event Code 323 and 324 293 13
Event Code 325 294 13
Event Code 326 295 13
Event Code 327 295 13
Event Code 328 296 13
Event Code 329 296 13
Event Code 331 296 13
Event Code 332 297 13
Event Code 333 297 13
Event Code 334 298 13
Event Code 336 298 13
Event Code 337 299 13
Event Code 346 299 13
Event Code 347 299 13
Event Code 349 299 13
Event Code 351 299 13
Event Code 368 300 13
Event Code 369 300 13
Event Code 372 300 13
Event Code 373 301 13
Event Code 378 301 13
Event Codes – ACCESS 4 302 13
Event Code 400 302 13
Event Code 402 303 13
Event Code 403 304 13
Event Code 407 305 13
Event Code 408 and 409 306 13
Event Code 411 and 430 307 14
Event Code 436 307 14
Event Code 437 307 14
Event Code 438 308 14
Event Code 439 308 14
Event Code 440 308 14
Event Code 441 309 14
Event Code 442 310 14
Event Code 443 310 14
Event Code 444 310 14
Event Code 445 311 14
Event Code 446 311 14
Event Code 447 312 14
Event Code 491 Through Event Code 499 313 14
Event Codes – ACCESS 5 314 14
Event Code 501 314 14
Event Code 502 315 14
Event Code 503 315 14
Event Code 504 316 14
Event Code 505 316 14
Event Code 507 317 14
Event Code 508 317 14
Event Code 509 and 510 318 14
Event Code 511 Through Event Code 521 318 14
Event Code 522 and 523 319 14
Event Code 524 and 525 320 14
Event Code 526 and 527 320 14
Event Code 528 and 529 320 14
Event Code 530 and 531 321 14
Event Code 532 and 533 322 14
Event Code 534 and 535 322 14
Event Code 536 323 14
Event Code 537 323 14
Event Code 538 and 539 323 14
Event Code 540 324 14
Event Code 541 324 14
Event Code 542 325 14
Event Code 543 326 14
Event Code 544 326 14
Event Code 545 326 14
Event Code 546 Through Event Code 550 326 14
Event Code 551 327 14
Event Code 552 and 553 327 14
Event Code 554 327 14
Event Code 555 and 556 327 14
Event Code 557 328 14
Event Code 558 Through Event Code 561 329 14
Event Code 562 330 14
Event Code 563 330 14
Event Code 564 330 14
Event Code 565 330 14
Event Code 566 331 14
Event Code 567 Through Event Code 570 332 14
Event Code 571 and 572 332 14
Event Code 576 Through Event Code 581 333 15
Event Code 582 Through Event Code 585 333 15
Event Code 586 and 587 334 15
Event Code 588 and 589 335 15
Event Code 590 and 591 336 15
Event Code 592 and 593 336 15
Event Code 594 336 15
Event Code 595 337 15
Event Code 596 337 15
Event Code 597 337 15
Event Codes – ACCESS 6 339 15
Event Code 605 339 15
Event Code 611, 612 and 621 Through Event Code 628 339 15
Event Code 631 339 15
Event Code 632 339 15
Event Code 633 340 15
Event Code 636 341 15
Event Code 637 341 15
Event Code 638 and 639 341 15
Event Code 652 Through Event Code 659 342 15
Event Code 660 Through Event Code 663 343 15
Event Code 664 Through Event Code 667 343 15
Event Code 668 Through Event Code 671 343 15
Event Code 672 344 15
Event Codes – ACCESS 7 345 15
Event Code 700 345 15
Event Code 701 346 15
Event Code 702 347 15
Event Code 707 348 15
Event Code 708 and 709 349 15
Event Code 711 Through Event Code 720 350 15
Event Code 736 350 15
Event Code 737 351 15
Event Code 738 351 15
Event Code 739 352 15
Event Code 740 352 15
Event Code 741 353 15
Event Code 742 353 15
Event Code 743 354 15
Event Code 744 354 15
Event Code 745 355 15
Event Code 746 355 15
Event Code 747 Through Event Code 749 356 15
Event Code 750 356 15
Event Code 751 357 15
Event Code 752 358 15
Event Code 753 359 15
Event Code 754 360 15
Event Code 755 361 15
Event Code 756 362 15
Event Code 757 363 15
Event Code 758 363 15
Event Code 759 363 15
Event Code 760 364 15
Event Code 761 365 16
Event Code 762 366 16
Event Code 763 366 16
Event Code 764 367 16
Event Code 765 367 16
Event Code 767 368 16
Event Code 768 368 16
Event Code 769 369 16
Event Code 770 369 16
Event Code 771 370 16
Event Code 772 370 16
Event Code 773 370 16
Event Code 774 371 16
Event Code 775 371 16
Event Code 776 372 16
Event Code 777 372 16
Event Code 778 373 16
Event Code 779 373 16
Event Code 780 374 16
Event Code 781 375 16
Event Code 782 376 16
Event Code 783 376 16
Event Code 784 377 16
Event Code 785 377 16
Event Code 790 Through Event Code 799 378 16
Event Codes – ACCESS 8 379 16
Event Code 800 379 16
Event Code 801 379 16
Event Code 802 380 16
Event Code 803 381 16
Event Code 804 382 16
Event Code 805 383 16
Event Code 806 384 16
Event Code 807 385 16
Event Code 816 386 16
Event Code 821 386 16
Event Code 822 386 16
Event Code 823 387 16
Event Code 824 387 16
Event Code 825 388 16
Event Code 836 388 16
Event Code 837 389 16
Event Code 838 389 16
Event Code 839 390 16
Event Code 840 391 16
Event Code 841 392 16
Event Code 842 392 16
Event Code 843 393 16
Event Code 844 393 16
Event Code 845 393 16
Event Code 846 394 16
Event Code 847 394 16
Event Code 848 396 16
Event Code 849 397 16
Event Code 850 Through Event Code 852 399 17
Event Code 853 Through Event Code 855 399 17
Event Code 856 Through Event Code 859 400 17
Event Code 860 Through Event Code 863 400 17
Event Code 864 Through Event Code 867 401 17
Event Code 868 and 869 401 17
Event Code 870 and 871 402 17
Event Code 872 Through Event Code 874 403 17
Event Code 875 Through Event Code 877 404 17
Event Code 878 Through Event Code 880 406 17
Brake System page serial no cut Rev 17
Brake 409 17
Brake Force Adjustment 409 17
Torque Gap Adjustment 409 17
Air Gap Adjustment 411 17
Rotor and Brake Pad Replacement 412 17
Brake Assembly 412 17
Steering page serial no cut Rev 17
Steering Feedback 417 17
Replacing Steering Feedback Assembly Encoder 417 17
Replacing Steering Feedback Assembly Gears 418 17
Steering Motor 420 17
Steering Motor Brushes 420 17
Replacing Steering Motor 420 17
Steering Gearbox 422 17
Replacing Steering Gearbox 422 17
Lifting Mechanism page serial no cut Rev 17
Mast 427 17
TN (Telescopic No Free Lift) Mast 427 17
TF (Telescopic Full Free Lift) Mast 427 17
TT (Triple Telescopic Full Free Lift) Mast 427 17
New Truck Assembly Procedures 427 17
To Assemble Power Unit, Mainframe and Platform and Load Handler: 428 17
Second Stage Mast Removal TF and TN 431 17
Removing Second Stage Mast TF and TN 431 17
Removing Second Stage Mast TF and TN 435 17
Removing Second and Third Stages from TT Mast Assembly 435 17
Roller Adjustment 443 17
Installing Second Stage Mast TF and TN 443 17
Installing Second Stage Mast TF and TN 445 17
Installing Second and Third Stage TT Mast 446 17
Hose Take-Up Cable 451 17
Load Wheels 453 18
Load Wheel Removal 453 18
Tire Replacement 453 18
Lathe Cutting 453 18
Lift Chains 455 18
Inspection 455 18
Lift Chain Lubrication 457 18
Lift Chain Replacement 458 18
Fork Inspection 460 18
Cylinders page serial no cut Rev 18
TF Lift Cylinders 467 18
Pivoting The Tip-Out Assembly 467 18
Primary (Free) Lift Cylinder Repair 470 18
Cylinder Packing Installation 472 18
Reassembling Mast Tip-Out 473 18
Primary (Free) Lift Cylinder Removal 474 18
Secondary (Main) Lift Cylinder Removal 475 18
Primary (Free) Lift Cylinder Installation 476 18
Secondary (Main) Lift Cylinder Installation 476 18
Lift Cylinder Bleeding 477 18
TN Lift Cylinder 478 18
Pivoting the Tip-Out Assembly 478 18
Lift Cylinder Repair 480 18
Cylinder Packing Installation 482 18
Reassembling Mast Tip-Out 482 18
Lift Cylinder Removal 483 18
Lift Cylinder Installation 484 18
Lift Cylinder Bleeding 485 18
Auxiliary Lift Cylinder 486 18
Auxiliary Lift Cylinder Repair 486 18
Rod Packing Installation 489 18
Auxiliary Lift Cylinder Bleeding 489 18
Fork Cylinders 490 18
Cylinder Disassembly 491 18
Piston Rod Disassembly 492 18
Cylinder Reassembly 492 18
Pivot Cylinders 494 19
Cylinder Removal 494 19
Cylinder Disassembly 495 19
Cylinder Reassembly 496 19
Cylinder Installation 498 19
Pivot Cylinder Bleeding 498 19
Platform page serial no cut Rev 19
Platform 501 19
Inspection and Adjustment 501 19
Lubrication 502 19
Mast Shield 503 19
Gates 504 19
GTSL & GTSR 505 19
Chain Anchor and Platform Height Adjustment 505 19
Side Thrust Roller Adjustment – Platform (TF, TN and TT Mast) 506 19
Traverse Hose Replacement 506 19
Platform Removal 508 19
Platform Assembly 511 19
Height Sensing System 519 19
Height Sensor Assembly Removal 519 19
Height Sensor Assembly Installation 520 19
Height Cable Broken Switch (HCS) 520 19
Height Sensor Assembly 521 19
Cable Replacement 521 19
Glossary page serial no cut Rev 19
Glossary 525 19
Schematic Diagrams page serial no cut Rev 19
Introduction to Diagram Usage 533 19
Schematic 533 19
Pictorials 533 19
Hydraulic Schematic page serial no cut Rev 20
Introduction 21
Introduction 23
Operator Instructions 23
Operator Training 23
Service Training 23
Replacement Parts 23
Safety 25
General Maintenance Instructions 27
Cleaning of Material Handling Equipment 29
Cleaning Methods 29
Control of Hazardous Energy 30
Lockout/Tagout 30
Battery 30
Safety Rules 30
Battery Care 30
Charging 30
Battery Removal 31
Battery Installation 31
Lockout – Tagout 31
Capacitance 32
Brake 33
Hydraulic 34
Towing Truck 35
Towing by Pulling in Power Unit First Direction 35
Towing by Pushing in Forks First Direction 36
Lifting and Blocking 38
Main Mast, Auxiliary Mast and Platform 39
Main Mast – TF & TN 39
Main Mast – TT 39
Blocking Third Stage Mast Above Second Stage Mast 39
Auxiliary Mast 40
Platform – TT 40
Height Sensor 42
Tool Fabrication 42
Spring Removal 42
Spring Installation 43
Auxiliary Mast and Platform Lifting 44
Auxiliary Mast 44
Platform 44
Planned Maintenance – Lubricants 45
Lubrication & Adjustment 49
Lubrication and Adjustment 51
General 51
Component Accessibility 51
Componentry 62
Introduction 62
Audible Indicators 63
ALM1 63
ALM2 63
HN 63
Battery 64
BATT 64
Contactors 65
ED1, ED2 65
K2 65
Encoders 67
ECR1 67
ECR2 67
ECR3 67
ECR4 67
ECR5 69
ECR6 69
ECR7 69
ECR8 69
Fuses 71
FU1 71
FU2 71
FU3 71
FU4 71
FU5 71
FU6 72
FU7 72
FU8 72
FU9 73
FU10 73
FU11 74
FU12 74
FU13 74
FU14 74
FU15 74
FU16 74
FU17 76
FU18 76
FU19 76
FU20 76
FU21 76
Lights 78
LGT1 78
LGT2 78
LGT3 78
LGT4 78
LGT5 78
LGT 6 80
LGT 7 80
LGT8 80
LGT9 80
Miscellaneous 82
BRK 82
EAC Distribution Panel 82
FAN1 82
FAN3 82
FSB1 82
FSB2 82
JC 84
P1 84
PS1 84
PS2 84
HYDRAULIC RESERVOIR 84
Modules 86
ACCESS 1 86
ACCESS 2 86
ACCESS 3 86
ACCESS 4 86
ACCESS 5 88
ACCESS 6 88
ACCESS 7 88
ACCESS 8 88
Motors 90
M1 90
M2 90
M3 90
Potentiometers 92
POT1 92
POT2 92
POT3 92
POT4 92
POT5 92
Relays 94
K1 94
Resistors 94
RES1 94
RES2 94
RES3 94
RES4 94
RES5 94
Sensors 96
CS1 96
EACA1 96
EACA2 96
EACB1 96
EACB2 96
GS1 98
GS2 98
LS 98
PDS 98
TS1 98
TS2 98
Solenoid Valves100
EML100
MVL100
PCML100
PVAL100
PVAR100
PVF1102
PVF2102
PVLH102
PVML104
PVMR104
PVP1104
PVP2104
PVT1104
PVT2104
SP1106
SVAL106
SVML106
Suppressor Blocks108
SB11108
SB31108
SB41108
Switches110
APS110
BRES110
BRS1110
BRS2110
BRS3110
BRS4110
CHS1112
CHS2112
CHS3112
CHS4112
CHS5112
CHS6112
CHS7114
CHS8114
CTS (TF Mast Only)114
DTS114
EDS114
EMS1114
EMS2116
FHSL116
FHSR116
FNS116
FPS1116
FPS2116
FPS3118
FPS4118
FPS5118
FPS6118
FPS7118
FPS8118
FPS9120
FS120
GTSL120
GTSR120
GUS120
HCS120
HGTRS1122
HGTRS2122
HNS122
HPSL122
HPSR122
KYS122
LGS1124
LGS2124
LGS3124
ORS1124
PLS124
PRS124
RGSL126
RGSR126
RS126
RSS126
SES126
SLS126
SPS128
TBS128
TDS128
TVRS128
ZSS128
Metric Torque Values130
Grade130
Torque Values133
Grade133
Hydraulic System135
General Information137
Hydraulic Lines and Fittings137
Reservoir137
Filter138
Drift Test138
Lift Drift Test138
Freezer Preparation139
Hydraulic Circuits140
Main Lift Circuit140
Main Lower Circuit141
Main Lower Circuit (MVL)142
Load Handler Circuit through Main Frame Manifold143
Auxiliary Lift Circuit144
Auxiliary Lower Circuit145
Traverse Left Circuit146
Traverse Right Circuit148
Fork Extend Circuit150
Fork Retract Circuit152
Pivot Right Circuit154
Pivot Left Circuit156
Hydraulic Schematic Symbols158
Hydraulic Pump162
Pump Replacement162
Initial Start Up Procedure163
Manifold164
Relief Valve (RV1)164
Proportional Valves164
Manifold Block O-Ring Replacement165
Hydraulic Motor167
Preparation Before Disassembly167
Tools and Materials Required for Servicing167
Disassembly and Inspection169
Reassembly176
Final Checks183
Drive Unit185
Drive Unit187
Drive Tire Replacement187
Lathe Cutting188
Drive Unit Lubrication189
Drive Unit Removal189
Drive Unit Installation190
Drive Motor Removal190
Drive Motor Installation190
Electrical System191
ACCESS 123®193
When a Malfunction Occurs193
Power Cable Connections193
Software Package Version Level193
Main Menu196
Analyzer Menus197
Input Menus198
Platform Menu200
Seat Controls Menu201
Power Unit Menu202
Outputs Menu205
Load Handler Menu206
Platform Menu or Seat Controls Menu209
Power Unit Menu210
Test Outputs Menu214
Load Handler Menu215
Platform Menu or Seat Controls Menu216
Power Unit Menu217
Calibration Menu220
Handles Menu221
Hydraulics Menu222
Pivot Sense Menu223
Main R Valve Menu224
Main L Valve225
Main HGT Sense Menu226
Aux Flow Valve Menu227
Traverse Valve Menu or Pivot Valve Menu228
Extend Valve229
Aux R Valve Menu230
Weight Sense Menu231
Aux Valve Menu232
Aux HGT Sense Menu233
Tilt Valve Menu234
Height Cutouts Menu235
Steer Encoder Menu236
Wire Guide Menu237
Calibrate Menu238
Adjust X-Offset Menu241
Features Menu242
Mast Type, Measurement, Collapsed Height , Lift Height or Traverse Frame Menu243
Fork Type Menu244
Fork Length, Pallet Width, Pallet Length or Battery Compartment Menu246
Truck Weight, Max Load or Lift Motor Menu247
Capacity Data Monitor Menu248
Wire Guidance or Manual Wire Sense Menu249
End Aisle, Battery Retainer SW or Travel Alarm Menu250
Language or User Performance Menu251
User Codes or Cold Condition Menu252
Options Menu253
Front Rail, Zone Switch, Aux Mast, Screen Setup or Save Menu255
Hour Meters Menu256
Event Codes Menu257
Performance Menu258
P1 Setup P1 Menu259
P2 Setup P2 Menu261
P3 Setup P3 Menu263
Plug, Coast, Braking or Free Range Speeds Menu265
Guided Speeds Menu266
EAC Setup Menu267
Main Hoist R or L Menu269
Aux Hoist R or L Menu270
PDS Setup Menu270
Utilities Menu272
Active Tow Mode, Shipping Mode, Truck lockout or Traverse Valve Menu273
Wire Guidance274
Operation Modes275
Manual275
Automatic275
Sensors276
Line Driver Output276
Field Strength Cross Reference Chart277
Calibration277
Troubleshooting278
End Aisle Control (EAC)279
Wire Guidance Calibration Speeds280
EAC Zones:280
Troubleshooting280
EAC Event Codes:280
Termination Point Locations281
Access 5 (EAC Distribution Module)281
Contactor282
Inspection282
Contacts282
Coil282
Component Replacement283
Contact Replacement283
Coil Replacement283
K2 Logic Power Contactor283
Battery284
Safety Rules284
Battery Care284
Charging285
Battery Removal285
Battery Installation285
Checking285
Charging286
Cleaning287
Troubleshooting288
Motor289
Event Codes290
ACCESS Module Listing:290
Some Troubleshooting Basics290
When a Malfunction Occurs290
No Event Code?290
To Locate Malfunctioning Components290
Test Points290
Power Cable Connections290
Event Codes – ACCESS 1292
Event Code 101292
ACCESS 1 module CAN error292
Event Code 104293
ACCESS 1 and ACCESS 4 module CAN error293
Event Code 105293
ACCESS 1 and ACCESS 5 module CAN error293
Event Code 106294
ACCESS 1 and ACCESS 6 module CAN error294
Event Code 107295
ACCESS 1 and ACCESS 7 module CAN error295
Event Code 108296
ACCESS 1 and ACCESS 8 module CAN error296
Event Code 112297
ACCESS 2 module software not compatible with the other modules297
Event Code 113297
ACCESS 3 module software not compatible with the other modules297
Event Code 114297
ACCESS 4 module software not compatible with the other modules297
Event Code 115297
ACCESS 5 module software not compatible with the other modules297
Event Code 116297
ACCESS 6 module software not compatible with the other modules297
Event Code 117297
ACCESS 7 module software not compatible with the other modules297
Event Code 118297
ACCESS 8 module software not compatible with the other modules297
Event Codes – ACCESS 2298
Event Code 212298
ACCESS 2 module current out of range298
Event Code 213298
ACCESS 2 module current sensor error298
Event Code 214298
ACCESS 2 module precharge error298
Event Code 215298
ACCESS 2 module below operating temperature298
Event Code 216298
ACCESS 2 module above operating temperature298
Event Code 217299
ACCESS 2 module battery voltage out of range299
Event Code 218299
ACCESS 2 module battery voltage out of range299
Event Code 221299
ACCESS 2 module low temperature cutback299
Event Code 222299
ACCESS 2 module high temperature cutback299
Event Code 223300
ACCESS 2 module under voltage cutback300
Event Code 224300
ACCESS 2 module overvoltage cutback300
Event Code 225300
ACCESS 2 module 5V supply out of range300
Event Code 228301
ACCESS 2 module hydraulic pump motor (M2) high temperature cutback301
Event Code 229301
ACCESS 2 hydraulic pump motor M2 temperature sensor TS2 error301
Event Code 231302
ACCESS 2 module high performance hydraulics fan driver shorted or open302
Event Code 232303
ACCESS 2 module horn (HN) driver shorted or open303
Event Code 233303
ACCESS 2 module SVML driver shorted or open303
Event Code 234305
ACCESS 2 module SP1 driver shorted or open305
Event Code 235306
ACCESS 2 module PVMR driver shorted or open306
Event Code 236307
ACCESS 2 module hydraulic pump motor feedback encoder (ECR8) count out of tolerance307
Event Code 237307
Pump motor open (M2)307
Event Code 246308
ACCESS 2 module defaults not loaded308
Event Code 247308
ACCESS 2 module internal fault308
Event Code 249308
ACCESS 2 module parameter change error308
Event Code 251308
ACCESS 2 module general fault308
Event Code 255308
ACCESS 2 Main Chain Slack308
Event Code 256308
ACCESS 2 Main Chain Break308
Event Code 268309
ACCESS 2 module internal fault309
Event Code 269309
ACCESS 2 module 5 V power supply out of range309
Event Code 272309
ACCESS 2 module CAN timeout309
Event Code 273310
ACCESS 2 module ECR8 hydraulic pump motor (M2) encoder count out of range310
Event Code 278310
ACCESS 2 module internal fault310
Event Codes – ACCESS 3311
Event Code 300311
ACCESS 3 module pre-charge timeout or failure to follow ACCESS 5 module ED1 and ED2 (if present) command311
Event Code 312311
ACCESS 3 module over current condition311
Event Code 313311
ACCESS 3 module traction motor (M1) current sensor fault311
Event Code 315311
ACCESS 3 module heat sink temperature less than -40 C (-40 F)311
Event Code 317 and 318311
ACCESS 3 module +BV under or over range311
Event Code 321313
ACCESS 3 module internal temperature less than -25 C (-13 F)313
Event Code 322313
ACCESS 3 has internal temperature in excess of 85 C (185 F)313
Event Code 323 and 324313
ACCESS 3 module +BV cutback313
Event Code 325314
ACCESS 3 module 5 V for ECR7 is out of range314
Event Code 326315
ACCESS 3 module pedestrian detection system (PDS) Platform Down driver pin #19 over current315
Event Code 327315
ACCESS 3 module pedestrian detection system (PDS) Quit Button driver pin #20 over current315
Event Code 328316
ACCESS 3 module traction motor (M1) temperature above acceptable range316
Event Code 329316
ACCESS 3 module traction motor (M1) temperature sensor (TS1) out of range316
Event Code 331316
ACCESS 3 module pedestrian detection system (PDS) End of Aisle driver pin #6 shorted, open316
Event Code 332317
ACCESS 3 module ED open or shorted driver317
Event Code 333317
ACCESS 3 module travel alarm (ALM2) wiring open or short317
Event Code 334318
ACCESS 3 module pedestrian detection system (PDS) In Aisle driver pin #3 shorted, open318
Event Code 336318
Traction encoder (ECR7) count error318
Event Code 337319
ACCESS 3 module traction motor (M1) open319
Event Code 346319
ACCESS 3 module default parameters not loaded319
Event Code 347319
ACCESS 3 module interlock sequence parameter setup error319
Event Code 349319
ACCESS 3 module parameter change during operation319
Event Code 351319
ACCESS 3 module parameter invalid value319
Event Code 368320
ACCESS 3 module VCM program error320
Event Code 369320
ACCESS 3 module traction encoder (ECR7) 5V out of range320
Event Code 372320
ACCESS 3 module CAN timeout320
Event Code 373321
Traction encoder (ECR7) count error321
Event Code 378321
ACCESS 3 module internal fault321
Event Codes – ACCESS 4322
Event Code 400322
ACCESS 4 or ACCESS 8 module CAN error322
Event Code 402323
ACCESS 4 or ACCESS 1 module CAN error323
Event Code 403324
ACCESS 4 or ACCESS 7 module CAN error324
Event Code 407325
ACCESS 4 or ACCESS 2 module CAN error325
Event Code 408 and 409326
ACCESS 4 or ACCESS 5 module CAN error326
Event Code 411 and 430327
ACCESS 4 module internal fault327
Event Code 436327
ACCESS 4 module seat locking solenoid over current327
Event Code 437327
ACCESS 4 module main height encoder ECR5 power supply wire open327
Event Code 438328
ACCESS 4 module main height encoder ECR5 channel CHA or CHB open328
Event Code 439328
ACCESS 4 module main height encoder ECR5 count error328
Event Code 440328
ACCESS 4 module main height encoder ECR5 reset error328
Event Code 441329
ACCESS 4 module main mast broken height sensor cable329
Event Code 442330
ACCESS 4 module main height encoder ECR5 count error330
Event Code 443330
ACCESS 4 module main height encoder ECR5 counting in reverse direction330
Event Code 444330
ACCESS 4 module cable tension slack330
Event Code 445331
ACCESS 4 module main chain slack331
Event Code 446331
ACCESS 4 module main chain break331
Event Code 447332
ACCESS 4 module main height encoder ECR5 power supply out of range332
Event Code 491 Through Event Code 499333
ACCESS 4 module internal fault333
Event Codes – ACCESS 5334
Event Code 501334
ACCESS 1 module CAN timeout334
Event Code 502335
ACCESS 5 communication (CAN) with ACCESS 2 module timeout335
Event Code 503335
ACCESS 3 module CAN timeout335
Event Code 504336
ACCESS 4 module CAN timeout336
Event Code 505336
ACCESS 5 module CAN error336
Event Code 507337
ACCESS 7 module CAN timeout337
Event Code 508337
ACCESS 8 module CAN timeout337
Event Code 509 and 510338
ACCESS 6 module CAN timeout338
Event Code 511 Through Event Code 521338
ACCESS 5 module internal event338
Event Code 522 and 523339
ACCESS 5 Module 5 V power supply out of range339
Event Code 524 and 525340
ACCESS 5 module +BV out of range340
Event Code 526 and 527340
ACCESS 5 module +BV brake voltage out of range340
Event Code 528 and 529340
ACCESS 5 module inner brake +BV out of range340
Event Code 530 and 531341
ACCESS 5 module outer brake +BV out of range341
Event Code 532 and 533342
ACCESS 5 module 5 V battery current sensor (CS1) supply out of range342
Event Code 534 and 535342
ACCESS 5 module battery current out of range342
Event Code 536343
ACCESS 5 module battery current sensor (CS1) improperly installed343
Event Code 537343
ACCESS 5 module battery current sensor (CS1) zero reading out of range343
Event Code 538 and 539343
ACCESS 5 module BDI voltage out of range343
Event Code 540344
ACCESS 5 +BV out of range344
Event Code 541344
ACCESS 5 module ED contactor failed to energize344
Event Code 542345
Open fuse345
Event Code 543346
ACCESS 5 module ED1 (ED2 if present) tips welded346
Event Code 544346
ACCESS 5 module ED turn ON error346
Event Code 545346
ACCESS 5 module ED turn OFF event346
Event Code 546 Through Event Code 550346
ACCESS 2 module or ACCESS 3 module failed ED load bus pre-charge346
Event Code 551347
ACCESS 5 module parameter error347
Event Code 552 and 553347
ACCESS 5 module parameter error347
Event Code 554347
ACCESS 5 module EAC parameter error347
Event Code 555 and 556347
ACCESS 5 module steering feedback encoder (ECR6) counts out of range347
Event Code 557348
ACCESS 5 module steering feedback encoder (ECR6) index line error348
Event Code 558 Through Event Code 561349
ACCESS 5 module steering feedback encoder (ECR6) error349
Event Code 562350
ACCESS 5 module steering system short circuit350
Event Code 563350
ACCESS 5 module ACCESS 6 communication error350
Event Code 564350
ACCESS 5 module wire guidance enable error350
Event Code 565350
ACCESS 3 and ACCESS 5 module traction sensor ECR7 error350
Event Code 566351
ACCESS 5 module End Aisle Control (EAC) enable error351
Event Code 567 Through Event Code 570352
ACCESS 5 module End Aisle Control (EAC) sensor latched ON error352
Event Code 571 and 572352
ACCESS 5 module End Aisle Control (EAC) magnet error352
Event Code 576 Through Event Code 581353
ACCESS 5 module brake current or resistance error353
Event Code 582 Through Event Code 585353
ACCESS 5 module brake current out of range353
Event Code 586 and 587354
ACCESS 5 module brake load error354
Event Code 588 and 589355
ACCESS 5 module brake supply voltage error355
Event Code 590 and 591356
ACCESS 5 module brake driver error356
Event Code 592 and 593356
ACCESS 5 module brake driver error356
Event Code 594356
ACCESS 5 PVML (proportional flow valve) load error356
Event Code 595357
ACCESS 5 module proportional flow valve (PVML) driver error357
Event Code 596357
ACCESS 5 module proportional flow valve (PVML) load error357
Event Code 597357
ACCESS 5 module proportional flow valve (PVML) driver error357
Event Codes – ACCESS 6359
Event Code 605359
ACCESS 6 module CAN timeout359
Event Code 611, 612 and 621 Through Event Code 628359
ACCESS 6 module internal module fault359
Event Code 631359
ACCESS 6 module wire guidance sensor amplifier self-test error359
Event Code 632359
ACCESS 6 module load wheel wire guidance sensor bar fault359
Event Code 633360
ACCESS 6 module steer wheel wire guidance sensor bar fault360
Event Code 636361
ACCESS 6 module allowable truck angle in relationship to guide wire has been exceeded361
Event Code 637361
ACCESS 6 module wire guidance system loss of wire signal at both sensor bars361
Event Code 638 and 639361
ACCESS 6 module wire guidance system loss of wire signal from one of the two sensor bars361
Event Code 652 Through Event Code 659362
ACCESS 6 module EAC sensor signal out of range362
Event Code 660 Through Event Code 663363
ACCESS 6 module EAC sensor digital signal error363
Event Code 664 Through Event Code 667363
ACCESS 6 module EAC magnet field strength weak363
Event Code 668 Through Event Code 671363
ACCESS 6 module EAC sensor self test error363
Event Code 672364
ACCESS 6 module multiple EAC sensors active364
Event Codes – ACCESS 7365
Event Code 700365
ACCESS 7 and ACCESS 8 module CAN timeout365
Event Code 701366
ACCESS 7 and ACCESS 4 module CAN timeout366
Event Code 702367
ACCESS 7 and ACCESS 1 module CAN timeout367
Event Code 707368
ACCESS 7 and ACCESS 2 module CAN timeout368
Event Code 708 and 709369
ACCESS 7 and ACCESS 5 module CAN timeout369
Event Code 711 Through Event Code 720370
ACCESS 7 module internal error detected during self test370
Event Code 736370
ACCESS 7 module proportional flow valve auxiliary raise (PVAR) over current370
Event Code 737371
ACCESS 7 module proportional flow valve auxiliary lower (PVAL) over current371
Event Code 738371
ACCESS 7 module proportional flow valve traverse motor (PVT1) over current371
Event Code 739372
ACCESS 7 module proportional flow valve traverse motor (PVT2) over current372
Event Code 740372
ACCESS 7 module proportional flow valve pivot (PVP1) over current372
Event Code 741373
ACCESS 7 module proportional flow valve pivot (PVP2) over current373
Event Code 742373
ACCESS 7 module proportional flow fork extend (PVF1) over current373
Event Code 743374
ACCESS 7 module proportional flow fork retract (PVF2) over current374
Event Code 744374
ACCESS 7 module auxiliary cylinder lowering solenoid valve (SVAL) over current374
Event Code 745375
ACCESS 7 module proportional flow auxiliary relief (PVLH) over current375
Event Code 746375
ACCESS 7 module proportional flow auxiliary raise (PVAR) over current375
Event Code 747 Through Event Code 749376
ACCESS 7 module internal driver short detected during self test376
Event Code 750376
ACCESS 7 module auxiliary cylinder lowering solenoid valve (SVAL) driver shorted or load open376
Event Code 751377
ACCESS 7 module proportional flow auxiliary relief (PVLH) driver shorted or load open377
Event Code 752378
ACCESS 7 module proportional flow valve auxiliary raise (PVAR) driver or load open378
Event Code 753379
ACCESS 7 module proportional flow valve auxiliary lower (PVAL) driver or load open379
Event Code 754380
ACCESS 7 module proportional flow valve traverse motor (PVT2) driver or load open380
Event Code 755381
Access 7 module proportional flow valve traverse motor (PVT1) driver or load open381
Event Code 756382
ACCESS 7 module proportional flow valve pivot (PVP1) driver or load open382
Event Code 757383
ACCESS 7 module auxiliary cylinder lowering solenoid valve (SVAL) open driver383
Event Code 758383
ACCESS 7 module proportional flow auxiliary relief (PVLH) driver open383
Event Code 759383
ACCESS 7 module proportional flow valve pivot (PVP2) driver or load open383
Event Code 760384
ACCESS 7 module proportional flow fork extend (PVF1) driver or load open384
Event Code 761385
ACCESS 7 module proportional flow fork retract (PVF2) driver or load open385
Event Code 762386
ACCESS 7 module load sense transducer (LS) open386
Event Code 763386
ACCESS 7 module load sense transducer (LS) shorted386
Event Code 764387
ACCESS 7 module pivot position potentiometer (POT5) above or below electrical limit387
Event Code 765387
ACCESS 7 module pivot potentiometer (POT5) voltage fluctuation387
Event Code 767388
ACCESS 7 module pivot potentiometer (POT5) voltage changing to quickly388
Event Code 768388
ACCESS 7 module pivot potentiometer (POT5) rotating in the wrong direction388
Event Code 769389
ACCESS 7 module pivot potentiometer (POT5) voltage changing to slowly389
Event Code 770389
ACCESS 7 module pivot potentiometer (POT5) voltage out of calibration limit389
Event Code 771390
ACCESS 7 module auxiliary height encoder (ECR3) count change with no auxiliary movement390
Event Code 772390
ACCESS 7 module auxiliary height encoder (ECR3) count in wrong direction390
Event Code 773390
ACCESS 7 module auxiliary height encoder (ECR3) CH A or CH B open390
Event Code 774391
ACCESS 7 module auxiliary height encoder (ECR3) power supply wire open391
Event Code 775391
ACCESS 7 module auxiliary height encoder (ECR3) power supply out of range391
Event Code 776392
ACCESS 7 module traverse encoder (ECR4) not counting392
Event Code 777392
ACCESS 7 module traverse encoder (ECR4) count error392
Event Code 778393
ACCESS 7 module traverse encoder (ECR4) reset switch (TVRS) did not toggle393
Event Code 779393
ACCESS 7 module traverse encoder (ECR4) count speed out of range393
Event Code 780394
ACCESS 7 module traverse encoder (ECR4) count direction incorrect394
Event Code 781395
ACCESS 7 module auxiliary lower velocity fuse trip395
Event Code 782396
ACCESS 7 module traverse encoder (ECR4) calibration out of range396
Event Code 783396
ACCESS 7 module auxiliary height encoder (ECR3) not counting396
Event Code 784397
ACCESS 7 module auxiliary height reset failed to toggle397
Event Code 785397
ACCESS 7 module auxiliary fork height encoder (ECR3) counts out of range397
Event Code 790 Through Event Code 799398
ACCESS 7 module internal fault398
Event Codes – ACCESS 8399
Event Code 800399
ACCESS 8 and ACCESS 5 module CAN time out399
Event Code 801399
ACCESS 8 and ACCESS 5 module CAN time out399
Event Code 802400
ACCESS 8 and ACCESS 1 module CAN time out400
Event Code 803401
ACCESS 8 and ACCESS 4 module CAN time out401
Event Code 804402
ACCESS 8 and ACCESS 7 module CAN time out402
Event Code 805403
ACCESS 8 and ACCESS 1 module CAN time out403
Event Code 806404
ACCESS 8 and ACCESS 4 module CAN time out404
Event Code 807405
ACCESS 8 and ACCESS 5 module CAN time out405
Event Code 816406
ACCESS 8 module internal fault406
Event Code 821406
ACCESS 8 module 5 V power supply out of regulation406
Event Code 822406
ACCESS 8 module 15 V power supply out of regulation406
Event Code 823407
ACCESS 8 module steer encoder ECR2 power supply out of regulation407
Event Code 824407
ACCESS 8 module optical switch board FS/RS power supply out of regulation407
Event Code 825408
ACCESS 8 module steer encoder ECR1 power supply out of regulation408
Event Code 836408
ACCESS 8 module traction potentiometer POT1 out of electrical limits408
Event Code 837409
ACCESS 8 module traction potentiometer POT2 out of electrical limits409
Event Code 838409
ACCESS 8 module POT3 auxiliary raise, lower potentiometer out of electrical limits409
Event Code 839410
ACCESS 8 module POT4 traverse potentiometer out of electrical limits410
Event Code 840411
ACCESS 8 module hand presence switch HPSL (left hand presence switch) or HPSR (right hand presence switch) photo diode open411
Event Code 841412
ACCESS 8 module traction potentiometer (POT1) does not match forward switch (FS)412
Event Code 842412
ACCESS 8 module traction potentiometer (POT1) does not match reverse switch (RS)412
Event Code 843413
ACCESS 8 module forward switch (FS) and reverse switch (RS) indicate both closing at the same time413
Event Code 844413
ACCESS 8 module cold condition heater driver current to high413
Event Code 845413
ACCESS 8 module left hand presence switch (HPSL) open receiver413
Event Code 846414
ACCESS 8 module right hand presence switch (HPSR) open receiver414
Event Code 847414
ACCESS 8 module steer tiller encoders (ECR1 and ECR2) turn rate error414
Event Code 848416
ACCESS 8 module ECR1 and ECR2 (steer tiller encoders) direction of rotation error416
Event Code 849417
ACCESS 8 module steer tiller encoders (ECR1 and ECR2) direction of rotation error417
Event Code 850 Through Event Code 852419
ACCESS 8 or ACCESS 5 module CAN receiving error419
Event Code 853 Through Event Code 855419
ACCESS 8 and ACCESS 6 module CAN receiving error419
Event Code 856 Through Event Code 859420
ACCESS 8 and ACCESS 1 module receiving error420
Event Code 860 Through Event Code 863420
ACCESS 8 and ACCESS 4 module CAN receiving error420
Event Code 864 Through Event Code 867421
ACCESS 8 and ACCESS 7 module CAN receiving error421
Event Code 868 and 869421
ACCESS 8 and ACCESS 5 module CAN error421
Event Code 870 and 871422
ACCESS 8 and ACCESS 6 module CAN error422
Event Code 872 Through Event Code 874423
ACCESS 8 and ACCESS 1 module CAN error423
Event Code 875 Through Event Code 877424
ACCESS 8 and ACCESS 4 module CAN error424
Event Code 878 Through Event Code 880426
ACCESS 8 and ACCESS 7 module CAN error426
Brake System427
Brake429
Brake Force Adjustment429
Torque Gap Adjustment429
Air Gap Adjustment431
Rotor and Brake Pad Replacement432
To disassemble rotor and brake pad assembly:432
Brake Assembly432
Steering435
Steering Feedback437
Replacing Steering Feedback Assembly Encoder437
Replacing Steering Feedback Assembly Gears438
Steering Motor440
Steering Motor Brushes440
Replacing Steering Motor Brushes440
Replacing Steering Motor440
Steering Gearbox442
Replacing Steering Gearbox442
Lifting Mechanism445
Mast447
TN (Telescopic No Free Lift) Mast447
TF (Telescopic Full Free Lift) Mast447
TT (Triple Telescopic Full Free Lift) Mast447
New Truck Assembly Procedures447
To Assemble Power Unit, Mainframe and Platform and Load Handler:448
Second Stage Mast Removal TF and TN451
Removing Second Stage Mast TF and TN451
(Without Sufficient Overhead Clearance)451
Removing Second Stage Mast TF and TN455
(With Sufficient Overhead Clearance)455
Removing Second and Third Stages from TT Mast Assembly455
Roller Adjustment463
Column Rollers463
Side Thrust Rollers TF and TN463
Installing Second Stage Mast TF and TN463
(Without Sufficient Overhead Clearance)463
Installing Second Stage Mast TF and TN465
(With Sufficient Overhead Clearance)465
Installing Second and Third Stage TT Mast466
2nd stage mast side thrust roller adjustment466
3rd stage mast side thrust roller adjustment467
Hose Take-Up Cable471
Load Wheels473
Load Wheel Removal473
Tire Replacement473
Lathe Cutting473
Lift Chains475
Inspection475
Wear475
Rust and Corrosion476
Cracked Plates476
Tight Joints477
Protruding or Turned Pins477
Chain Side Wear477
Unequal Chain Tension477
Non Alignment of Lifting Components477
Lift Chain Lubrication477
Lift Chain Replacement478
Chain Anchors and Pulleys479
Leaf Chain Disconnect479
Disconnect Procedures479
Fork Inspection480
Abrasion480
Blade Measurement480
Hanger Bore Measurement481
Overloading483
Fatigue483
Bent or Twisted Forks483
Hanger484
Cylinders485
TF Lift Cylinders487
Pivoting The Tip-Out Assembly487
(Accessing the Lift Cylinders)487
Primary (Free) Lift Cylinder Repair490
Cylinder Packing Installation492
Reassembling Mast Tip-Out493
Primary (Free) Lift Cylinder Removal494
Secondary (Main) Lift Cylinder Removal495
Primary (Free) Lift Cylinder Installation496
Secondary (Main) Lift Cylinder Installation496
Lift Cylinder Bleeding497
TN Lift Cylinder498
Pivoting the Tip-Out Assembly498
(Accessing the Lift Cylinder)498
Lift Cylinder Repair500
Cylinder Packing Installation502
Reassembling Mast Tip-Out502
Lift Cylinder Removal503
Lift Cylinder Installation504
Lift Cylinder Bleeding505
Auxiliary Lift Cylinder506
Auxiliary Lift Cylinder Repair506
Rod Packing Installation509
Auxiliary Lift Cylinder Bleeding509
Fork Cylinders510
Cylinder Disassembly511
Piston Rod Disassembly512
Cylinder Reassembly512
Pivot Cylinders514
Cylinder Removal514
Cylinder Disassembly515
Cylinder Reassembly516
Cylinder Installation518
Pivot Cylinder Bleeding518
Platform519
Platform521
Inspection and Adjustment521
Column Roller Area521
Overhead Guard Area521
Operator Controls521
Lower Platform Area521
Lubrication522
Mast Shield523
Gates524
GTSL & GTSR525
Gate Switches525
Chain Anchor and Platform Height Adjustment525
Side Thrust Roller Adjustment – Platform (TF, TN and TT Mast)526
Traverse Hose Replacement526
Platform Removal528
Platform Assembly531
Seat Pivot Bearing Assembly532
Seat Rotate Switch Adjustment533
Seat Coil Cord Installation534
Seat Up/Down Switch Adjustment535
Mirror Installation And Adjustment536
Mirror Adjustment538
Height Sensing System539
Height Sensor Assembly Removal539
Height Sensor Assembly Installation540
Height Cable Broken Switch (HCS)540
Height Sensor Assembly541
Encoder (ECR5)541
Cable Replacement541
Glossary543
Glossary545
Schematic Diagrams551
Introduction to Diagram Usage553
Schematic553
Pictorials553
Electrical Diagrams Index554
Platform Schematic555
Power Unit Schematic556
Platform Distribution Panel557
Platform Distribution Panel w/InfoLink558
Power Unit Distribution Panel559
Lights And Fans560
ACCESS 1 Operator Display561
Platform Chain Switches562
ACCESS 4 Vehicle Control Module563
Platform Seat Area564
Platform Floor Area565
ACCESS 3 Traction Control Module566
ACCESS 5 Steering Control Module567
Contactor Panel568
Traction Motor, ECR6, ECR7, FSB1 & Brake569
ACCESS 2 Hydraulic Control Module570
Hydraulic Motor, ECR8571
ACCESS 8 Operator Control Module572
Platform Left Armrest573
ACCESS 6 Guidance Control Module574
ECR7, FSB1, FSB2 & PDS575
ACCESS 7 Accessory Control Module576
Power Cables577
Wiring Harnesses578
Hydraulic Schematic581
Hydraulic Schematic583TSP 6000 SERIES 1
Table of Contents 3
Introduction page serial no cut Rev 5
Introduction 3 5
Operator Instructions 3 5
Operator Training 3 5
Service Training 3 5
Replacement Parts 3 5
Safety page serial no cut Rev 5
General Maintenance Instructions 7 5
Cleaning of Material Handling Equipment 9 5
Cleaning Methods 9 5
Control of Hazardous Energy 10 5
Lockout/Tagout 10 5
Battery 10 5
Capacitance 12 5
Brake 13 5
Hydraulic 14 5
Towing Truck 15 5
Lifting and Blocking 18 5
Main Mast, Auxiliary Mast and Platform 19 5
Height Sensor 22 5
Auxiliary Mast and Platform Lifting 24 5
Planned Maintenance – Lubricants 25 5
Lubrication & Adjustment page serial no cut Rev 5
Lubrication and Adjustment 31 5
General 31 5
Component Accessibility 31 5
Componentry 42 5
Introduction 42 5
Audible Indicators 43 6
ALM1 43 6
ALM2 43 6
HN 43 6
Battery 44 6
BATT 44 6
Contactors 45 6
ED1, ED2 45 6
K2 45 6
Encoders 47 6
ECR1 47 6
ECR2 47 6
ECR3 47 6
ECR4 47 6
ECR5 49 6
ECR6 49 6
ECR7 49 6
ECR8 49 6
Fuses 51 6
FU1 51 6
FU2 51 6
FU3 51 6
FU4 51 6
FU5 51 6
FU6 52 6
FU7 52 6
FU8 52 6
FU9 53 6
FU10 53 6
FU11 54 6
FU12 54 6
FU13 54 6
FU14 54 6
FU15 54 6
FU16 54 6
FU17 56 6
FU18 56 6
FU19 56 6
FU20 56 6
FU21 56 6
Lights 58 6
LGT1 58 6
LGT2 58 6
LGT3 58 6
LGT4 58 6
LGT5 58 6
LGT 6 60 6
LGT 7 60 6
LGT8 60 6
LGT9 60 6
Miscellaneous 62 7
BRK 62 7
EAC Distribution Panel 62 7
FAN1 62 7
FAN3 62 7
FSB1 62 7
FSB2 62 7
JC 64 7
P1 64 7
PS1 64 7
PS2 64 7
HYDRAULIC RESERVOIR 64 7
Modules 66 7
ACCESS 1 66 7
ACCESS 2 66 7
ACCESS 3 66 7
ACCESS 4 66 7
ACCESS 5 68 7
ACCESS 6 68 7
ACCESS 8 68 7
Motors 70 7
M1 70 7
M2 70 7
M3 70 7
Potentiometers 72 7
POT1 72 7
POT2 72 7
POT3 72 7
POT4 72 7
POT5 72 7
Relays 74 7
K1 74 7
Resistors 74 7
RES1 74 7
RES2 74 7
RES3 74 7
RES4 74 7
RES5 74 7
Sensors 76 7
CS1 76 7
EACA1 76 7
EACA2 76 7
EACB1 76 7
EACB2 76 7
GS1 78 7
GS2 78 7
LS 78 7
PDS 78 7
TS1 78 7
TS2 78 7
Solenoid Valves 80 8
EML 80 8
MVL 80 8
PCML 80 8
PVAL 80 8
PVAR 80 8
PVF1 82 8
PVF2 82 8
PVLH 82 8
PVML 84 8
PVMR 84 8
PVP1 84 8
PVP2 84 8
PVT1 84 8
PVT2 84 8
SP1 86 8
SVAL 86 8
SVML 86 8
Suppressor Blocks 88 8
SB11 88 8
SB31 88 8
SB41 88 8
Switches 90 8
APS 90 8
BRES 90 8
BRS1 90 8
BRS2 90 8
BRS3 90 8
BRS4 90 8
CHS1 92 8
CHS2 92 8
CHS3 92 8
CHS4 92 8
CHS5 92 8
CHS6 92 8
CHS7 94 8
CHS8 94 8
CTS (TF Mast Only) 94 8
DTS 94 8
EDS 94 8
EMS1 94 8
EMS2 96 8
FHSL 96 8
FHSR 96 8
FNS 96 8
FPS1 96 8
FPS2 96 8
FPS3 98 8
FPS4 98 8
FPS5 98 8
FPS6 98 8
FPS7 98 8
FPS8 98 8
FPS9 100 8
FS 100 9
GTSL 100 9
GTSR 100 9
GUS 100 9
HCS 100 9
HGTRS1 102 9
HGTRS2 102 9
HNS 102 9
HPSL 102 9
HPSR 102 9
KYS 102 9
LGS1 104 9
LGS2 104 9
LGS3 104 9
ORS1 104 9
PLS 104 9
PRS 104 9
RGSL 106 9
RGSR 106 9
RS 106 9
RSS 106 9
SES 106 9
SLS 106 9
SPS 108 9
TBS 108 9
TDS 108 9
TVRS 108 9
ZSS 108 9
Metric Torque Values 110 9
Grade 110 9
Torque Values 113 9
Grade 113 9
Hydraulic System page serial no cut Rev 9
General Information 117 9
Hydraulic Lines and Fittings 117 9
Reservoir 117 9
Filter 118 9
Drift Test 118 9
Lift Drift Test 118 9
Freezer Preparation 119 9
Hydraulic Circuits 120 9
Main Lift Circuit 120 9
Main Lower Circuit 121 9
Main Lower Circuit (MVL) 122 9
Load Handler Circuit through Main Frame Manifold 123 9
Auxiliary Lift Circuit 124 9
Auxiliary Lower Circuit 125 9
Traverse Left Circuit 126 9
Traverse Right Circuit 128 9
Fork Extend Circuit 130 9
Fork Retract Circuit 132 9
Pivot Right Circuit 134 9
Pivot Left Circuit 136 9
Hydraulic Schematic Symbols 138 10
Hydraulic Pump 142 10
Pump Replacement 142 10
Initial Start Up Procedure 143 10
Manifold 144 10
Relief Valve (RV1) 144 10
Proportional Valves 144 10
Manifold Block O-Ring Replacement 145 10
Hydraulic Motor 147 10
Preparation Before Disassembly 147 10
Tools and Materials Required for Servicing 147 10
Disassembly and Inspection 149 10
Reassembly 156 10
Final Checks 163 10
Drive Unit page serial no cut Rev 10
Drive Unit 167 10
Drive Tire Replacement 167 10
Lathe Cutting 168 10
Drive Unit Lubrication 169 10
Drive Unit Removal 169 10
Drive Unit Installation 170 10
Drive Motor Removal 170 10
Drive Motor Installation 170 10
Electrical System page serial no cut Rev 10
ACCESS 123® 173 10
When a Malfunction Occurs 173 10
Power Cable Connections 173 10
Software Package Version Level 173 10
Main Menu 176 10
Analyzer Menus 177 10
Input Menus 178 10
Platform Menu 180 10
Seat Controls Menu 181 10
Power Unit Menu 182 10
Outputs Menu 185 10
Load Handler Menu 186 10
Platform Menu or Seat Controls Menu 189 10
Power Unit Menu 190 10
Test Outputs Menu 194 10
Load Handler Menu 195 10
Platform Menu or Seat Controls Menu 196 10
Power Unit Menu 197 10
Calibration Menu 200 10
Handles Menu 201 10
Hydraulics Menu 202 10
Pivot Sense Menu 203 10
Main R Valve Menu 204 10
Main L Valve 205 10
Main HGT Sense Menu 206 10
Aux Flow Valve Menu 207 10
Traverse Valve Menu or Pivot Valve Menu 208 10
Extend Valve 209 11
Aux R Valve Menu 210 11
Weight Sense Menu 211 11
Aux Valve Menu 212 11
Aux HGT Sense Menu 213 11
Tilt Valve Menu 214 11
Height Cutouts Menu 215 11
Steer Encoder Menu 216 11
Wire Guide Menu 217 11
Calibrate Menu 218 11
Adjust X-Offset Menu 221 11
Features Menu 222 11
Mast Type, Measurement, Collapsed Height , Lift Height or Traverse Frame Menu 223 11
Fork Type Menu 224 11
Fork Length, Pallet Width, Pallet Length or Battery Compartment Menu 226 11
Truck Weight, Max Load or Lift Motor Menu 227 11
Capacity Data Monitor Menu 228 11
Wire Guidance or Manual Wire Sense Menu 229 11
End Aisle, Battery Retainer SW or Travel Alarm Menu 230 11
Language or User Performance Menu 231 11
User Codes or Cold Condition Menu 232 11
Options Menu 233 11
Front Rail, Zone Switch, Aux Mast, Screen Setup or Save Menu 235 11
Hour Meters Menu 236 11
Event Codes Menu 237 11
Performance Menu 238 11
P1 Setup P1 Menu 239 11
P2 Setup P2 Menu 241 11
P3 Setup P3 Menu 243 11
Plug, Coast, Braking or Free Range Speeds Menu 245 11
Guided Speeds Menu 246 11
EAC Setup Menu 247 11
Main Hoist R or L Menu 249 11
Aux Hoist R or L Menu 250 11
PDS Setup Menu 250 11
Utilities Menu 252 11
Active Tow Mode, Shipping Mode, Truck lockout or Traverse Valve Menu 253 11
Wire Guidance 254 11
Operation Modes 255 11
Sensors 256 11
Line Driver Output 256 11
Calibration 257 11
Troubleshooting 258 11
End Aisle Control (EAC) 259 11
Wire Guidance Calibration Speeds 260 11
Troubleshooting 260 11
Termination Point Locations 261 11
Contactor 262 12
Inspection 262 12
Component Replacement 263 12
Battery 264 12
Safety Rules 264 12
Battery Care 264 12
Charging 265 12
Battery Removal 265 12
Battery Installation 265 12
Checking 265 12
Charging 266 12
Cleaning 267 12
Troubleshooting 268 12
Motor 269 12
Event Codes 270 12
ACCESS Module Listing: 270 12
Event Codes – ACCESS 1 272 12
Event Code 101 272 12
Event Code 104 273 12
Event Code 105 273 12
Event Code 106 274 12
Event Code 107 275 12
Event Code 108 276 12
Event Code 112 277 12
Event Code 113 277 12
Event Code 114 277 12
Event Code 115 277 12
Event Code 116 277 12
Event Code 117 277 12
Event Code 118 277 12
Event Codes – ACCESS 2 278 12
Event Code 212 278 12
Event Code 213 278 12
Event Code 214 278 12
Event Code 215 278 12
Event Code 216 278 12
Event Code 217 279 12
Event Code 218 279 12
Event Code 221 279 12
Event Code 222 279 12
Event Code 223 280 12
Event Code 224 280 12
Event Code 225 280 12
Event Code 228 281 12
Event Code 229 281 13
Event Code 231 282 13
Event Code 232 283 13
Event Code 233 283 13
Event Code 234 285 13
Event Code 235 286 13
Event Code 236 287 13
Event Code 237 287 13
Event Code 246 288 13
Event Code 247 288 13
Event Code 249 288 13
Event Code 251 288 13
Event Code 255 288 13
Event Code 256 288 13
Event Code 268 289 13
Event Code 269 289 13
Event Code 272 289 13
Event Code 273 290 13
Event Code 278 290 13
Event Codes – ACCESS 3 291 13
Event Code 300 291 13
Event Code 312 291 13
Event Code 313 291 13
Event Code 315 291 13
Event Code 317 and 318 291 13
Event Code 321 293 13
Event Code 322 293 13
Event Code 323 and 324 293 13
Event Code 325 294 13
Event Code 326 295 13
Event Code 327 295 13
Event Code 328 296 13
Event Code 329 296 13
Event Code 331 296 13
Event Code 332 297 13
Event Code 333 297 13
Event Code 334 298 13
Event Code 336 298 13
Event Code 337 299 13
Event Code 346 299 13
Event Code 347 299 13
Event Code 349 299 13
Event Code 351 299 13
Event Code 368 300 13
Event Code 369 300 13
Event Code 372 300 13
Event Code 373 301 13
Event Code 378 301 13
Event Codes – ACCESS 4 302 13
Event Code 400 302 13
Event Code 402 303 13
Event Code 403 304 13
Event Code 407 305 13
Event Code 408 and 409 306 13
Event Code 411 and 430 307 14
Event Code 436 307 14
Event Code 437 307 14
Event Code 438 308 14
Event Code 439 308 14
Event Code 440 308 14
Event Code 441 309 14
Event Code 442 310 14
Event Code 443 310 14
Event Code 444 310 14
Event Code 445 311 14
Event Code 446 311 14
Event Code 447 312 14
Event Code 491 Through Event Code 499 313 14
Event Codes – ACCESS 5 314 14
Event Code 501 314 14
Event Code 502 315 14
Event Code 503 315 14
Event Code 504 316 14
Event Code 505 316 14
Event Code 507 317 14
Event Code 508 317 14
Event Code 509 and 510 318 14
Event Code 511 Through Event Code 521 318 14
Event Code 522 and 523 319 14
Event Code 524 and 525 320 14
Event Code 526 and 527 320 14
Event Code 528 and 529 320 14
Event Code 530 and 531 321 14
Event Code 532 and 533 322 14
Event Code 534 and 535 322 14
Event Code 536 323 14
Event Code 537 323 14
Event Code 538 and 539 323 14
Event Code 540 324 14
Event Code 541 324 14
Event Code 542 325 14
Event Code 543 326 14
Event Code 544 326 14
Event Code 545 326 14
Event Code 546 Through Event Code 550 326 14
Event Code 551 327 14
Event Code 552 and 553 327 14
Event Code 554 327 14
Event Code 555 and 556 327 14
Event Code 557 328 14
Event Code 558 Through Event Code 561 329 14
Event Code 562 330 14
Event Code 563 330 14
Event Code 564 330 14
Event Code 565 330 14
Event Code 566 331 14
Event Code 567 Through Event Code 570 332 14
Event Code 571 and 572 332 14
Event Code 576 Through Event Code 581 333 15
Event Code 582 Through Event Code 585 333 15
Event Code 586 and 587 334 15
Event Code 588 and 589 335 15
Event Code 590 and 591 336 15
Event Code 592 and 593 336 15
Event Code 594 336 15
Event Code 595 337 15
Event Code 596 337 15
Event Code 597 337 15
Event Codes – ACCESS 6 339 15
Event Code 605 339 15
Event Code 611, 612 and 621 Through Event Code 628 339 15
Event Code 631 339 15
Event Code 632 339 15
Event Code 633 340 15
Event Code 636 341 15
Event Code 637 341 15
Event Code 638 and 639 341 15
Event Code 652 Through Event Code 659 342 15
Event Code 660 Through Event Code 663 343 15
Event Code 664 Through Event Code 667 343 15
Event Code 668 Through Event Code 671 343 15
Event Code 672 344 15
Event Codes – ACCESS 7 345 15
Event Code 700 345 15
Event Code 701 346 15
Event Code 702 347 15
Event Code 707 348 15
Event Code 708 and 709 349 15
Event Code 711 Through Event Code 720 350 15
Event Code 736 350 15
Event Code 737 351 15
Event Code 738 351 15
Event Code 739 352 15
Event Code 740 352 15
Event Code 741 353 15
Event Code 742 353 15
Event Code 743 354 15
Event Code 744 354 15
Event Code 745 355 15
Event Code 746 355 15
Event Code 747 Through Event Code 749 356 15
Event Code 750 356 15
Event Code 751 357 15
Event Code 752 358 15
Event Code 753 359 15
Event Code 754 360 15
Event Code 755 361 15
Event Code 756 362 15
Event Code 757 363 15
Event Code 758 363 15
Event Code 759 363 15
Event Code 760 364 15
Event Code 761 365 16
Event Code 762 366 16
Event Code 763 366 16
Event Code 764 367 16
Event Code 765 367 16
Event Code 767 368 16
Event Code 768 368 16
Event Code 769 369 16
Event Code 770 369 16
Event Code 771 370 16
Event Code 772 370 16
Event Code 773 370 16
Event Code 774 371 16
Event Code 775 371 16
Event Code 776 372 16
Event Code 777 372 16
Event Code 778 373 16
Event Code 779 373 16
Event Code 780 374 16
Event Code 781 375 16
Event Code 782 376 16
Event Code 783 376 16
Event Code 784 377 16
Event Code 785 377 16
Event Code 790 Through Event Code 799 378 16
Event Codes – ACCESS 8 379 16
Event Code 800 379 16
Event Code 801 379 16
Event Code 802 380 16
Event Code 803 381 16
Event Code 804 382 16
Event Code 805 383 16
Event Code 806 384 16
Event Code 807 385 16
Event Code 816 386 16
Event Code 821 386 16
Event Code 822 386 16
Event Code 823 387 16
Event Code 824 387 16
Event Code 825 388 16
Event Code 836 388 16
Event Code 837 389 16
Event Code 838 389 16
Event Code 839 390 16
Event Code 840 391 16
Event Code 841 392 16
Event Code 842 392 16
Event Code 843 393 16
Event Code 844 393 16
Event Code 845 393 16
Event Code 846 394 16
Event Code 847 394 16
Event Code 848 396 16
Event Code 849 397 16
Event Code 850 Through Event Code 852 399 17
Event Code 853 Through Event Code 855 399 17
Event Code 856 Through Event Code 859 400 17
Event Code 860 Through Event Code 863 400 17
Event Code 864 Through Event Code 867 401 17
Event Code 868 and 869 401 17
Event Code 870 and 871 402 17
Event Code 872 Through Event Code 874 403 17
Event Code 875 Through Event Code 877 404 17
Event Code 878 Through Event Code 880 406 17
Brake System page serial no cut Rev 17
Brake 409 17
Brake Force Adjustment 409 17
Torque Gap Adjustment 409 17
Air Gap Adjustment 411 17
Rotor and Brake Pad Replacement 412 17
Brake Assembly 412 17
Steering page serial no cut Rev 17
Steering Feedback 417 17
Replacing Steering Feedback Assembly Encoder 417 17
Replacing Steering Feedback Assembly Gears 418 17
Steering Motor 420 17
Steering Motor Brushes 420 17
Replacing Steering Motor 420 17
Steering Gearbox 422 17
Replacing Steering Gearbox 422 17
Lifting Mechanism page serial no cut Rev 17
Mast 427 17
TN (Telescopic No Free Lift) Mast 427 17
TF (Telescopic Full Free Lift) Mast 427 17
TT (Triple Telescopic Full Free Lift) Mast 427 17
New Truck Assembly Procedures 427 17
To Assemble Power Unit, Mainframe and Platform and Load Handler: 428 17
Second Stage Mast Removal TF and TN 431 17
Removing Second Stage Mast TF and TN 431 17
Removing Second Stage Mast TF and TN 435 17
Removing Second and Third Stages from TT Mast Assembly 435 17
Roller Adjustment 443 17
Installing Second Stage Mast TF and TN 443 17
Installing Second Stage Mast TF and TN 445 17
Installing Second and Third Stage TT Mast 446 17
Hose Take-Up Cable 451 17
Load Wheels 453 18
Load Wheel Removal 453 18
Tire Replacement 453 18
Lathe Cutting 453 18
Lift Chains 455 18
Inspection 455 18
Lift Chain Lubrication 457 18
Lift Chain Replacement 458 18
Fork Inspection 460 18
Cylinders page serial no cut Rev 18
TF Lift Cylinders 467 18
Pivoting The Tip-Out Assembly 467 18
Primary (Free) Lift Cylinder Repair 470 18
Cylinder Packing Installation 472 18
Reassembling Mast Tip-Out 473 18
Primary (Free) Lift Cylinder Removal 474 18
Secondary (Main) Lift Cylinder Removal 475 18
Primary (Free) Lift Cylinder Installation 476 18
Secondary (Main) Lift Cylinder Installation 476 18
Lift Cylinder Bleeding 477 18
TN Lift Cylinder 478 18
Pivoting the Tip-Out Assembly 478 18
Lift Cylinder Repair 480 18
Cylinder Packing Installation 482 18
Reassembling Mast Tip-Out 482 18
Lift Cylinder Removal 483 18
Lift Cylinder Installation 484 18
Lift Cylinder Bleeding 485 18
Auxiliary Lift Cylinder 486 18
Auxiliary Lift Cylinder Repair 486 18
Rod Packing Installation 489 18
Auxiliary Lift Cylinder Bleeding 489 18
Fork Cylinders 490 18
Cylinder Disassembly 491 18
Piston Rod Disassembly 492 18
Cylinder Reassembly 492 18
Pivot Cylinders 494 19
Cylinder Removal 494 19
Cylinder Disassembly 495 19
Cylinder Reassembly 496 19
Cylinder Installation 498 19
Pivot Cylinder Bleeding 498 19
Platform page serial no cut Rev 19
Platform 501 19
Inspection and Adjustment 501 19
Lubrication 502 19
Mast Shield 503 19
Gates 504 19
GTSL & GTSR 505 19
Chain Anchor and Platform Height Adjustment 505 19
Side Thrust Roller Adjustment – Platform (TF, TN and TT Mast) 506 19
Traverse Hose Replacement 506 19
Platform Removal 508 19
Platform Assembly 511 19
Height Sensing System 519 19
Height Sensor Assembly Removal 519 19
Height Sensor Assembly Installation 520 19
Height Cable Broken Switch (HCS) 520 19
Height Sensor Assembly 521 19
Cable Replacement 521 19
Glossary page serial no cut Rev 19
Glossary 525 19
Schematic Diagrams page serial no cut Rev 19
Introduction to Diagram Usage 533 19
Schematic 533 19
Pictorials 533 19
Hydraulic Schematic page serial no cut Rev 20
Introduction 21
Introduction 23
Operator Instructions 23
Operator Training 23
Service Training 23
Replacement Parts 23
Safety 25
General Maintenance Instructions 27
Cleaning of Material Handling Equipment 29
Cleaning Methods 29
Control of Hazardous Energy 30
Lockout/Tagout 30
Battery 30
Safety Rules 30
Battery Care 30
Charging 30
Battery Removal 31
Battery Installation 31
Lockout – Tagout 31
Capacitance 32
Brake 33
Hydraulic 34
Towing Truck 35
Towing by Pulling in Power Unit First Direction 35
Towing by Pushing in Forks First Direction 36
Lifting and Blocking 38
Main Mast, Auxiliary Mast and Platform 39
Main Mast – TF & TN 39
Main Mast – TT 39
Blocking Third Stage Mast Above Second Stage Mast 39
Auxiliary Mast 40
Platform – TT 40
Height Sensor 42
Tool Fabrication 42
Spring Removal 42
Spring Installation 43
Auxiliary Mast and Platform Lifting 44
Auxiliary Mast 44
Platform 44
Planned Maintenance – Lubricants 45
Lubrication & Adjustment 49
Lubrication and Adjustment 51
General 51
Component Accessibility 51
Componentry 62
Introduction 62
Audible Indicators 63
ALM1 63
ALM2 63
HN 63
Battery 64
BATT 64
Contactors 65
ED1, ED2 65
K2 65
Encoders 67
ECR1 67
ECR2 67
ECR3 67
ECR4 67
ECR5 69
ECR6 69
ECR7 69
ECR8 69
Fuses 71
FU1 71
FU2 71
FU3 71
FU4 71
FU5 71
FU6 72
FU7 72
FU8 72
FU9 73
FU10 73
FU11 74
FU12 74
FU13 74
FU14 74
FU15 74
FU16 74
FU17 76
FU18 76
FU19 76
FU20 76
FU21 76
Lights 78
LGT1 78
LGT2 78
LGT3 78
LGT4 78
LGT5 78
LGT 6 80
LGT 7 80
LGT8 80
LGT9 80
Miscellaneous 82
BRK 82
EAC Distribution Panel 82
FAN1 82
FAN3 82
FSB1 82
FSB2 82
JC 84
P1 84
PS1 84
PS2 84
HYDRAULIC RESERVOIR 84
Modules 86
ACCESS 1 86
ACCESS 2 86
ACCESS 3 86
ACCESS 4 86
ACCESS 5 88
ACCESS 6 88
ACCESS 7 88
ACCESS 8 88
Motors 90
M1 90
M2 90
M3 90
Potentiometers 92
POT1 92
POT2 92
POT3 92
POT4 92
POT5 92
Relays 94
K1 94
Resistors 94
RES1 94
RES2 94
RES3 94
RES4 94
RES5 94
Sensors 96
CS1 96
EACA1 96
EACA2 96
EACB1 96
EACB2 96
GS1 98
GS2 98
LS 98
PDS 98
TS1 98
TS2 98
Solenoid Valves100
EML100
MVL100
PCML100
PVAL100
PVAR100
PVF1102
PVF2102
PVLH102
PVML104
PVMR104
PVP1104
PVP2104
PVT1104
PVT2104
SP1106
SVAL106
SVML106
Suppressor Blocks108
SB11108
SB31108
SB41108
Switches110
APS110
BRES110
BRS1110
BRS2110
BRS3110
BRS4110
CHS1112
CHS2112
CHS3112
CHS4112
CHS5112
CHS6112
CHS7114
CHS8114
CTS (TF Mast Only)114
DTS114
EDS114
EMS1114
EMS2116
FHSL116
FHSR116
FNS116
FPS1116
FPS2116
FPS3118
FPS4118
FPS5118
FPS6118
FPS7118
FPS8118
FPS9120
FS120
GTSL120
GTSR120
GUS120
HCS120
HGTRS1122
HGTRS2122
HNS122
HPSL122
HPSR122
KYS122
LGS1124
LGS2124
LGS3124
ORS1124
PLS124
PRS124
RGSL126
RGSR126
RS126
RSS126
SES126
SLS126
SPS128
TBS128
TDS128
TVRS128
ZSS128
Metric Torque Values130
Grade130
Torque Values133
Grade133
Hydraulic System135
General Information137
Hydraulic Lines and Fittings137
Reservoir137
Filter138
Drift Test138
Lift Drift Test138
Freezer Preparation139
Hydraulic Circuits140
Main Lift Circuit140
Main Lower Circuit141
Main Lower Circuit (MVL)142
Load Handler Circuit through Main Frame Manifold143
Auxiliary Lift Circuit144
Auxiliary Lower Circuit145
Traverse Left Circuit146
Traverse Right Circuit148
Fork Extend Circuit150
Fork Retract Circuit152
Pivot Right Circuit154
Pivot Left Circuit156
Hydraulic Schematic Symbols158
Hydraulic Pump162
Pump Replacement162
Initial Start Up Procedure163
Manifold164
Relief Valve (RV1)164
Proportional Valves164
Manifold Block O-Ring Replacement165
Hydraulic Motor167
Preparation Before Disassembly167
Tools and Materials Required for Servicing167
Disassembly and Inspection169
Reassembly176
Final Checks183
Drive Unit185
Drive Unit187
Drive Tire Replacement187
Lathe Cutting188
Drive Unit Lubrication189
Drive Unit Removal189
Drive Unit Installation190
Drive Motor Removal190
Drive Motor Installation190
Electrical System191
ACCESS 123®193
When a Malfunction Occurs193
Power Cable Connections193
Software Package Version Level193
Main Menu196
Analyzer Menus197
Input Menus198
Platform Menu200
Seat Controls Menu201
Power Unit Menu202
Outputs Menu205
Load Handler Menu206
Platform Menu or Seat Controls Menu209
Power Unit Menu210
Test Outputs Menu214
Load Handler Menu215
Platform Menu or Seat Controls Menu216
Power Unit Menu217
Calibration Menu220
Handles Menu221
Hydraulics Menu222
Pivot Sense Menu223
Main R Valve Menu224
Main L Valve225
Main HGT Sense Menu226
Aux Flow Valve Menu227
Traverse Valve Menu or Pivot Valve Menu228
Extend Valve229
Aux R Valve Menu230
Weight Sense Menu231
Aux Valve Menu232
Aux HGT Sense Menu233
Tilt Valve Menu234
Height Cutouts Menu235
Steer Encoder Menu236
Wire Guide Menu237
Calibrate Menu238
Adjust X-Offset Menu241
Features Menu242
Mast Type, Measurement, Collapsed Height , Lift Height or Traverse Frame Menu243
Fork Type Menu244
Fork Length, Pallet Width, Pallet Length or Battery Compartment Menu246
Truck Weight, Max Load or Lift Motor Menu247
Capacity Data Monitor Menu248
Wire Guidance or Manual Wire Sense Menu249
End Aisle, Battery Retainer SW or Travel Alarm Menu250
Language or User Performance Menu251
User Codes or Cold Condition Menu252
Options Menu253
Front Rail, Zone Switch, Aux Mast, Screen Setup or Save Menu255
Hour Meters Menu256
Event Codes Menu257
Performance Menu258
P1 Setup P1 Menu259
P2 Setup P2 Menu261
P3 Setup P3 Menu263
Plug, Coast, Braking or Free Range Speeds Menu265
Guided Speeds Menu266
EAC Setup Menu267
Main Hoist R or L Menu269
Aux Hoist R or L Menu270
PDS Setup Menu270
Utilities Menu272
Active Tow Mode, Shipping Mode, Truck lockout or Traverse Valve Menu273
Wire Guidance274
Operation Modes275
Manual275
Automatic275
Sensors276
Line Driver Output276
Field Strength Cross Reference Chart277
Calibration277
Troubleshooting278
End Aisle Control (EAC)279
Wire Guidance Calibration Speeds280
EAC Zones:280
Troubleshooting280
EAC Event Codes:280
Termination Point Locations281
Access 5 (EAC Distribution Module)281
Contactor282
Inspection282
Contacts282
Coil282
Component Replacement283
Contact Replacement283
Coil Replacement283
K2 Logic Power Contactor283
Battery284
Safety Rules284
Battery Care284
Charging285
Battery Removal285
Battery Installation285
Checking285
Charging286
Cleaning287
Troubleshooting288
Motor289
Event Codes290
ACCESS Module Listing:290
Some Troubleshooting Basics290
When a Malfunction Occurs290
No Event Code?290
To Locate Malfunctioning Components290
Test Points290
Power Cable Connections290
Event Codes – ACCESS 1292
Event Code 101292
ACCESS 1 module CAN error292
Event Code 104293
ACCESS 1 and ACCESS 4 module CAN error293
Event Code 105293
ACCESS 1 and ACCESS 5 module CAN error293
Event Code 106294
ACCESS 1 and ACCESS 6 module CAN error294
Event Code 107295
ACCESS 1 and ACCESS 7 module CAN error295
Event Code 108296
ACCESS 1 and ACCESS 8 module CAN error296
Event Code 112297
ACCESS 2 module software not compatible with the other modules297
Event Code 113297
ACCESS 3 module software not compatible with the other modules297
Event Code 114297
ACCESS 4 module software not compatible with the other modules297
Event Code 115297
ACCESS 5 module software not compatible with the other modules297
Event Code 116297
ACCESS 6 module software not compatible with the other modules297
Event Code 117297
ACCESS 7 module software not compatible with the other modules297
Event Code 118297
ACCESS 8 module software not compatible with the other modules297
Event Codes – ACCESS 2298
Event Code 212298
ACCESS 2 module current out of range298
Event Code 213298
ACCESS 2 module current sensor error298
Event Code 214298
ACCESS 2 module precharge error298
Event Code 215298
ACCESS 2 module below operating temperature298
Event Code 216298
ACCESS 2 module above operating temperature298
Event Code 217299
ACCESS 2 module battery voltage out of range299
Event Code 218299
ACCESS 2 module battery voltage out of range299
Event Code 221299
ACCESS 2 module low temperature cutback299
Event Code 222299
ACCESS 2 module high temperature cutback299
Event Code 223300
ACCESS 2 module under voltage cutback300
Event Code 224300
ACCESS 2 module overvoltage cutback300
Event Code 225300
ACCESS 2 module 5V supply out of range300
Event Code 228301
ACCESS 2 module hydraulic pump motor (M2) high temperature cutback301
Event Code 229301
ACCESS 2 hydraulic pump motor M2 temperature sensor TS2 error301
Event Code 231302
ACCESS 2 module high performance hydraulics fan driver shorted or open302
Event Code 232303
ACCESS 2 module horn (HN) driver shorted or open303
Event Code 233303
ACCESS 2 module SVML driver shorted or open303
Event Code 234305
ACCESS 2 module SP1 driver shorted or open305
Event Code 235306
ACCESS 2 module PVMR driver shorted or open306
Event Code 236307
ACCESS 2 module hydraulic pump motor feedback encoder (ECR8) count out of tolerance307
Event Code 237307
Pump motor open (M2)307
Event Code 246308
ACCESS 2 module defaults not loaded308
Event Code 247308
ACCESS 2 module internal fault308
Event Code 249308
ACCESS 2 module parameter change error308
Event Code 251308
ACCESS 2 module general fault308
Event Code 255308
ACCESS 2 Main Chain Slack308
Event Code 256308
ACCESS 2 Main Chain Break308
Event Code 268309
ACCESS 2 module internal fault309
Event Code 269309
ACCESS 2 module 5 V power supply out of range309
Event Code 272309
ACCESS 2 module CAN timeout309
Event Code 273310
ACCESS 2 module ECR8 hydraulic pump motor (M2) encoder count out of range310
Event Code 278310
ACCESS 2 module internal fault310
Event Codes – ACCESS 3311
Event Code 300311
ACCESS 3 module pre-charge timeout or failure to follow ACCESS 5 module ED1 and ED2 (if present) command311
Event Code 312311
ACCESS 3 module over current condition311
Event Code 313311
ACCESS 3 module traction motor (M1) current sensor fault311
Event Code 315311
ACCESS 3 module heat sink temperature less than -40 C (-40 F)311
Event Code 317 and 318311
ACCESS 3 module +BV under or over range311
Event Code 321313
ACCESS 3 module internal temperature less than -25 C (-13 F)313
Event Code 322313
ACCESS 3 has internal temperature in excess of 85 C (185 F)313
Event Code 323 and 324313
ACCESS 3 module +BV cutback313
Event Code 325314
ACCESS 3 module 5 V for ECR7 is out of range314
Event Code 326315
ACCESS 3 module pedestrian detection system (PDS) Platform Down driver pin #19 over current315
Event Code 327315
ACCESS 3 module pedestrian detection system (PDS) Quit Button driver pin #20 over current315
Event Code 328316
ACCESS 3 module traction motor (M1) temperature above acceptable range316
Event Code 329316
ACCESS 3 module traction motor (M1) temperature sensor (TS1) out of range316
Event Code 331316
ACCESS 3 module pedestrian detection system (PDS) End of Aisle driver pin #6 shorted, open316
Event Code 332317
ACCESS 3 module ED open or shorted driver317
Event Code 333317
ACCESS 3 module travel alarm (ALM2) wiring open or short317
Event Code 334318
ACCESS 3 module pedestrian detection system (PDS) In Aisle driver pin #3 shorted, open318
Event Code 336318
Traction encoder (ECR7) count error318
Event Code 337319
ACCESS 3 module traction motor (M1) open319
Event Code 346319
ACCESS 3 module default parameters not loaded319
Event Code 347319
ACCESS 3 module interlock sequence parameter setup error319
Event Code 349319
ACCESS 3 module parameter change during operation319
Event Code 351319
ACCESS 3 module parameter invalid value319
Event Code 368320
ACCESS 3 module VCM program error320
Event Code 369320
ACCESS 3 module traction encoder (ECR7) 5V out of range320
Event Code 372320
ACCESS 3 module CAN timeout320
Event Code 373321
Traction encoder (ECR7) count error321
Event Code 378321
ACCESS 3 module internal fault321
Event Codes – ACCESS 4322
Event Code 400322
ACCESS 4 or ACCESS 8 module CAN error322
Event Code 402323
ACCESS 4 or ACCESS 1 module CAN error323
Event Code 403324
ACCESS 4 or ACCESS 7 module CAN error324
Event Code 407325
ACCESS 4 or ACCESS 2 module CAN error325
Event Code 408 and 409326
ACCESS 4 or ACCESS 5 module CAN error326
Event Code 411 and 430327
ACCESS 4 module internal fault327
Event Code 436327
ACCESS 4 module seat locking solenoid over current327
Event Code 437327
ACCESS 4 module main height encoder ECR5 power supply wire open327
Event Code 438328
ACCESS 4 module main height encoder ECR5 channel CHA or CHB open328
Event Code 439328
ACCESS 4 module main height encoder ECR5 count error328
Event Code 440328
ACCESS 4 module main height encoder ECR5 reset error328
Event Code 441329
ACCESS 4 module main mast broken height sensor cable329
Event Code 442330
ACCESS 4 module main height encoder ECR5 count error330
Event Code 443330
ACCESS 4 module main height encoder ECR5 counting in reverse direction330
Event Code 444330
ACCESS 4 module cable tension slack330
Event Code 445331
ACCESS 4 module main chain slack331
Event Code 446331
ACCESS 4 module main chain break331
Event Code 447332
ACCESS 4 module main height encoder ECR5 power supply out of range332
Event Code 491 Through Event Code 499333
ACCESS 4 module internal fault333
Event Codes – ACCESS 5334
Event Code 501334
ACCESS 1 module CAN timeout334
Event Code 502335
ACCESS 5 communication (CAN) with ACCESS 2 module timeout335
Event Code 503335
ACCESS 3 module CAN timeout335
Event Code 504336
ACCESS 4 module CAN timeout336
Event Code 505336
ACCESS 5 module CAN error336
Event Code 507337
ACCESS 7 module CAN timeout337
Event Code 508337
ACCESS 8 module CAN timeout337
Event Code 509 and 510338
ACCESS 6 module CAN timeout338
Event Code 511 Through Event Code 521338
ACCESS 5 module internal event338
Event Code 522 and 523339
ACCESS 5 Module 5 V power supply out of range339
Event Code 524 and 525340
ACCESS 5 module +BV out of range340
Event Code 526 and 527340
ACCESS 5 module +BV brake voltage out of range340
Event Code 528 and 529340
ACCESS 5 module inner brake +BV out of range340
Event Code 530 and 531341
ACCESS 5 module outer brake +BV out of range341
Event Code 532 and 533342
ACCESS 5 module 5 V battery current sensor (CS1) supply out of range342
Event Code 534 and 535342
ACCESS 5 module battery current out of range342
Event Code 536343
ACCESS 5 module battery current sensor (CS1) improperly installed343
Event Code 537343
ACCESS 5 module battery current sensor (CS1) zero reading out of range343
Event Code 538 and 539343
ACCESS 5 module BDI voltage out of range343
Event Code 540344
ACCESS 5 +BV out of range344
Event Code 541344
ACCESS 5 module ED contactor failed to energize344
Event Code 542345
Open fuse345
Event Code 543346
ACCESS 5 module ED1 (ED2 if present) tips welded346
Event Code 544346
ACCESS 5 module ED turn ON error346
Event Code 545346
ACCESS 5 module ED turn OFF event346
Event Code 546 Through Event Code 550346
ACCESS 2 module or ACCESS 3 module failed ED load bus pre-charge346
Event Code 551347
ACCESS 5 module parameter error347
Event Code 552 and 553347
ACCESS 5 module parameter error347
Event Code 554347
ACCESS 5 module EAC parameter error347
Event Code 555 and 556347
ACCESS 5 module steering feedback encoder (ECR6) counts out of range347
Event Code 557348
ACCESS 5 module steering feedback encoder (ECR6) index line error348
Event Code 558 Through Event Code 561349
ACCESS 5 module steering feedback encoder (ECR6) error349
Event Code 562350
ACCESS 5 module steering system short circuit350
Event Code 563350
ACCESS 5 module ACCESS 6 communication error350
Event Code 564350
ACCESS 5 module wire guidance enable error350
Event Code 565350
ACCESS 3 and ACCESS 5 module traction sensor ECR7 error350
Event Code 566351
ACCESS 5 module End Aisle Control (EAC) enable error351
Event Code 567 Through Event Code 570352
ACCESS 5 module End Aisle Control (EAC) sensor latched ON error352
Event Code 571 and 572352
ACCESS 5 module End Aisle Control (EAC) magnet error352
Event Code 576 Through Event Code 581353
ACCESS 5 module brake current or resistance error353
Event Code 582 Through Event Code 585353
ACCESS 5 module brake current out of range353
Event Code 586 and 587354
ACCESS 5 module brake load error354
Event Code 588 and 589355
ACCESS 5 module brake supply voltage error355
Event Code 590 and 591356
ACCESS 5 module brake driver error356
Event Code 592 and 593356
ACCESS 5 module brake driver error356
Event Code 594356
ACCESS 5 PVML (proportional flow valve) load error356
Event Code 595357
ACCESS 5 module proportional flow valve (PVML) driver error357
Event Code 596357
ACCESS 5 module proportional flow valve (PVML) load error357
Event Code 597357
ACCESS 5 module proportional flow valve (PVML) driver error357
Event Codes – ACCESS 6359
Event Code 605359
ACCESS 6 module CAN timeout359
Event Code 611, 612 and 621 Through Event Code 628359
ACCESS 6 module internal module fault359
Event Code 631359
ACCESS 6 module wire guidance sensor amplifier self-test error359
Event Code 632359
ACCESS 6 module load wheel wire guidance sensor bar fault359
Event Code 633360
ACCESS 6 module steer wheel wire guidance sensor bar fault360
Event Code 636361
ACCESS 6 module allowable truck angle in relationship to guide wire has been exceeded361
Event Code 637361
ACCESS 6 module wire guidance system loss of wire signal at both sensor bars361
Event Code 638 and 639361
ACCESS 6 module wire guidance system loss of wire signal from one of the two sensor bars361
Event Code 652 Through Event Code 659362
ACCESS 6 module EAC sensor signal out of range362
Event Code 660 Through Event Code 663363
ACCESS 6 module EAC sensor digital signal error363
Event Code 664 Through Event Code 667363
ACCESS 6 module EAC magnet field strength weak363
Event Code 668 Through Event Code 671363
ACCESS 6 module EAC sensor self test error363
Event Code 672364
ACCESS 6 module multiple EAC sensors active364
Event Codes – ACCESS 7365
Event Code 700365
ACCESS 7 and ACCESS 8 module CAN timeout365
Event Code 701366
ACCESS 7 and ACCESS 4 module CAN timeout366
Event Code 702367
ACCESS 7 and ACCESS 1 module CAN timeout367
Event Code 707368
ACCESS 7 and ACCESS 2 module CAN timeout368
Event Code 708 and 709369
ACCESS 7 and ACCESS 5 module CAN timeout369
Event Code 711 Through Event Code 720370
ACCESS 7 module internal error detected during self test370
Event Code 736370
ACCESS 7 module proportional flow valve auxiliary raise (PVAR) over current370
Event Code 737371
ACCESS 7 module proportional flow valve auxiliary lower (PVAL) over current371
Event Code 738371
ACCESS 7 module proportional flow valve traverse motor (PVT1) over current371
Event Code 739372
ACCESS 7 module proportional flow valve traverse motor (PVT2) over current372
Event Code 740372
ACCESS 7 module proportional flow valve pivot (PVP1) over current372
Event Code 741373
ACCESS 7 module proportional flow valve pivot (PVP2) over current373
Event Code 742373
ACCESS 7 module proportional flow fork extend (PVF1) over current373
Event Code 743374
ACCESS 7 module proportional flow fork retract (PVF2) over current374
Event Code 744374
ACCESS 7 module auxiliary cylinder lowering solenoid valve (SVAL) over current374
Event Code 745375
ACCESS 7 module proportional flow auxiliary relief (PVLH) over current375
Event Code 746375
ACCESS 7 module proportional flow auxiliary raise (PVAR) over current375
Event Code 747 Through Event Code 749376
ACCESS 7 module internal driver short detected during self test376
Event Code 750376
ACCESS 7 module auxiliary cylinder lowering solenoid valve (SVAL) driver shorted or load open376
Event Code 751377
ACCESS 7 module proportional flow auxiliary relief (PVLH) driver shorted or load open377
Event Code 752378
ACCESS 7 module proportional flow valve auxiliary raise (PVAR) driver or load open378
Event Code 753379
ACCESS 7 module proportional flow valve auxiliary lower (PVAL) driver or load open379
Event Code 754380
ACCESS 7 module proportional flow valve traverse motor (PVT2) driver or load open380
Event Code 755381
Access 7 module proportional flow valve traverse motor (PVT1) driver or load open381
Event Code 756382
ACCESS 7 module proportional flow valve pivot (PVP1) driver or load open382
Event Code 757383
ACCESS 7 module auxiliary cylinder lowering solenoid valve (SVAL) open driver383
Event Code 758383
ACCESS 7 module proportional flow auxiliary relief (PVLH) driver open383
Event Code 759383
ACCESS 7 module proportional flow valve pivot (PVP2) driver or load open383
Event Code 760384
ACCESS 7 module proportional flow fork extend (PVF1) driver or load open384
Event Code 761385
ACCESS 7 module proportional flow fork retract (PVF2) driver or load open385
Event Code 762386
ACCESS 7 module load sense transducer (LS) open386
Event Code 763386
ACCESS 7 module load sense transducer (LS) shorted386
Event Code 764387
ACCESS 7 module pivot position potentiometer (POT5) above or below electrical limit387
Event Code 765387
ACCESS 7 module pivot potentiometer (POT5) voltage fluctuation387
Event Code 767388
ACCESS 7 module pivot potentiometer (POT5) voltage changing to quickly388
Event Code 768388
ACCESS 7 module pivot potentiometer (POT5) rotating in the wrong direction388
Event Code 769389
ACCESS 7 module pivot potentiometer (POT5) voltage changing to slowly389
Event Code 770389
ACCESS 7 module pivot potentiometer (POT5) voltage out of calibration limit389
Event Code 771390
ACCESS 7 module auxiliary height encoder (ECR3) count change with no auxiliary movement390
Event Code 772390
ACCESS 7 module auxiliary height encoder (ECR3) count in wrong direction390
Event Code 773390
ACCESS 7 module auxiliary height encoder (ECR3) CH A or CH B open390
Event Code 774391
ACCESS 7 module auxiliary height encoder (ECR3) power supply wire open391
Event Code 775391
ACCESS 7 module auxiliary height encoder (ECR3) power supply out of range391
Event Code 776392
ACCESS 7 module traverse encoder (ECR4) not counting392
Event Code 777392
ACCESS 7 module traverse encoder (ECR4) count error392
Event Code 778393
ACCESS 7 module traverse encoder (ECR4) reset switch (TVRS) did not toggle393
Event Code 779393
ACCESS 7 module traverse encoder (ECR4) count speed out of range393
Event Code 780394
ACCESS 7 module traverse encoder (ECR4) count direction incorrect394
Event Code 781395
ACCESS 7 module auxiliary lower velocity fuse trip395
Event Code 782396
ACCESS 7 module traverse encoder (ECR4) calibration out of range396
Event Code 783396
ACCESS 7 module auxiliary height encoder (ECR3) not counting396
Event Code 784397
ACCESS 7 module auxiliary height reset failed to toggle397
Event Code 785397
ACCESS 7 module auxiliary fork height encoder (ECR3) counts out of range397
Event Code 790 Through Event Code 799398
ACCESS 7 module internal fault398
Event Codes – ACCESS 8399
Event Code 800399
ACCESS 8 and ACCESS 5 module CAN time out399
Event Code 801399
ACCESS 8 and ACCESS 5 module CAN time out399
Event Code 802400
ACCESS 8 and ACCESS 1 module CAN time out400
Event Code 803401
ACCESS 8 and ACCESS 4 module CAN time out401
Event Code 804402
ACCESS 8 and ACCESS 7 module CAN time out402
Event Code 805403
ACCESS 8 and ACCESS 1 module CAN time out403
Event Code 806404
ACCESS 8 and ACCESS 4 module CAN time out404
Event Code 807405
ACCESS 8 and ACCESS 5 module CAN time out405
Event Code 816406
ACCESS 8 module internal fault406
Event Code 821406
ACCESS 8 module 5 V power supply out of regulation406
Event Code 822406
ACCESS 8 module 15 V power supply out of regulation406
Event Code 823407
ACCESS 8 module steer encoder ECR2 power supply out of regulation407
Event Code 824407
ACCESS 8 module optical switch board FS/RS power supply out of regulation407
Event Code 825408
ACCESS 8 module steer encoder ECR1 power supply out of regulation408
Event Code 836408
ACCESS 8 module traction potentiometer POT1 out of electrical limits408
Event Code 837409
ACCESS 8 module traction potentiometer POT2 out of electrical limits409
Event Code 838409
ACCESS 8 module POT3 auxiliary raise, lower potentiometer out of electrical limits409
Event Code 839410
ACCESS 8 module POT4 traverse potentiometer out of electrical limits410
Event Code 840411
ACCESS 8 module hand presence switch HPSL (left hand presence switch) or HPSR (right hand presence switch) photo diode open411
Event Code 841412
ACCESS 8 module traction potentiometer (POT1) does not match forward switch (FS)412
Event Code 842412
ACCESS 8 module traction potentiometer (POT1) does not match reverse switch (RS)412
Event Code 843413
ACCESS 8 module forward switch (FS) and reverse switch (RS) indicate both closing at the same time413
Event Code 844413
ACCESS 8 module cold condition heater driver current to high413
Event Code 845413
ACCESS 8 module left hand presence switch (HPSL) open receiver413
Event Code 846414
ACCESS 8 module right hand presence switch (HPSR) open receiver414
Event Code 847414
ACCESS 8 module steer tiller encoders (ECR1 and ECR2) turn rate error414
Event Code 848416
ACCESS 8 module ECR1 and ECR2 (steer tiller encoders) direction of rotation error416
Event Code 849417
ACCESS 8 module steer tiller encoders (ECR1 and ECR2) direction of rotation error417
Event Code 850 Through Event Code 852419
ACCESS 8 or ACCESS 5 module CAN receiving error419
Event Code 853 Through Event Code 855419
ACCESS 8 and ACCESS 6 module CAN receiving error419
Event Code 856 Through Event Code 859420
ACCESS 8 and ACCESS 1 module receiving error420
Event Code 860 Through Event Code 863420
ACCESS 8 and ACCESS 4 module CAN receiving error420
Event Code 864 Through Event Code 867421
ACCESS 8 and ACCESS 7 module CAN receiving error421
Event Code 868 and 869421
ACCESS 8 and ACCESS 5 module CAN error421
Event Code 870 and 871422
ACCESS 8 and ACCESS 6 module CAN error422
Event Code 872 Through Event Code 874423
ACCESS 8 and ACCESS 1 module CAN error423
Event Code 875 Through Event Code 877424
ACCESS 8 and ACCESS 4 module CAN error424
Event Code 878 Through Event Code 880426
ACCESS 8 and ACCESS 7 module CAN error426
Brake System427
Brake429
Brake Force Adjustment429
Torque Gap Adjustment429
Air Gap Adjustment431
Rotor and Brake Pad Replacement432
To disassemble rotor and brake pad assembly:432
Brake Assembly432
Steering435
Steering Feedback437
Replacing Steering Feedback Assembly Encoder437
Replacing Steering Feedback Assembly Gears438
Steering Motor440
Steering Motor Brushes440
Replacing Steering Motor Brushes440
Replacing Steering Motor440
Steering Gearbox442
Replacing Steering Gearbox442
Lifting Mechanism445
Mast447
TN (Telescopic No Free Lift) Mast447
TF (Telescopic Full Free Lift) Mast447
TT (Triple Telescopic Full Free Lift) Mast447
New Truck Assembly Procedures447
To Assemble Power Unit, Mainframe and Platform and Load Handler:448
Second Stage Mast Removal TF and TN451
Removing Second Stage Mast TF and TN451
(Without Sufficient Overhead Clearance)451
Removing Second Stage Mast TF and TN455
(With Sufficient Overhead Clearance)455
Removing Second and Third Stages from TT Mast Assembly455
Roller Adjustment463
Column Rollers463
Side Thrust Rollers TF and TN463
Installing Second Stage Mast TF and TN463
(Without Sufficient Overhead Clearance)463
Installing Second Stage Mast TF and TN465
(With Sufficient Overhead Clearance)465
Installing Second and Third Stage TT Mast466
2nd stage mast side thrust roller adjustment466
3rd stage mast side thrust roller adjustment467
Hose Take-Up Cable471
Load Wheels473
Load Wheel Removal473
Tire Replacement473
Lathe Cutting473
Lift Chains475
Inspection475
Wear475
Rust and Corrosion476
Cracked Plates476
Tight Joints477
Protruding or Turned Pins477
Chain Side Wear477
Unequal Chain Tension477
Non Alignment of Lifting Components477
Lift Chain Lubrication477
Lift Chain Replacement478
Chain Anchors and Pulleys479
Leaf Chain Disconnect479
Disconnect Procedures479
Fork Inspection480
Abrasion480
Blade Measurement480
Hanger Bore Measurement481
Overloading483
Fatigue483
Bent or Twisted Forks483
Hanger484
Cylinders485
TF Lift Cylinders487
Pivoting The Tip-Out Assembly487
(Accessing the Lift Cylinders)487
Primary (Free) Lift Cylinder Repair490
Cylinder Packing Installation492
Reassembling Mast Tip-Out493
Primary (Free) Lift Cylinder Removal494
Secondary (Main) Lift Cylinder Removal495
Primary (Free) Lift Cylinder Installation496
Secondary (Main) Lift Cylinder Installation496
Lift Cylinder Bleeding497
TN Lift Cylinder498
Pivoting the Tip-Out Assembly498
(Accessing the Lift Cylinder)498
Lift Cylinder Repair500
Cylinder Packing Installation502
Reassembling Mast Tip-Out502
Lift Cylinder Removal503
Lift Cylinder Installation504
Lift Cylinder Bleeding505
Auxiliary Lift Cylinder506
Auxiliary Lift Cylinder Repair506
Rod Packing Installation509
Auxiliary Lift Cylinder Bleeding509
Fork Cylinders510
Cylinder Disassembly511
Piston Rod Disassembly512
Cylinder Reassembly512
Pivot Cylinders514
Cylinder Removal514
Cylinder Disassembly515
Cylinder Reassembly516
Cylinder Installation518
Pivot Cylinder Bleeding518
Platform519
Platform521
Inspection and Adjustment521
Column Roller Area521
Overhead Guard Area521
Operator Controls521
Lower Platform Area521
Lubrication522
Mast Shield523
Gates524
GTSL & GTSR525
Gate Switches525
Chain Anchor and Platform Height Adjustment525
Side Thrust Roller Adjustment – Platform (TF, TN and TT Mast)526
Traverse Hose Replacement526
Platform Removal528
Platform Assembly531
Seat Pivot Bearing Assembly532
Seat Rotate Switch Adjustment533
Seat Coil Cord Installation534
Seat Up/Down Switch Adjustment535
Mirror Installation And Adjustment536
Mirror Adjustment538
Height Sensing System539
Height Sensor Assembly Removal539
Height Sensor Assembly Installation540
Height Cable Broken Switch (HCS)540
Height Sensor Assembly541
Encoder (ECR5)541
Cable Replacement541
Glossary543
Glossary545
Schematic Diagrams551
Introduction to Diagram Usage553
Schematic553
Pictorials553
Electrical Diagrams Index554
Platform Schematic555
Power Unit Schematic556
Platform Distribution Panel557
Platform Distribution Panel w/InfoLink558
Power Unit Distribution Panel559
Lights And Fans560
ACCESS 1 Operator Display561
Platform Chain Switches562
ACCESS 4 Vehicle Control Module563
Platform Seat Area564
Platform Floor Area565
ACCESS 3 Traction Control Module566
ACCESS 5 Steering Control Module567
Contactor Panel568
Traction Motor, ECR6, ECR7, FSB1 & Brake569
ACCESS 2 Hydraulic Control Module570
Hydraulic Motor, ECR8571
ACCESS 8 Operator Control Module572
Platform Left Armrest573
ACCESS 6 Guidance Control Module574
ECR7, FSB1, FSB2 & PDS575
ACCESS 7 Accessory Control Module576
Power Cables577
Wiring Harnesses578
Hydraulic Schematic581
Hydraulic Schematic583

IMAGES PREVIEW OF THE MANUAL:

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S.M 5/24