UT 1.

5 WE
Electric Pallet Truck
Service Manual

76502807(R0)

1
Content
1 Overview ......................................................................................................................................................................... 3
1.1 How to disassemble the covering parts ................................................................................................................. 5
1.1.1 How to disassemble the upper cover ......................................................................................................... 5
1.1.2 How to disassemble the rear cover and rear panel ..................................................................................... 5
1.1.3 How to disassemble the case cover ............................................................................................................ 6
1.2 Internal overview .......................................................................................................................................... 6
2 Electrical Components ..................................................................................................................................................... 7
2.1 Electrical systematic layout .................................................................................................................................. 7
2.2 Electrical schematic diagram ................................................................................................................................ 8
2.3 Component functions ............................................................................................................................................ 9
2.3.1 Controller ................................................................................................................................................... 9
2.3.2 Operation panel ........................................................................................................................................ 11
2.3.3 Operation handle ...................................................................................................................................... 13
2.3.4 Drive motor .............................................................................................................................................. 14
2.4 Trouble shooting ................................................................................................................................................. 14
2.4.1 Can not lift or lower ................................................................................................................................. 14
2.4.2 Cannot travel ............................................................................................................................................ 15
2.5 Controller handheld unit. .................................................................................................................................... 18
3 Maintenance of mechanical structure ............................................................................................................................ 22
3.1 How to disassemble the brake ............................................................................................................................ 22
3.2 How to disassemble the motor ............................................................................................................................ 23
3.3 How to disassemble the wheel ............................................................................................................................ 24
3.4 How to disassemble the battery .......................................................................................................................... 24
3.5 How to disassemble the handle ........................................................................................................................... 25
3.6 Adjusting length of pull connecting rod.............................................................................................................. 26
3.7 How to disassemble the load wheel .................................................................................................................... 27
3.8 Adjustment of the system pressure ..................................................................................................................... 27
3.9 Adding the hydraulic oil ..................................................................................................................................... 28

2
 1 Overview
Tiller Handle

Upper Cover

Charging Plug

Fault indicator light

Charging indication light

Hour & Charge meter (BDI)

Emergency stop switch

Load wheel
Ignition Key

Rear cover

Rear panel Frame

Balance wheel
Drive wheel

3
 Case cover

Fork
Guide wheel caster

Rocker arm
Pull Connecting rod

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 1.1 How to disassemble the covering parts
1.1.1 How to disassemble the upper cover
View after Cover Removal
1

① Loosen screw (1);

② Remove the coil (2) through the upper cover hole;

③ Push charging plug (3) inside cover through the hole;

④ Lift off the upper cover (4);

1.1.2 How to disassemble the rear cover and rear panel

View after Cover Removal
1 2

3 4

① Loosen screw (1) on each side;

② Lift off the rear cover (2);

③ Loosen two screws (3) on each side;

④ Remove the rear panel forwards;

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 1.1.3 How to disassemble the case cover

View after Cover Removal

1
2

① Loosen two screws (1) on each side;

② Lift off the case cover (2);

1.2 Internal overview

Hydraulic power unit

Charger
Controller
Battery Brake

Motor

Gear box

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2 Electrical Components
2.1 Electrical systematic layout

Item Description Item Description

1 Tiller Handle 11 Charger
2 Microswitch（handle switch） 12 Fuse （10A）
3 Drive motor 13 Fuse Bracket
4 Electromagnetic brake 14 Hydraulic pump
5 BDI Display 15 Alarm
6 Key switch 16 Cooling fan
7 LED light 17 Emergency stop switch
8 Controller 18 Microswitch（height limit switch）
9 Fuse bracket 19 Storage battery
10 Fuse （50A）

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2.2 Electrical schematic diagram

Basic Operation：
1、 Travel: The truck is energizes by pulling on the emergency stop switch and turning key switch
to-ON- position. By pressing down on the tiller handle, TILLER SWITCH (SW) closes allowing the
controller A6 port to energize； further clockwise rotation increases the acceleration, and the
controller A1 receives 0-5V analog voltage output by the accelerator. The controller power module
drive motor rotates clockwise; the motor speed is proportional to the accelerator output voltage. By
rotating the accelerator counterclockwise, the BACKWARD SWITCH (SW) closes allowing the
controller A12 port to energize and activates the brake, the motor rotates counterclockwise. The motor
speed is proportional to the accelerator output voltage.
2、 Other operations
Lift：By pressing on the lift button, the Lifting SWITCH (SW) closes allowing 28 wire to
energize, crossing the relay in the INDICATOR (INDICATOR detects the battery charge level, if
greater than 20%, the relay energizes, allowing the lift. If the battery level is less than 20%, the
relay remains open forbidding the lift) activating the drive and lift contactor KM1 to make the
hydraulic motor M2 and the pump to lift forks. At maximum lift, the Height Limit SWITCH (SW)
activates stopping the lifting of the forks.

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 Lower：By pressing on the lower button, the Lowering SWITCH (SW) closes allowing the
solenoid valve to energize and the fork lowers.
Alarm：By pressing the horn switch, the Horn SWITCH (SW) closes allowing the alarm to
energize and sound.

2.3 Component functions

2.3.1 Controller

1
1

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2

 Checks at the controller MOSFET

Step a. Use 30Ω, 5W resistance to discharge the B+, B- terminal before testing.

Step b. Outputs of the controller are as follows:

Multimeter terminal Range of normal value
Red terminal Black terminal Red terminal Black terminal
1 B+ B- Above 40KΩ
2 B+ M2 Above 80KΩ
3 B+ M1 Above 80KΩ
4 M1 M2 Above 60KΩ
5 B- M2 0.3～0.6 V
6 B- M1 0.3～0.6 V

Set the multimeter to Ω (Resistance value detection)

Set the multimeter to (Polarity value detection）
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 2.3.2 Operation panel

BDI Display Status LED

Emergency stop
switch

Key Switch

Charging
LED

 BDI Display
Battery charge level

Time
accumulation

No. Terminal function No. Terminal function

1 Debugging port 5 Negative pole
2 Key switch 6 Timing port
3 Relay 7
4 Relay 8 Positive pole
 Status LED
During normal operation, with no faults present, the status LED is steadily on. If the controller detects a fault,
the status LED flashes a 2-digit fault identification code continuously until the fault is corrected.
For example, code “1,4”—under voltage—appears as:

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 Fault codes listed（see more details in 4.4.2 troubleshooting）

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 Charging LED

Blue flash = Fault

LED instruction Red flash = No battery connected
Red on = Normal charging
Green on = Fully charged
Emergency
2.3.3 Operation handle
reverse button Accelerator
Slow button
Lift button Lift button

Lower
Lower button button

Horn

Emergency reverse button Accelerator

Wire Function
Red Positive pole 24V
Accelerator wire
Black Negative pole
Brown Emergency reverse
Lift/lower White Accelerator 0-5V
Blue Forward
Emergency Green Backward
reverse button Yellow Lift
Purple Lower
Slow button
Lift/lower Orange Slow
Horn Pink Horn

black blue green purple pink

red brown white yellow orange

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2.3.4 Drive motor

Electric brush

Commutator segment

Armature iron core

Main pole

Basic performance of motor

Model Z130D650-24A1-26.5S Electric strength 660V/S
Rated voltage 24VDC Insulation grade F
Rated power 650W IP grade IP44
Rated current 38A Service environment -10-+40
temperature
Rated RPM 2650 rpm Noise <60dB(L=100cm)
Rated torque 2.34N.m
Current, unload <5A
RPM, unload 3100 rpm Motor wiring
Work system S2(45min)
Insulation resistance >20MΩ
Carbon brush lifetime 1200h

2.4 Trouble shooting

2.4.1 Can not lift or lower
Check the following: lift switch, power meter, height limit switch, lift contactor; or lower
solenoid valve and oil line according to 2.3 electrical schematic diagram (Basic Operation page 8).
 Can not Lift
After closing the lift switch, the voltage between 28 wire and B- should be 24V（If not
the switch could be damaged or the wire could be broken），the voltage between 28# wire
and B- should be 24V（if not, the power meter could be damaged or the battery voltage is
too low），the voltage between 28A wire and B- should be 24V（if not, the height limit
switch could be damaged or the wire could be broken），the voltage between the two motor
terminals should be 24V(if not, the contactor could be damaged)，or the motor could be
damaged or the oil line could have issues.

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  Can not Lower
After closing the lower switch, the voltage between 29# wire and B- is 24V（if not, the
switch could be damaged or the wire could be broken），the electromagnet actuates（if not,
the electromagnetic coil could be damaged），or the oil/oil line could have issues.

If there is electricity in the battery

2.4.2 Cannot travel

Check if the input signal is normal (use

programmer or voltmeter) such as：
TILLER SW, accelerator signal,

Input and external

device, the output
is abnormal.
BACKWARD
Normal flash type

Controller
fault
If the motor is normal

If the wiring is Related

normal component
If it flashes normally

fault
If other devices
are normal
The truck cannot travel

Check LED light for

Use the programmer to check fault cause

Fault flash type

Trouble shooting
fault flashes

Check the fault code corresponding to the

LED light flash compared to the use
instruction
If off, connect the programmer

Check input
signal of the Normal Controller fault
No
key switch
display
Abnormal Key switch or fuse fault

Display Controller or wiring fault

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  FAULT CODES;
 1,1 THERMAL FAULT  1,2 THROTTLE FAULT
Over-/under-temperature cutback Pot Low and/or Pot Wiper out of range
a. Temperature >80°C or < -10°C. a. Throttle input wire open or has a short.
b. Excessive load on vehicle. b. Throttle pot defective.
c. Operation in extreme environments. c. Wrong throttle type selected.
d. Electromagnetic brake not releasing  Refer to fault 3,5 Test methods.
 Check the controller temperature, if it is out of range let cool. After
cooling the truck and temperature is normal but still fault exists,  3,1 WIRING FAULT
could be the controller temperature sensor is damaged, replace the HPD fault present >10 sec.
controller. a. Mis-adjusted throttle.
b. Broken throttle pot or throttle mechanism.
 1,4 UNDERVOLTAGE FAULT  Refer to fault 3,5 Test methods.
Battery voltage too low
a. Battery voltage <17 volts.
 3,2 BRAKE ON FAULT
b. Bad connection at battery or controller.
Brake On fault
a. Electromagnetic brake driver has a short.
A. Measure the battery voltage B. Measure controller B+/B-voltage
b. Electromagnetic brake coil is open.

C. Measure control circuit10# and B- voltage

 If A is abnormal, charge or replace the
battery.
 If B is abnormal, check if 50A fuse、
emergency stop switch and wiring is
normal.
 If C is abnormal, check if 10A fuse、
key switch、charger interlock switch
and wiring is normal.
 1,5 OVERVOLTAGE FAULT
Battery voltage too high
a. Battery voltage >31 volts.
b. Vehicle operating with charger attached.
c. Intermittent battery connection.
 Refer to fault 1,4 Test methods.
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 Set the multimeter to Ω(resistance value
measurement)，measure C1/C2 resistance,it
should be about 31±5Ω, if greater, means the
brake or wire has an open circuit, if less than,
means the brake or wire has a short circuit.
 3,3 PRECHARGE FAULT
Precharge fault
a. Brake driver has a short.
b. Precharge circuit damaged.
c. MOSFET failure.
 The detection method refers to
2.3.1“controller MOSFET Outputs”
 3,4 BRAKE OFF FAULT
Brake Off fault
a. Electromagnetic brake driver open.
b. Electromagnetic brake coil has a short.
 Refer to 3.2 Troubleshooting method
  3,5 HPD FAULT
 4,1 CURRENT SENSE FAULT
HPD (High Pedal Disable)
Current sense out of range
a. Improper sequence of throttle and KSI,
a. Short in motor or in motor wiring.
push, or inhibit inputs.
b. Controller failure. ★
b. Mis-adjusted throttle pot.
 The normal starting sequence：
 4,2 HARDWARE FAIL SAFE
1、Key 2、TILLER SW 3、Throttle
Motor voltage out of range
 With handle is upright, the voltage between A6 and B- is 0±5V
(a1)
a. Motor voltage does not correspond to throttle request.
b. Short in motor or in motor wiring.
c. Controller failure. ★
 First check if the motor wires or other parts has a short
circuit or bonding, if the wires are normal, replace the
motor, the multimeter cannot measure the short circuit of
the motor.
(a2) Press down the handle, the voltage between A6 and B- is 24±3V

 4,3 EEPROM CHECKSUM FAULT

EEPROM fault
a. EEPROM failure or fault.
 Replace the controller.

 4,4 MOTOR OPEN 

(b1) Not rotating the accelerator, the voltage between A1 and B- is 0V、
Motor open fault the voltage between A12 and B- is 0V.
a. Motor wiring is open.

Set the multimeter to Ω(resistance
value measurement)，measure
M1/M2 resistance, it should be
about 0±0.5Ω, if greater, means
the motor has an open circuit、the (b2) Rotating the accelerator, the voltage between A1 and B- is 5±
carbon brush could be damaged or 0.5V、the voltage between A12 and B- is 24±3V.
the wires could be broken.

4,5 BATTERY DISCONNECT FAULT

Battery disconnected
a. Battery not connected.
b. Poor connection to battery terminals.
 Refer to fault 1.4 detection methods.

★ Jack up vehicle and retest to confirm diagnosis.

Clean connections, inspect system wiring, and retest.

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2.5 Controller handheld unit.

Model 1313
Handheld Programmer

Connect the handheld programmer

into the control system by plugging it
into the controller’s charger / program-
mer port.
The programmer automatically
powers up, and displays this screen
while it loads information from the
controller.

Once the programmer has uploaded

the information from the controller, it
displays the Main Menu.
If the controller is not turned on when
the programmer is connected, you can
power up the programmer by pressing
the Power key; the message “No System
detected” will be displayed.

 General functions.

In the Main Menu, highlight the

System Info icon and press the
“Select” soft key to go to the System
Info menu. You can return to the
Main Menu by pressing the Main

18 Menu key
 The System Info menu opens directly to a
detail screen providing information about
the motor controller to which the pro-
grammer is connected:

In the Main Menu, highlight the

Parameters icon and press the “Select”
soft key to go to the Parameters menu.
You can return to the Main Menu at any
time by pressing the Main Menu key

.
The Parameters menu is likely to be
the menu you use most. This is where you
can adjust the settings of the control
system’s adjustable parameters.
You navigate through this complex
menu using the arrow keys, +/- keys, and
Soft keys

With some “+\-” parameters, the item

can be expanded to show a bar graph
indicating where the setting lies within the
available range.
Here is a parameter called Forward
Max, as it first appears

And here it is expanded, by pressing

the right-arrow key

Note that the “+\-” symbol is repeated
on this screen, to remind you of the type of
item this is.

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 In the Main Menu, highlight the Monitor
icon and press the “Select” soft key to go to
the Monitor menu. You can return to the
Main Menu at any time by pressing the

Main Menu key

The Monitor menu provides real-time
data from the control system, especially
useful in testing and troubleshooting.

Monitor the status of the input and

output signal of the controller in the
Monitor menu, convenient to user when
faults occur and avoid using the
multimeter.

In the Main Menu, highlight the

Diagnostics icon and press the “Select” soft
key to go to the Monitor menu. You can
return to the Main Menu at any time by

pressing the Main Menu key

The Diagnostics menu contains two

folders: Present Errors and Fault History.
Note: Sometimes the fault circuits catch
a temporary event that is not a true fault in
the system; it is always a good idea to turn
the control system off and back on again to
see whether the fault clears itself.

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 Present Errors folder
All existing faults are listed here, in
chronological order. An item in this folder
can only be removed by remedying the
fault. As long as the fault exists, it will be
included in the Present Errors folder. The
“1/3” in the upper right corner of the screen
indicates that Missing Contactor is the first
of three present faults.

Fault History folder

This folder lists all the faults
encountered since the Fault History was
last cleared. You can clear the entire
contents of this folder to allow a fresh
Fault History to be started.

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 3 Maintenance of mechanical structure
3.1 How to disassemble the brake

3
2

After removing the rear cover and rear panel, Turn the brake on Unplug the connector and take off the brake (2)，
the steering gear outward，loosen three screws (1) in the Pic. e, remove the snap ring (3) with tools.

Remove the flat key (5) to complete the whole disassembly. Remove the spline gear (4).
Reassemble using instructions in opposite direction.

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 3.2 How to disassemble the motor 2

After removing the rear cover and rear After removing the brake as above,
panel, Remove the motor wiring (1). loosen the four lock screws (2).

4
5
6
3
7

Remove the snap ring(4) on the motor shaft, and Turn the motor on the steering gear
remove gear (5), oil retainer (6) and O-ring (7). outwards, remove the motor slowly.

Lastly, remove the flat key (8) to complete the

disassembly of the motor. Reassemble using
instructions in opposite direction.

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 3.3 How to disassemble the wheel

After removing the rear cover and rear

panel, turn the drive wheel outwards. Reassemble using instructions in opposite direction.
Loosen five screws (1), the truck won’t
turn over because of the balance wheels.
Remove the wheel.

3.4 How to disassemble the battery

After removing the upper cover and the Notice: FIRST disconnecting the negative pole wires.
case cover, just loosen screw (1) on each Disconnect the wires on the battery terminal (2) with the
side, do not remove screws. spanner wrench, (4) in total.

Remove the battery (3) from the frame. Reassemble using

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instructions in opposite direction.
 3.5 How to disassemble the handle

2
1

Locate the handle wiring harness connector, Unplug (2) wiring harness.
loosen lock nut (1).

4
3
5

Lower the handle (5), remove clamp (4) Turn the steering gear as shown in the Pic., loosen
from the frame. two screws (3).

Notice：during the disassembly

6
of the handle, align the oil
cylinder gap plane (6) and
handle plane (7).

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 3.6 Adjusting length of pull connecting rod.

Remove the snap ring (1) between the pull rod Remove the pin roll (2) from
and rocker arm. the mounting hole.

3
4 5

With the truck stable, the minium clearance between point

(4) of the wheel stand and the lower surface of the fork Adjust the length of the pull rod by rotating the rod
should be larger than 1 mm after adjustment. end(3). To Reduce the length turn clockwise.

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 3.7 How to disassemble the load wheel

2
1

Remove pin roll (2).

Remove two spring pins (1).

Remove load wheel (3)，the disassembly and assembly of the

single wheel and double wheels are basically same.
3.8 Adjustment of the system pressure

2
1

Adjust the screw (2) with hexagon spanner wrench, to increase

After removing the upper cover, locate the relief valve cover
the pressure turn clockwise. NOTE: Max. pressure is 115% of
(1) of the hydraulic power unit and remove.
the rated capacity, replace & tighten the relief valve cover (1 )
after adjusting pressure.
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 3.9 Adding the hydraulic oil

After removing the upper cover, locate the Check fluid level and add the hydraulic fluid to the tank, as
hydraulic tank cover (1). required. Check fluid level using dip stick (2). Do not fill
past Max. fluid level marked on gauge (2).

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 UTILEV TECHNICAL PUBLICATIONS

“UTILEV” is a registered trademark. THE UTILITY LIFT TRUCK and UTILITY YOU CAN TRUST are trademarks
in the United States and certain other jurisdictions.

P/N 76502807 08/2016

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