Download Atlet Forklift A-Ergo Service Manual (D003936)

Service Manual A-Ergo — D003936, C, GBR, Translated

01 General information and technical data

01

GENERAL INFORMATION AND TECHNICAL DATA 2013B

1.1

Introduction 1.1.1 1.1.2 1.1.3 1.1.4

1.2

1.3

1.5

1.6

5

We respect the environment.............................................................................................. 5

6

1.4.1 1.4.2

Service............................................................................................................................... 6 Trouble shooting ................................................................................................................ 6

Data

6

1.5.1 1.5.2 1.5.3

Designations...................................................................................................................... 6 Dimensions and weights.................................................................................................... 9 Component specification ................................................................................................. 10

Recommended consumable materials

11

Oil and grease types.........................................................................................................11

Standards and abbreviations 1.7.1 1.7.2 1.7.3 1.7.4 1.7.5 1.7.6

A-Ergo

General.............................................................................................................................. 4 Truck modification.............................................................................................................. 4 Lifting the truck .................................................................................................................. 5 Welding on the truck.......................................................................................................... 5

Preparations

1.6.1

1.7

4

Environmental considerations 1.3.1

1.4

General.............................................................................................................................. 3 The trucks.......................................................................................................................... 3 Structure of the Manual ..................................................................................................... 3 Symbol key ........................................................................................................................ 3

Safety 1.2.1 1.2.2 1.2.3 1.2.4

3

12

Screws............................................................................................................................. 12 Standard abbreviations and units .................................................................................... 13 Screw types and tensile grades....................................................................................... 14 Colour coding according to NCS ..................................................................................... 14 Colour codes for wiring diagrams .................................................................................... 15 Designations for electrical components........................................................................... 15

1

Service Manual A-Ergo — D003936, C, GBR, Translated

01 General information and technical data

2

A-Ergo

Service Manual A-Ergo — D003936, C, GBR, Translated

01 General information and technical data

01

GENERAL INFORMATION AND TECHNICAL DATA

1.1

Introduction

1.1.1

General This manual describes the service procedures for UniCarriers A-Ergo series standing stackers. Use the manual for quick and correct service of respective truck models.

The Manual describes models manufactured from and including the introduction of A-Ergo at the end of 2002.

You may find contradictions in this Manual compared to the models supplied due to special design features, upgrades, and other detail differences.

The electrical system must never be rewired in any form after delivery without written authorisation from UniCarriers since this may change the measured and applicable EMC. The content of this Manual is protected by copyright law and may not be copied, fully or in part, without written permission. The material has undergone careful examination with regard to correctness. Subject to alteration.

In the event of inconsistent information in the Swedish and translated editions, it is the Swedish edition that applies.

Modifications and updates will be distributed via UniCarriers Service Manual Change.

1.1.2

The trucks Stand-on stacker fork lift trucks in the A-Ergo series are available in a number of different variants with mast systems, adjustable straddle legs, fold-out stabilizers and telescopic forks (ATF).

1.1.3

Structure of the Manual The manual is built up according to the same principles as ATLET spare parts catalogues, with the truck divided into one subsystem per section.

Chapters 1 - 3 in this Manual contain more general information regarding technical data, service instructions and tools.

Sections 4-12 in this Manual each contain information limited to a specific area in the truck in respect of descriptions of the mechanical handling of the different components. For example Masts (section 6) and the Hydraulic system (section 8).

The software is described in section 10.

The main principle for extra accessories is to place them in their respective Chapters.

Otherwise they are placed in section 12 "Miscellaneous". For this reason section is not always included in the Service Manual.

For specific problems or information about procedures, look in the main index for the correct section in the manual.

1.1.4

Symbol key WARNING! Used for risk of personal injury.

CAUTION! Used with the risk of damage to the machine.

NOTE! Used for general observation.

A-Ergo

3

Service Manual A-Ergo — D003936, C, GBR, Translated

01 General information and technical data

1.2

Safety

1.2.1

General Extreme importance must be placed on precautionary measures to avoid accidents during all work on the vehicle.

A general rule is to always implement preventive measures that are adapted to the type of vehicle to be worked on. The general rules below must always be observed: • • • • • •

•

Local fire directives should always be followed.

Smoking or naked flames are strictly forbidden as there is a risk of explosion in the vicinity of batteries and while working on gas equipped vehicles.

The battery should always be protected during grinding work.

The drive wheel must always be lifted up free from the floor during service work to prevent the vehicle from moving.

Before working on the electrical system, the battery plug must be pulled out When working on or close by the electrical system, all metal objects such as watches and rings should be taken off. A short-circuit from such objects can result in serious burn injuries.

To prevent injuries caused by crushing the battery plug should always be removed when working on and around the mast and hydraulic unit. The mast or hydraulic unit can be actuated and move due to an electrical fault or a mistake while working. The battery plug may only be connected while trouble shooting, while taking great care (with the truck raised).

WARNING! Having the power connected to the truck while working on and around the mast can lead to fatal injury!

• •

•

1.2.2

When working on and around lifting devices and the hydraulic unit, they must be locked by using the mast lock, wooden blocks or some other appropriate means.

No other persons should be in the vicinity of the truck when it is test run in conjunction with repair work, in view of the risk of accidents or near-accidents from the truck making an unexpected manoeuvre.

The system should not be pressurised, e.g. the pump motor shut off and the forks down, when dismantling parts of the hydraulic system.

Truck modification NOTE! Unauthorized truck modification is not permitted.

No modifications or alterations to a powered industrial fork lift truck, which may affect, for example, the capacity, stability or safety requirements of the truck, shall be made without the prior written approval of the truck manufacturer, its authorized representative, or a successor thereof. Contact an authorized dealer before making any modification or alteration to your industrial truck that may affect, for example braking, steering, visibility and the addition of removable attachments. After obtaining approval from the truck manufacturer, its authorized representative, or a successor thereof, the capacity plate, decals, labels and operation and maintenance handbooks shall also be changed appropriately.

Only in the event that the truck manufacturer is no longer in business and there is no successor in the interest to the business, the user may arrange for a modification or alteration to a powered industrial truck, provided, however, that the user shall:

4

A-Ergo

Service Manual A-Ergo — D003936, C, GBR, Translated

01 General information and technical data

• • • •

1.2.3

Arrange for the modification or alteration to be designed, tested and implemented by an engineer(s) expert in industrial trucks and their safety; Maintain a permanent record of the design, test(s) and implementation of the modification or alteration; Approve measures and in an equivalent manner make appropriate changes to the capacity plate(s), decals, labels and Instruction Handbooks.

Affix a permanent and readily visible label to the truck stating the manner in which the truck has been modified or altered together with the date of the modification or alteration, and the name and address of the organization that accomplished the tasks.

Lifting the truck Inspection and preparation • When the truck is lifted using a jack, make sure you secure it with blocks. The truck must not rest on the jack, while work is carried out.

• Ensure that straps, wires or chains have a sufficient lifting capacity before lifting the truck.

• Ensure that the drive wheel runs free of the floor before trouble shooting.

Lifting points

Figure 1. Permitted A-Ergo lifting points

The illustration shows where the permitted lifting points are located on the truck. The lifting points are marked with a decal representing a lifting hook; the lifting holes in the outer mast must be used.

WARNING! The machine must never be lifted from the driver’s protection frame.

1.2.4

Welding on the truck •

•

During welding work the battery plug must always be disconnected and all connections to the control units and controllers (applies to all electronic units) disconnected. On completion of welding work the connectors must first be connected to the electronic units, after which the battery plug is then connected to the battery.

The welding ground connection must always be connected as close to the welding area as possible to eliminate damage to surrounding components.

1.3

Environmental considerations

1.3.1

We respect the environment The majority of our products consist of steel, and can be completely recycled.

A-Ergo

5

Service Manual A-Ergo — D003936, C, GBR, Translated

01 General information and technical data

Environmental impact All products have an impact on the environment throughout their entire life cycle.

The consumption of energy when in use is one of the most important factors that influences the environment.

Through correct care, maintenance and use the consumption of energy can be reduced, thereby reducing the environmental impact.

Waste Waste material in conjunction with repairs, maintenance, cleaning, or scrapping, must be collected and disposed of in an environment-friendly way and in accordance with the directives of respective countries.

Such work should only be carried out in areas intended for this purpose.

Recyclable material should be taken care of by specialised authorities.

Environmentally hazardous waste, such as oil filters, hydraulic oil, batteries and electronic equipment, can, if handled incorrectly, have a negative effect on the environment and human health.

1.4

Preparations

1.4.1

Service •

Go through all the safety instructions.

• •

Make sure that you have all the essential tools close at hand before starting work.

Before wiring or other electrical components are disconnected, check the colour codes and check for any damage to the wiring or connections.

When complex components are repaired and dismantled, make sure that you keep track of the different component parts to avoid the risk of confusion.

When repairing or maintaining sensitive components, make sure that you use clean tools and work on a clean work surface.

Dismantle, inspect and adjust components according to the prescribed routines. Refer to the respective Chapters for detailed information.

• • •

1.4.2

Trouble shooting When you suspect that a component is defective, do not replace it immediately. First check the surrounding equipment and carry out complete trouble shooting routines. Make sure you know the reason for the fault before replacing a component.

1.5

Data

1.5.1

Designations

1.5.1.1

Truck designation Table 1. Truck designations Truck Type

Load capacity

6

A-Ergo

Standard standing stacker

A-Ergo TF

Standing stacker with telescopic forks

A-Ergo

1600 or alternatively 2000 kg

A-Ergo TF

1000 kg

A-Ergo

Service Manual A-Ergo — D003936, C, GBR, Translated

01 General information and technical data

1.5.1.2

Type designation

Figure 2. Example of type plate (–2006w36) 1.

2.

Model designation.

Type Series no./Version (S=Special ver.).

3.

4.

A-Ergo

Year of manufacture, week, and warranty period in months (only Sweden). (On the assumption that the service instructions in the warranty regulations are followed).

Where appropriate, load limitations depending on the position of the load on the forks (D) and/or lifting height (Q).

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Service Manual A-Ergo — D003936, C, GBR, Translated

01 General information and technical data

Figure 3. Example of type plate (2006w37-) 1.

2.

Model designation.

Type Series no./Version (S=Special ver.).

3.

4.

Year of manufacture, week, and warranty period in months (only Sweden). (On the assumption that the service instructions in the warranty regulations are followed).

Where appropriate, load limitations depending on the position of the load on the forks (D) and/or lifting height (Q).

NOTE! If the machine plate is lost or becomes illegible, it must be replaced as soon as possible. In order to identify the serial number of the machine there is a label placed on each principal component, such as the traction motor, gearbox, hydraulic unit, TMC, etc. On some machines there is also a label glued inside the battery space or the serial number is punched on the side of the mast.

8

A-Ergo

Service Manual A-Ergo — D003936, C, GBR, Translated

01 General information and technical data

Figure 4. Example of a serial number label.

1.5.1.3

Explanation of Model designation Example: A 160 S DTF V S 360 225 40 Truck Type

A

Load capacity/10

160

Narrow gauge

S

Broad gauge

B

Telescopic mast

T

Telescopic mast, Free-lift

TF

Double telescopic mast

DT

Double telescopic mast, Free-lift

DTF

Free-view mast

V

Stabilizers

S

Vertically adjustable straddle legs

H

S

DTF

V S

Lifting height in cm

360

Battery Ah/5

225

Charger Ampere

40

1.5.2

Dimensions and weights

1.5.2.1

Dimensions

Figure 5. Positions for dimensions A-Ergo

A-Ergo

9

Service Manual A-Ergo — D003936, C, GBR, Translated

01 General information and technical data

Figure 6. Positions for dimensions A-Ergo TF

1.5.3

Component specification Table 2. Component specification Component Traction motor

Specification Drive voltage

16 V

Output standard

2.2/2.4 kW S2 60 min

Gearbox Hydraulic system

Hydraulic unit (motor and pump)

Control system for traction motor

Control system for steering wheel

Fuses

Insulation resistance

>24 kΩ

Gear ratio (standard)

16,95:1

Oil volume

1.5 litre

Max pressure

17,5 MPa (=175 kp/cm²)

Oil volume

max 19 litre

Type Output 1

3.5 kW

Type Output 2

4.5 kW

Type Output 3

7.6 kW

Type Zapi AC1

AC Transistor

Voltage

24 V

Max. current

250A (RMS) for 2 min

Type Zapi AC1

AC Transistor

Voltage

24 V

Max. current

70 A

Control fuses 2 pcs.

7.5 A 30,0 A

10

Pump motor fuse 1

250 A

Traction motor fuse 1

160 A

A-Ergo

Service Manual A-Ergo — D003936, C, GBR, Translated

01 General information and technical data

1.6

Recommended consumable materials

1.6.1

Oil and grease types The table below shows the lubricants which are used in production and are recommended for servicing. They have been carefully selected and are suitable for, among other things: • • •

extending the life of the products reducing electrical consumption having the greatest respect for the environment

If the recommended lubricants cannot be obtained, alternative lubricants must comply with the stated classifications. Bear in mind that it is important to follow the Atlet requirements for environmentally-friendly oils for the guarantee to be valid.

Biodegradable-classified oils have a poor conductive ability and therefore require that both the oil and the filter are well grounded to the chassis. If secure grounding is not present, this can cause problems, such as static discharge through the oil. If this takes place the oil becomes black (due to the build-up of sediment) and must be changed to prevent jamming of the hydraulic valves. We currently have grounding of all the truck models that may be affected by this problem. It is important that different products and brands are not mixed, particularly synthetic and mineral oils.

Refer to the purchasing documentation for more information about the products.

CAUTION! Never mix different lubricants, and definitely not synthetic oil with mineral oil!

Product

Brand name and type Part no.

Class

Standard

Mobil DTE 10 Exel

107173

ISO VG 46, viscosity index 150 or greater.

Cold store

Mobil Univis HVI 26

008936

ISO VG 26, viscosity index 300 or greater, (Liquid temperature, -40°C or better).

Biodegradable oil

Mobil EAL Hydraulic 32 014160

Hydraulic oil

SS 15 54 34.

CAUTION! The guarantee only applies if the truck is delivered with this oil from the factory, as this oil cannot be mixed with other types of oil.

Oil for the food industry Mobil DTE FM 32

014161

NSF H1.

CAUTION! The guarantee only applies if the truck is delivered with this oil from the factory, as this oil cannot be mixed with other types of oil.

Gearbox oil Drive unit, all models Standard

A-Ergo

Mobilube HD-A 85w-90 116444

Class GL5, 85W-90.

For ZF drive units the oil must be approved in the ZF list of TE-ML 17B lubricants.

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Service Manual A-Ergo — D003936, C, GBR, Translated

01 General information and technical data

Product

Brand name and type Part no.

Class

Cold store

Mobile Devac synthetic 116447 Gear Oil 75W-90

Class GL5, 75W-90. For ZF drive units the oil must be approved in the ZF list of TE-ML 17B lubricants.

Standard/Cold stores

Molykote G-4501

014163 180 kg

Fully synthetic, lithium complex, NLGI grade 1.5. viscosity 220.

-40°C till +180°C.

Standard

Mobilux EP 2

001197 0.4 kg tube

-20°C to +110°C.

Cold store

Molykote G-4501

014164 0.4 kg tube

-40°C to +180°C.

Grease, ball bearings

SKF grease

001207

Grease for bearings.

High performance grease

Molycote, Multilube

014165 0.4 kg tube

Good load capability, water-resistant.

Electronics grease; electrical system. Only for cold stores.

Kryotox El 2

124525 30 g tube

Tool for tube, part no. 110782.

Electrical grease specification.

-50°C to +270°C.

Tectyl/Dinitrol

014162

No specification.

Chain spray

001196

No specification.

Electronics spray

001198

No specification.

Lubrication spray

001195

No specification.

Degreasing compound

112268

No specification.

Biodegradable oil Grease

Miscellaneous Rust protection

1.7

Standards and abbreviations

1.7.1

Screws

1.7.1.1

Tightening torques for screws and nuts Table 3. Tensile grade DIM

4,6 Nm

8,8 Nm

10,9 Nm

12,9 Nm

M4

1,1

2,9

4,0

4,9

M5

2,2

5,7

8,1

9,7

M6

3,7

9,8

14

17

M8

8,9

24

33

40

M10

17

47

65

79

M12

30

81

114

136

M14

48

128

181

217

M16

74

197

277

333

M18

103

275

386

463

M20

144

385

541

649

The tightening torques in the table are standard values. In some cases a specific tightening torque is specified in the respective Chapter. If no tightening torque is specified in the service instructions, the values shown in the table apply.

12

A-Ergo

Service Manual A-Ergo — D003936, C, GBR, Translated

01 General information and technical data

CAUTION! The above-mentioned tightening torques do not apply to screws tightened in plastic. Only tighten hand-tight so as not to damage the truck.

1.7.1.2

Tightening torques for hydraulic couplings Table 4. Pipe thread/metric threads DIM

Whitworth pipe thread MA (Nm) with pipe olive

MA (Nm) with elastic

M10 x 1

G 1/8"

25

10

30

20

M12 x 1.5 M14 x 1.5

G 1/4"

50

30

M16 x 1.5

G 3/8"

80

35

90

40

130

50

M22 x 1.5

150

60

M26 x 1.5

250

70

250

80

250

90

350

140

400

140

M18 x 1.5 M20 x 1.5

M27 x 1.5

G 1/2"

G 3/4"

M27 x 2 G 1" M33 x 2 M42 x 2

G 11/4"

600

240

M48 x 2

G 11/2"

800

300

NOTE! Other bolts and screws are to be tightened to the torques stated in this Chapter.

1.7.1.3

1.7.2

A-Ergo

Conversion table for tightening torques Newton metres (Nm)

Kilopond metre (kpm)

Pound force inch (lbg x in)

Pound force foot (lbf x ft)

1

0,10

8,85

0,74

9,81

1

86,80

7,23

0,11

0,01

1

0,08

1,36

0,14

12,00

1

Standard abbreviations and units Magnitude

Unit

Designations

Current

Ampere

A

Voltage

Volt

V

Resistance

Ohm

Ω

Output

Watt

W

Torque

Newton metre

Nm

Pressure

Pascal

Pa

-

Kilo (=1000)

k

-

Mega (=1 000 000)

M

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Service Manual A-Ergo — D003936, C, GBR, Translated

01 General information and technical data

1.7.3

Screw types and tensile grades Screw type

Description

Tensile grade

M6S

Hexagon screw

8,8 10,9

MC6S

Hexagon hole screw

8,8 10,9 12,9

MF6S

Hexagon hole screw, countersunk

10,9

MCS

Slotted screw

4,6

MVBF

Oval head countersunk screw

4,6

Markings with the manufacturer’s trademark, including the tensile grade, is compulsory for screws with a thread diameter from 5 mm and in tensile grades according to the table above.

Marking only takes place when the shape of the product permits this.

NOTE! Other screw heads and types exist, but they have no general tightening torques based on the tensile grade.

1.7.4

14

Colour coding according to NCS Machine colour

Designations

Yellow

NCS 0070-Y20R

Medium grey

NCS 7000

Dark grey

NCS 8000

A-Ergo

Service Manual A-Ergo — D003936, C, GBR, Translated

01 General information and technical data

1.7.5

Colour codes for wiring diagrams The colour markings of all cables included in the truck can be seen in the Atlet wiring diagrams. The abbreviations have the following significance: Code

Cable colour

BE

Beige

BL

Blue

BN

Brown

GN

Green

GR

Grey

OR

Orange

P

Pink

R

Red

SB

Black

VO

Violet

W

White

Y

Yellow

NOTE! Two-colour cables are shown with both colour codes separated by a slash.

Example: Blue/yellow cable is defined by colour code BL/Y.

1.7.6

Designations for electrical components Electrical components normally have a designation of two letters: Table 5. First letter

A-Ergo

Code

Description

Designation (Eng)

A

Component or function without its own letter in the list

Component or function without its own letter below

D

Diod

Diode

E

Elektronikkomponent

Electrical component

F

Säkring

Fuse

I

Indikator

Indicator

K

Kontaktor/relä

Contactor/relay

L

Lamp

Light

M

Motor

Motor

P

Plug

Plug

R

Relay

Relay

S

Switch

Switch/Change-over switch

T

Terminalanslutning

Terminal

V

Ventil/broms

Valve/brake

W

Ljudvarning/lampor/ljus

Audible warning unit/lamps/lights

15

Service Manual A-Ergo — D003936, C, GBR, Translated

01 General information and technical data

Table 6. Second letter Code

Description

Designation (Eng)

B

Brake Assembly

Brake

C

Kontrollsystem

Control system

E

Nödfunktion

Emergency function

F

Framåt

Forward

H

Tidsenhet

Hour

K

Nyckel

Key

L

Lower

Lower

M

Manöver

Manoeuvre

P

Pump

Pump

R

Reverse

Reverse

S

Speed

Speed

Example SL = Switch for Lowering function

16

A-Ergo

SERVICE MANUAL Machine:

A-Ergo

Manual No:

005975

Edition 2004A

2 Special tools Special tools A-Ergo ...................................................................................................... 2.3 Introduction .......................................................................................................... 2.3 List of tools .......................................................................................................... 2.3 Hand terminal ................................................................................................................. 2.3 Cleaning fluid .................................................................................................................. 2.4 Dismantling tool, buttons and lamps .............................................................................. 2.4 Crimping tool .................................................................................................................. 2.4 Lifting eye ....................................................................................................................... 2.4

ATLET SERVICE MANUAL A-ERGO

2.2

/ /

ATLET SERVICE MANUAL A-ERGO

Special tools / Special tools A-Ergo / Introduction

2.3

Edition 2004A

2 Special tools Special tools A-Ergo Introduction All special tools can be ordered from Atlet AB.

List of tools Hand terminal

Table 2.1 Hand terminal, programming tool Designation Hand terminal Zapi steering regulators

Part number

Applications

104 400

Programming tool for the control units for the drive motor and steering

1 PARAM.

IMAX BRAKING ACCEL. MAX SP. S.P.I S.P.II BYPASS

2 TESTER 3 SAVE 4 RESTORE

B.RECERSE COMPENS. R.BRAKE SPEED I SPEED II SPEED III FIELD WEAK..

I MOT V.POT. TEMP V.BATT V.MOT VMN.MOT. M.SW.TEST

5 ALARMS 6 ACCELERATOR 7 MOTOR DATA

1

3

5

ROLL ROLL

ENTER OUT

SET SET

2

4

6

10_003_SM_A-ERGO.eps

Figure 2.1 Hand terminal Zapi steering regulators, see section 10 for how they are used

SMA-Ergo_02_2004A.fm

ATLET SERVICE MANUAL A-ERGO

2.4

Special tools / Special tools A-Ergo / List of tools

Cleaning fluid

Table 2.2 Cleaning fluid, electronics Designation Cleaning fluid

Part number P/N 112268

Applications Cleaning of electric motors to counteract gearbox oil and other dirt

Dismantling tool, buttons and lamps

Table 2.3 Dismantling tool, buttons and lamps Designation Check nut extractor

Part number P/N 103 885

Applications Tool for releasing check nuts on lamps and buttons

Kontramutterdragare.eps

Figure 2.2 Check nut extractor

Crimping tool Table 2.4 Crimping tool Designation

Part number

Applications

Crimping tool Molex

P/N 006454

Cable connections

Pin extractor

P/N 006456

Cable connector

Lifting eye Table 2.5 Lifting eye Designation Lifting eye

Part number P/N 104737

Applications Lifting eye for drive unit.

For detailed information on the above products, please contact Atlet.

ATLET SERVICE MANUAL A-ERGO

Service Manual A-Ergo — D003936, B, GBR, Translated

03 Service

03 3.1

SERVICE Routine periodic maintenance 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8 3.1.9 3.1.10

3.2

A-Ergo

23

Introduction...................................................................................................................... 23 Safety .............................................................................................................................. 23 Recommendation ............................................................................................................ 23 Daily inspection ............................................................................................................... 23 Weekly inspection (30 hours of operation) ...................................................................... 23 Service , 500 hours interval ............................................................................................. 23 First service ..................................................................................................................... 24 Check list, service inspection .......................................................................................... 24 Code explanation............................................................................................................. 27 Lubrication chart ............................................................................................................. 30

Specific instructions

33

3.2.1 3.2.2 3.2.3 3.2.4

General............................................................................................................................ 33 Storage of machines and motors..................................................................................... 33 Traction motor.................................................................................................................. 33 Gearbox........................................................................................................................... 33

3.2.5 3.2.6 3.2.7 3.2.8 3.2.9

Lift chains and forks......................................................................................................... 33 Overhead guard............................................................................................................... 34 Mast................................................................................................................................. 34 Hydraulic oil ..................................................................................................................... 35 Recommended replacement ........................................................................................... 35

21

Service Manual A-Ergo — D003936, B, GBR, Translated

03 Service

22

A-Ergo

Service Manual A-Ergo — D003936, B, GBR, Translated

03 Service

03

SERVICE

3.1

Routine periodic maintenance

3.1.1

Introduction Service should be carried out regularly four times a year with normal truck usage, namely 1,000 operating hours per year. The planned service includes operations such as test driving, function tests, and the changing of filters and oils etc. Service is planned at different intervals depending on the running time of the truck. When the truck is working in extreme conditions or in demanding environments, servicing can be planned at tighter intervals.

3.1.2

Safety NOTE! Check under each separate section which safety instructions are applicable for work on the truck.

Inspection of the external functions in the power steering system should be carried out after every service and after work carried out in the electrical system. All functional tests of the safety system must be carried out with the truck speed controller in its neutral position, see Section 10, page 139.

3.1.3

Recommendation Information on what the truck owner should take into consideration.

Regular inspection should be carried out by specially appointed and trained personnel with a good working knowledge of the function and maintenance of the truck. To obtain the best results from your investment in your truck we advise you to contact your local Atlet representative and to sign up for a service contract for regular inspection.

3.1.4

Daily inspection For instructions, refer to the Operator´s Manual

3.1.5

Weekly inspection (30 hours of operation) For instructions, refer to the Operator´s Manual

3.1.6

Service , 500 hours interval Responsibility: The supervisor Refer to EN 1726 or ISO 3691 A Service is carried out by Atlet or by specially trained personnel. Servicing is normally carried out after 500 hours of operation, or every 6 months, however the working conditions and use must be taken into account when determining the service interval. A Service consists of a check of the entire truck with emphasis on both personal safety and operational safety. A service interval of 250 hours is recommended for trucks operating in cold stores.

• • • • • • • • •

A-Ergo

Comprehensive functional checks on the manoeuvring controls.

Check of the horn.

Test drive backwards and forwards, and turning.

Check of the drive unit.

Check the wheels Test of the brake function.

Check oil levels and for oil leakage.

Check of the hydraulic unit, pipes and hoses.

Check of the cylinders.

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Service Manual A-Ergo — D003936, B, GBR, Translated

03 Service • • • • • • • •

Function test, lifting and lowering.

Lubrication in accordance with lubrication chart.

Measurement and check of the battery and charging function.

Oil and filter change according to instructions.

Check for damage to the chassis.

Check of attachments and joints.

Check of damage to welds.

Check of the forks.

(See Section 3.1.8, page 24)

3.1.7

First service The first service must be carried out after 200 hours of use. For instructions, see Section 3.2, page 33.

3.1.8

Check list, service inspection For further information about procedures for inspections, repairs and replacements refer to respective sections. Planned service inspections are implemented in accordance with the following points: Chassis Inspection points

Symptom

Inspection

Service code

Signs/Decals

None, illegible

Visual

1024, 1101

Doors, panels

Attachment, damage

Visual, tools

1005, 1102, 1032

Overhead guard

Attachment

Visual, tools

1035

Deformation, cracks, other damage

Visual, tools

Damage, wear

Visual

Noise

Listen, tool

Attachment

Visual, tools

Damage, security, lubrication *

Visual, tools

1014, 1013 *

Rubber mats, compartments

Damage

Visual

1105, 1058

Attachment

Visual, tools

Chassis, general

Appearance

Visual

Damage

Visual

Loose screws

Tools

Rail wheel

Battery stops Battery rollers

1051, 1108

Battery locking

1033, 1112

* See Section 3.1.10, page 30.

Mast Inspection points

Symptom

Inspection

Service code

Lift chains**

Chain tensioning

By hand

2008

Lubrication *

Visual, tools

Damage, chain

Visual

Damage, chain bolt and Visual chain bolt mounting

24

A-Ergo

Service Manual A-Ergo — D003936, B, GBR, Translated

03 Service

Mast Inspection points

Symptom

Inspection

Service code

Forks**

Cracks

Visual

2026, 2107

Wear

Visual

Angle

Visual

Cracks/Weld damage

Visual, tools

Mast damping

Operating test

Lubrication *

Visual, tools

Play, damage, wear on rollers

Visual, tools, operating test

Angle, parallel deformation

Visual

Attachment rollers

Visual, tools

Cracks/Weld damage

Visual, tools

Wear, damage

Visual

Link system, bar

Locking, damage

Visual, tools

TF chains

Chain tensioning

Visual

TF forks

Locking, damage

Visual

Angle gear

Oil level

Visual, tools

Leakage

Visual, tools

Functionality

Visual, tools

Stabilizers

Functionality

Visual

Stabiliser cylinders

Functionality

Visual

Spring assembly, stabiliser cylinders

Lubrication

Visual

Mast

Fork carriage

2101, 2103

2007, 2004 2033

* See Section 3.1.10, page 30. ** Fork tests and chain tests must be carried out at least every 1,000 operating hours, see Section 06, page 61.

Drive unit Inspection points

Symptom

Inspection

Service code

Gearbox* Drive shaft, Pinion

Oil level

Visual, filling

3101, 3006, 3104, 3106

Noise

Listen, tool

Oil leakage

Visual, tools

Function, noise

Listen, tool

Cable connections

Visual, tools

Noise

Listen

Damage, wear

Visual

Attachments

Visual, tools

Noise, lubrication *

Listen, lubricate

Traction motor Drive wheel

Sliding bearing

7027, 7112, 7104 3005, 3102, 3002

3103

* See Section 3.1.10, page 30.

A-Ergo

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Service Manual A-Ergo — D003936, B, GBR, Translated

03 Service

Steering Inspection points

Symptom

Inspection

Service code

Gear

Noise

Listen, lubricate

4009

Servo motor

Attachments

Visual, tools

4014

Steering servo unit

Attachments

Visual, tools

4014

Visual, tools

4013

Steering wheel/stepping Attachments motor sensor Damage, wear

Visual, function test, tools Brake Assembly

Inspection points

Symptom

Inspection

Service code

Braking force *

Malfunction

Function test, tools

5012

Braking effect

Braking distance

Measure, tool

Parking brake

Malfunction

Function test, tools

5014

Brake discs

Wear

Visual, tools

5104

* See also Section 11, page 191 .

Hydraulic system Inspection points

Symptom

Inspection

Service code

Hydralic tank

Oil level

Visual, filling

6012, 6102

Damage, leakage, contamination

Visual, cleaning

Air, oil filter blocked *

Visual, replace

Functionality

Function test, stop watch

Damage

Visual, replace

Leakage

Visual, tools, replace

Cracks/Weld damage

Visual, tools, replace

Damage, chain attachments

Visual, tools

Leakage, damage

Visual, tools

Attachment

Visual, tools

Nipples

Leakage

Visual, tools

Pump motor

Function, noise

Listen, tool

Cable connections

Visual, tools

Leakage

Visual, tools

Damage

Visual, tools

Noise

Listen

Malfunction

Test of lever function

Malfunction

Calibration of levers

Leakage

Visual, tools

Cylinders

Hoses

Hydraulic pump

Proportional valve, on/off valve

6017, 6001

6106 6019

6109

6009

*Change the filter every 1,000 operating hours or when necessary (if it is dirty) For more information regarding the hydraulic system, see also Section 08, page 99 and Section 09, page 129.

26

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Service Manual A-Ergo — D003936, B, GBR, Translated

03 Service

Electrical system Inspection points

Symptom

Inspection

Cables, switch

Damage, operating faults

Visual, tools, replace

Contactors

Malfunction

Visual, tools, replace

Cable break

Visual, tools

Contactor tip

Visual, tools

Charging fault

Tools

Low acid level

Tools

Low acid weight

Tools

Damage

Visual

Low capacity after charging

Tools, DC voltmeter

Battery plug, operating fault

Function test, tools

AC Controller

Cable break

Visual, tools

7025

Cabling

Damage, break

Visual, tools

7104

Horn

Malfunction

Function test

7014

Speed control and brake Attachments pedal Malfunction

Visual, tools

7106

Malfunction

Calibration

Level selector

Malfunction

Function test

7034

Speed switch

Malfunction

Function test

7035

Fuses

Blown

Visual, measure, replace

7103

Battery plug

Malfunction

Visual, contact surfaces 7008

Video camera

Attachments

Visual, tools

Damage

Visual

Malfunction

Function test, tools

Battery

3.1.9

Service code

7107

7032

Function test

7037

Code explanation Table 9. Chassis Chassis Code

A-Ergo

Description

Check

Reference

1005

Doors

Bolts must be tightened.

Section 01, page 1

1013

Battery locking

Attachment and locking function

Section 04, page 37

1024

Machine plate/Warning decals

Attachment: text must correspond with machine type, and symbols and warning decals must and legible.

Section 01, page 1

1032

Panels

Attached with screws and clips, as well as bonded parts.

Section 04, page 37

1033

Colour

Paint scrapes and attachment/missing decals. Section 01, page 1

1035

Overhead guard

Cracks in welded joints, collision damage, tightening of screws

Section 01, page 1 and Section 04, page 37

1051

Rail wheel

Wheel wear, dirt

Section 04, page 37

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Service Manual A-Ergo — D003936, B, GBR, Translated

03 Service

Chassis Code

Description

Check

Reference

1058

Rubber strips

Attached with glue or screws.

-

1107

Seat

Settings, tilt function, load, angle adjustment, secure attachment to chassis.

Section 04, page 37

1108

Load wheel bearing The operation is frictionless, remove any string, plastic bands etc. that have stuck.

Section 04, page 37

1112

Accessories

-

User Manual, areometer and battery water bottle.

Table 10. Mast Mast Code

Description

Check

Reference

2004

Mast/ chassis attachment

Chassis to mast bolts

Section 06, page 61

2007

Rollers in fork carriage

Washers. Lubrication of roller surfaces.

Section 06, page 61

2008

Lift chains

Evenly tensioned, bolts locked, rust, wear, chain pulley wheels locked.

Section 06, page 61

2026

Forks

Cracks, damage, parallelism and locking devices.

Section 06, page 61

2033

Side Shift

Attachment to fork carriage

2101

Mast play

Check maximum play. Lubricate slide surfaces. Section 06, page 61

2103

Mast rollers

Washers, lubrication of roller surfaces

Section 06, page 61

Table 11. Drive unit Drive unit Code

28

Description

Check

Reference

3002

Drive wheel

Damage, wear. Clean.

Section 05, page 47

3005

Drive wheel bolt

Attachment, tightening torque.

Section 01, page 1

3006

Oil leakage

Leakage from shafts, joints, plugs or material.

Section 05, page 47

3101

Oil level

Oil level. Oil change.

Section 01, page 1 and Section 05, page 47

3102

Noise

Gears, nut tightening.

Section 01, page 1

3103

Sliding bearing

Noise, lubrication needed.

Section 01, page 1

3104

Drive shaft

Tightening of nuts.,.

Section 01, page 1 and Section 05, page 47

3106

Gears

Gear ratio

Section 01, page 1

A-Ergo

Service Manual A-Ergo — D003936, B, GBR, Translated

03 Service

Table 12. Steering Steering Code

Description

Check

Reference

4004

Gear drive

Play, lubrication.

Section 01, page 1

4009

Gear wheel

Shaft locking, lubrication

Section 01, page 1

4013

Mini-wheel

Attachment, rotation

Section 07, page 93

4014

Servo motor

Attachment

Section 07, page 93

Table 13. Brake unit Brake unit Code

Description

Check

Reference

5012

Braking force

Braking distance

Section 11, page 191

5014

Parking brake

Function, cable connections.

Section 11, page 191

5104

Brake discs

Friction surface greater than minimum level all round.

Section 11, page 191

Table 14. Hydraulic system Hydraulic system Code

Description

Check

Reference

6001

Lift cylinders

Leakage at attachments, welded joints, wiper seals, piston rod.

Section 09, page 129

6009

Hydraulic valve

Leakage between sections, connections

Section 08, page 99

6012

Oil level in tank

Oil level between min. and max.

Section 03, page 21

6017

Lowering

Check lowering speed.

Section 01, page 1

6019

Nipples

Leakage.

-

6102

Filter

Replacement necessary.

Section 08, page 99

6106

Hoses

Cracks, wear, damage

Section 01, page 1

6109

Hydraulic pump

Leakage between pump and motor.

-

6111

Accessories

Leakage from connections

Section 08, page 99

Table 15. Electrical system Electrical system Code

A-Ergo

Description

Check

Reference

7008

Battery connections That cable connections are not overheating.

Remove oxide.

Section 10, page 139

7012

Hour meter

Section 10, page 139

Read off the display

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Service Manual A-Ergo — D003936, B, GBR, Translated

03 Service

Electrical system Code

Description

Check

Reference

7014

Horn

Operation.

Section 10, page 139

7017

Microswitch

Operation.

Section 10, page 139

7025

Transistor system

Dirt, moisture. Cable connections. Oxidation.

Section 10, page 139

7027

Drive motor, bearings

Noise

Section 10, page 139

7030

Pump motor

Attachment. Cleaning.

Section 10, page 139

7032

Battery

Acid level, charging. Note: read-off from hydrometer, clean if necessary.

Section 10, page 139

7034

Level selector

Check the switch attachment, location and function.

Section 10, page 139

7035

Speed switch

Switches in mast, fork carriage, forks in respect Section 10, page of creep speed 139

7037

Video equipment

Check the operation and attachment of the camera and monitor. Check for damage and stretching of the wiring in the mast.

Section 10, page 139

7101

Contactors

Contact surfaces, cable connections, dust guard. Remove the contact strips if they are burnt.

Section 10, page 139

7103

Fuses

That they are not brittle, oxidised.

Section 10, page 139

7104

Cabling

Cable connections, attachment, run free from sharp edges. Insulation.

Section 10, page 139

7106

Speed Controller

Attachment and function.

Section 10, page 139

7112

Traction motor cables

Attachment, damage. Insulation. Oxidation.

Cleaning.

Section 10, page 139

7202

Keyboard

Mounting, damage, readability

Section 10, page 139

7203

Display

Attachment, damage

Section 10, page 139

3.1.10

Lubrication chart

3.1.10.1

A-Ergo NOTE! For recommended oil and grease types, see Section 1.6, page 11.

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A-Ergo

Service Manual A-Ergo — D003936, B, GBR, Translated

03 Service

Figure 9. Lubrication schedule for A-Ergo.

For symbol key, see Table 17, page 32.

Service on an Atlet truck can be divided into service that must be carried out regardless of how heavily the truck is loaded and used (see Section 3.1.8, page 24) and an annual recurrent service: 1.

2.

500 h service Annual service Location

Explanation

Locatio n

Explanation

A

Mast section - roller surfaces and slide E surfaces

Thrust rollers - all

B

Lift chains, all

F

Chain pulley, shaft

C

Fork carriage - support rollers

G

Hydraulic oil, filter

D

Bogie – axle (unloaded)

H

Gearbox oil

CAUTION! All torsion springs in the machine should be lubricated during each service.

A-Ergo

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Service Manual A-Ergo — D003936, B, GBR, Translated

03 Service 3.1.10.2

Supplementary lubrication schedule for telescopic forks (TF)

Figure 10. Supplementary lubrication schedule for TF.

For symbol key, see Table 17, page 32.

Table 16. Supplementary components requiring lubrication, TF Location

3.1.10.3

Explanation

Location

Explanation

I

Fork carriage - support rollers

K

Chains Fork driving

J

Forks, rollers, slide surfaces

L

Angle gear

Symbol key, lubrication chart Table 17. Symbols in the lubrication chart Symbol

Explanation

Symbol

Explanation

Hydraulic oil

Hydraulic oil, oil filter and air filter, change

Gearbox oil

Gearbox oil, change

Grease

Chain spray

Chain spray/oil

Only cold store version

Applicable in general for the symbols: • •

32

Unfilled symbol: Check/lubricate Filled symbol: Replacement

A-Ergo

Service Manual A-Ergo — D003936, B, GBR, Translated

03 Service

3.2

Specific instructions

3.2.1

General NOTE! For recommended oil and grease types, see Section 1.6, page 11.

3.2.2

Storage of machines and motors Machines in storage that will not to be used within one month, must be given special attention so that problems do not occur when they are to be used again. Dust, dirt, condensation and moisture caused by large changes in temperature and problems with rust and oxidisation must be prevented. Motors should therefore be protected with waxed paper or the like, and a moisture absorbing material.

3.2.3

Traction motor Preventive maintenance Preventive maintenance is implemented at the recommended intervals in accordance with the service chart.

In some cases, however, exceptions must be made and the intervals shortened in relation to the conditions at the customer, e.g. a severe environment with dust, high humidity levels, or salt, etc.

• •

•

3.2.4

Listen for abnormal noise from the bearings while the motor is running. Check that it does not vibrate abnormally.

The motor is blown clean with dry compressed air, or cleaned with a vacuum cleaner. If oil has leaked from the gearbox into the motor, a special cleaning fluid must be used to drive out oil and dirt, see Section 02, page 17. Finally, blow dry with compressed air.

Check the insulation resistance of the motor, see Section 1.5.3, page 10 for the correct value.

Gearbox First service After about 200 hours of operation: • •

The first oil change should be made after approx. 200 hours.

Top up with the recommended type of oil, see Section 1.6, page 11.

Preventive maintenance • The oil level is checked during each service.

• The guide bearing must be greased at least once a year. New greasing is essential if steam cleaning or high-pressure washing has been carried out.

NOTE! Remember to fill up the gearbox after changing the oil or changing the gearbox. Se Section 05, page 47 for the procedure.

NOTE! Spent oil should be taken care of and recycled according to the applicable legislation in respective countries.

3.2.5

Lift chains and forks Check For safety reasons the forks and all lifting chains should be checked during each service.

A-Ergo

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Service Manual A-Ergo — D003936, B, GBR, Translated

03 Service If a lifting chain fails to be approved in any respect, the complete chain must be replaced and it is not permitted to replace single parts of a lifting chain.

NOTE! If the lifting chain is not up to standard at any point, the complete chain must be replaced. See Section 06, page 61 for instructions concerning the checking of chains and forks.

Regular maintenance The chain should be kept clean.

Lubricant (see Section 3.1.8, page 24) must be regularly applied on the chain so that all the working surfaces are constantly lubricated.

The chains must be kept in motion when lubricating to ensure that the lubricant penetrates the working surfaces between the link plates and pins. All excess lubricant must be wiped off, but solvent must not be used.

If the chain runs dry it should be lubricated more often, and this also applies if the truck is working in special environments such as cold stores, etc.

3.2.6

Overhead guard

3.2.6.1

First service 1)

The screws securing the overhead guard to the chassis are to be retightened as part of the first service.

2)

Torque The tightening torque for securing the overhead guard to the chassis must be 81 Nm.

3.2.7

Mast

3.2.7.1

First service 1)

2)

34

The attachments between the mast and chassis must be retightened as part of the first service, after 200 hours. On Senior trucks, the senior spacers must also be retightened.

See Figure 11, page 35.

Torque The tightening torque between the mast and the machine housing, and for the senior spacers, must be 277 Nm.

A-Ergo

Service Manual A-Ergo — D003936, B, GBR, Translated

03 Service

Figure 11. Locations of the bolts securing the mast to the chassis.

3.2.8

Hydraulic oil NOTE! For recommended oil and grease types, see Section 1.6, page 11.

First service • Oil filters must be changed after hours.

Intervals After 500 hours of operation: The hydraulic oil filter and air filter to the hydraulic oil tank should be changed after no more than 500 hours of operation. This refers to those types of trucks that have replaceable filters. Clean the suction filter.

After every 1000 hours of operation: Change the hydraulic oil, oil filter and air filter after 1000 hours of operation, or once every year (which ever comes is first).

If the hydraulic oil has been heated over 60 degrees Celsius the oil and the filter should be immediately changed since its lubricating properties will have been altered.

If the hydraulic oil has been contaminated with water (e.g. from cold store) this can be detected in that the oil becomes milky, or smells bad.

It can also be checked with the following simple test: WARNING! Risk for burn injuries on the skin.

1.

2.

Use protective glasses, gloves and clothes, and observe the fire instructions for the premises.

Take a little hydraulic oil in a teaspoon and heat the spoon with, for example, a cigarette lighter – if there is a crackling sound this proves that it contains water and must be changed.

The hydraulic oil must be filtered when filling, by pouring the oil through the filter.

3.2.9

Recommended replacement Hydraulic hoses should be replaced after 5 years, since the rubber in the hose is perishable.

A-Ergo

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Service Manual A-Ergo — D003936, B, GBR, Translated

03 Service

36

A-Ergo

Service Manual A-Ergo — D003936, B, GBR, Translated

04 Chassis

04

CHASSIS

4.1

Design and function 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7

4.2

A-Ergo

39

Scope .............................................................................................................................. 39 Machine housing ............................................................................................................. 39 Overhead guard............................................................................................................... 39 Armrest and steering wheel panel ................................................................................... 39 Covers and panels........................................................................................................... 39 Foot plate......................................................................................................................... 39 Castor wheel.................................................................................................................... 40

Repair and maintenance instructions

40

4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7

Overhead guard............................................................................................................... 40 Armrest ............................................................................................................................ 41 Steering wheel panel ....................................................................................................... 42 Covers and panels........................................................................................................... 43 Foot plate......................................................................................................................... 43 castor wheel .................................................................................................................... 43 Adjusting the angle of the truck ....................................................................................... 44

4.2.8 4.2.9

Battery ............................................................................................................................. 45 Fitting the antistatic chain ................................................................................................ 45

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Service Manual A-Ergo — D003936, B, GBR, Translated

04 Chassis

38

A-Ergo

Service Manual A-Ergo — D003936, B, GBR, Translated

04 Chassis

04

CHASSIS

4.1

Design and function

4.1.1

Scope A chassis normally includes the supporting parts of a construction and in the case of a truck the chassis consists of the machine housing, panels and caster wheel.

The straddle lift and load wheel could be considered to be part of the chassis, but since they are part of the mast the instructions for these are to be found in Section 06, page 61.

4.1.2

Machine housing The chassis on A-Ergo trucks consists of a machine housing, which is available in different versions depending on the battery size.

The machine housing is where all the truck components, such as the mast, drive unit and hydraulic system are mounted, and therefore this is the most basic component in the truck.

The construction of the machine housing is prepared to take different sizes of battery. In cases where larger batteries are used, spacers are fitted between the machine housing and the mast (see Figure 12, page 39).

Figure 12. Machine housing prepared for a large battery

4.1.3

Overhead guard Driver protection consists of an overhead grille mounted on two stanchions. The grille is designed to provide good upwards visibility.

The structure is dimensioned to cope with loads in accordance with the applicable standards.

4.1.4

Armrest and steering wheel panel The function of the armrest is to provide an ergonomic posture for the driver. The armrest, together with the steering wheel panel, can be adjusted upwards and downwards in order to suit different drivers.

4.1.5

Covers and panels The function of the panels is to protect the driver from moving parts, electrical components, oils and fluids, and to protect the components inside from external damage and dirtying.

4.1.6

Foot plate The foot plate supports a soft mat and a brake pedal (see Section 11, page 191). The foot plate covers the castor wheel attachment.

A-Ergo

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Service Manual A-Ergo — D003936, B, GBR, Translated

04 Chassis

4.1.7

Castor wheel The castor wheel functions as a support wheel for the drive wheel, since the drive wheel is mounted asymmetrically on one side of the truck.

The castor wheel is a completely separate and free-turning wheel placed under the driver. It consists of a double-wheel mounted in a wheel fork. Between and at the sides of the wheel there are spacer washers, which have the purpose of guiding the wheel to the correct position in the wheel fork.

Shims are fitted between the castor wheel attachment plate and the machine housing to compensate for any difference in the diameters of the drive wheel and castor wheel.

CAUTION! When the drive wheel becomes worn, the shims between the castor wheel and the machine housing must be removed. This is done to counteract the entire truck leaning sideways, or the drive wheel spinning. Check the number of shims when replacing the drive wheel.

4.2

Repair and maintenance instructions

4.2.1

Overhead guard

4.2.1.1

Removing the overhead guard 1)

Remove the panel from the cab (5 screws).

Figure 13. Securing of the panel in the cab

4.2.1.2

2)

Secure a lifting strop to the overhead grille and take its weight from the truck.

3)

Remove the screws securing the machine housing to the overhead guard stanchions.

4)

Lift off the overhead guard.

Installing the overhead guard 1)

2) 3)

40

Torque Bolt the overhead guard to the stanchions. The tightening torque is 109 Nm. Secure a lifting strop to the overhead grille and lift it into place.

Torque Fit the screws securing the machine housing to the overhead guard stanchions. The tightening torque is 109 Nm.

A-Ergo

Service Manual A-Ergo — D003936, B, GBR, Translated

04 Chassis

Production week

Screw quality

Screw identification

Tightening torque Important comments

-2009w35

8.8

Bright zinc-coated

81 Nm

2009w36-

12.9

Black, “12.9” stamped into the screw head

109 Nm

4.2.2

Armrest

4.2.2.1

Removing the armrest

12.9 quality screws must be lubricated with special graphite grease.

See Section 2.1, page 19.

1)

Slacken the height adjustment wing nut.

2)

Remove the height adjustment knob from beneath the writing surface.

3)

Pull up the armrest so that the locking screw for the right hand bracket can be removed.

Figure 14. Armrest front securing screw

4)

Lift up the armrest and detach all the wiring at the connectors.

5)

Continue lifting the armrest so that the locking screw on the left bracket can be removed.

Figure 15. Armrest lifted up

A-Ergo

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Service Manual A-Ergo — D003936, B, GBR, Translated

04 Chassis

Figure 16. Armrest rear securing screw

6)

4.2.2.2

Lift off the panel.

Installing the armrest 1)

Align the left side guide rail into its track.

2)

Tighten the locking screw.

3)

Connect the connectors.

4)

Align the right side guide rail and gas spring into their tracks.

5)

Push the panel down so that the right side locking screw can be fitted.

6)

Push the panel down and lock it in the desired position.

4.2.3

Steering wheel panel

4.2.3.1

Removing the steering wheel panel 1)

Slacken the height adjustment wing nut.

2)

Lift the steering wheel panel up as far as possible, and lock it in place using the wing nut.

3)

Open the machine cover.

4)

Disconnect all the wiring to the components on the steering wheel panel.

5)

Slacken the inner guide rail locking knob.

Figure 17. Steering wheel panel locking knob

42

A-Ergo

Service Manual A-Ergo — D003936, B, GBR, Translated

04 Chassis 6)

4.2.3.2

Slacken the height adjustment wing nut and lift off the steering wheel panel.

Installing the steering wheel panel 1)

Hold the machine cover open during the whole installation procedure.

2)

Align the guide rails with their tracks.

3)

Tighten the locking screws when the panel is in its uppermost position.

4)

Connect the connectors.

5)

Close the machine cover.

6)

Push the panel down and lock it in the desired position.

4.2.4

Covers and panels

4.2.4.1

Removing the machine housing cover.

1)

Remove the panel from the cab.

2)

Slacken the height adjustment wing nut on the steering wheel panel.

3)

Lift the steering wheel panel up as far as possible, and lock it in place using the wing nut.

4)

Open the machine cover.

5)

Use an Allen key to hold the socket head cap screw in the hinge still, and unscrew the lock nut.

6)

Remove the screw from the hinge and lift the cover down.

4.2.5

Foot plate

4.2.5.1

Removing the foot plate 1)

Bend back the 4 pieces of the mat that cover the securing screws, to gain access to them.

Figure 18. Removing the foot plate

2)

Remove the screws and lift up the foot plate.

3)

Disconnect the brake pedal electrical connector.

4.2.6

castor wheel

4.2.6.1

Removing the castor wheel 1)

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Check that the battery is pushed in and locked.

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Service Manual A-Ergo — D003936, B, GBR, Translated

04 Chassis 2)

Remove the foot plate, see Section 4.2.5.1, page 43.

3)

Position the truck on a pallet (check that it is balanced properly).

4)

Loosen the bolts to the swivel wheel, and remove them.

WARNING! Pinch risk!

5)

4.2.6.2

4.2.6.3

4.2.6.4

4.2.7

Pull out the castor wheel.

Fitting the castor wheel 1)

Put the castor wheel under the truck (which is resting on a pallet).

2)

Lift up the wheel and place the shims in position.

3)

Torque Insert the bolts and tighten to 81 Nm.

4)

Lower the truck down to the floor.

5)

Check if the truck is leaning over, see Section 4.2.7, page 44.

Dismantling the castor wheel 1)

Remove the castor wheel from the truck, see Section 4.2.6.1, page 43.

2)

Brace the complete castor wheel in a vice by gripping the opposite side of the wheel fork where the clamping pin is fitted.

3)

Tap out the retaining pin and drive out the shaft.

4)

Lift out the castor wheel from the wheel fork; keep the spacers in a safe place.

5)

Remove the bearings from the castor wheel by using a bearing puller.

Assembling the castor wheel 1)

Use a mandrel to press the bearings into the castor wheel.

2)

The shaft is lubricated with oil before fitting.

3)

Insert the castor wheel with the spacers into the wheel fork.

4)

Check that the hole for the retaining pin in the shaft is aligned with the hole on the wheel fork.

5)

Carefully tap the shaft into place by using a hammer and a suitable mandrel.

6)

Insert the retaining pin.

7)

Turn the castor wheel and check that it rotates freely.

8)

Fit the castor wheel into the truck, see Section 4.2.6.2, page 44.

Adjusting the angle of the truck The angle of the truck can be adjusted by shimming the castor wheel.

1)

Place the truck on a level surface.

2)

Check if the truck is leaning over.

• •

44

or 1: hold a spirit level to the side of the mast and check whether the mast and truck is leaning to one side. or 2: measure with a ruler, on both sides of the truck, the distances from the floor to the truck machine housing.

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Service Manual A-Ergo — D003936, B, GBR, Translated

04 Chassis 3)

If realignment is necessary, remove the castor wheel in accordance with Section 4.2.6.1, page 43.

4)

Add or remove shims. Shims are available in several different dimensions.

5)

Fit the castor wheel, see Section 4.2.6.2, page 44, and check the measurements.

4.2.8

Battery

4.2.8.1

Battery replacement WARNING! Observe care to avoid splashing waste acid or oxide from the battery.

1)

Separate the battery plug.

2)

Lift up the battery lock.

Figure 19. Battery lock

4.2.8.2

4.2.9

3)

Roll the battery out on to the charging/storage structure.

4)

Roll in the new battery.

5)

Lock the battery in place with the battery lock and put back the battery plug.

Replacing the battery rollers 1)

Remove the battery.

2)

The battery rollers are loose in their attachments. Lift up the rollers in the back edge, and pull backwards and upwards.

Fitting the antistatic chain In some applications customers can experience disturbances in the truck operation due to large static electricity build up in the machine. One way to limit the negative effects of this can be to fit a metal chain dragging on the floor to improve potential equalisation of the truck.

See the illustration for the recommended installation points for a chain on the truck.

NOTE! This information may not be interpreted as a basis for warranty claims.

1)

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In accordance with the illustration, drill an M6 diameter hole.

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Service Manual A-Ergo — D003936, B, GBR, Translated

04 Chassis

2)

Cut the chain to the calculated length, so that no more than two links are in contact with the floor.

3)

Secure the anti-static chain with an M6 x 18 bolt and washer on the top.

Ensure that the chain will not affect any moving parts after installation.

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Service Manual A-Ergo — D003936, B, GBR, Translated

05 Drive unit

05

DRIVE UNIT

5.1

Design and function 5.1.1 5.1.2 5.1.3

5.2

5.3

49

Preparatory work ............................................................................................................. 49 Traction motor.................................................................................................................. 49 Gearbox........................................................................................................................... 51 Replacing the drive unit ................................................................................................... 52 Reconditioning the gearbox............................................................................................. 53 Drive wheel...................................................................................................................... 57

Diagnostics and trouble shooting 5.3.1

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Introduction...................................................................................................................... 49 Traction motor.................................................................................................................. 49 Gearbox........................................................................................................................... 49

Maintenance and repair instructions 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6

49

58

Troubleshooting chart ...................................................................................................... 58

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05 Drive unit

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Service Manual A-Ergo — D003936, B, GBR, Translated

05 Drive unit

05

DRIVE UNIT

5.1

Design and function

5.1.1

Introduction The drive unit is mounted in an assembly containing the brakes, drive motor, gearbox and drive wheel. The steering servo motor is mounted on the same motor bed. For technical data regarding the component parts, see Section 01, page 1.

5.1.2

Traction motor The dive motor is a three phase asynchronous motor. A pulse transducer is enclosed in the bearing on the non-driving end of the motor and this provides speed feedback to the traction controller, see Section 10, page 139.

The motor is mounted directly on the gearbox and the transmission of power takes place via individually adjusted gear wheels.

5.1.3

Gearbox The gearbox is designed to produce the best gear ratio over the speed range of the traction motor.

The traction motor and drive wheel are mounted on the gearbox.

The gearbox is mounted on the truck chassis. A crown wheel bearing is located on the gearbox. The steering servo motor turns the crown wheel bearing and thus turns the gearbox housing and drive wheel in the desired direction as the truck is steered.

5.2

Maintenance and repair instructions

5.2.1

Preparatory work 1)

Switch off all electrical power.

2)

Release the control units panel and fold it out, see Section 10, page 139

5.2.2

Traction motor

5.2.2.1

Removing the traction motor WARNING! The battery plug must be removed and the truck lifted so that the drive wheel runs free of the ground while working on the motor.

1)

Disconnect the wiring from the traction motor and electric brake.

2)

Remove the 8 socket head cap bolts which secure the motor to the gearbox, see (item 2).

3)

Carefully lift out the motor away from the gearbox, so that the pinion is not damaged.

4)

If the motor is to be exchanged, the gear wheel must be removed and fitted to the new motor. The gear wheel is matched to the gearbox.

NOTE! It is vital that the gear wheel accompanies the gearbox to which it is matched.

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05 Drive unit

5.2.2.2

5)

If the motor is to be repaired or reconditioned, refer to Section 5.2.2.3, page 50.

6)

Check/replace the sealing ring, (item 1)

Fitting the traction motor 1)

Torque Tighten the pinion on to the motor shaft. Tightening torque 50 Nm.

2)

Smear oil on to the sealing ring.

3)

Carefully lower the motor into the gearbox.

CAUTION! The gear wheel could be damaged!

In order to facilitate assembly, it may be advantageous to insert 3 bolts without heads into 3 of the 8 bolt holes and use them as dowels.

5.2.2.3

4)

Bolt the motor to the gearbox (removing any dowels that may be present).

5)

Connect all the wiring.

6)

Fold the control units panel inwards and secure it.

Dismantling the traction motor 1)

Remove the motor from the machine housing, see Section 5.2.2.1, page 49.

2)

Remove the end shields and rotor. As the tacho sensor is integrated into the bearing at the non-driving end of the motor, great care must be taken not to damage it.

3)

Change the motor bearings. Press on the inner ring. Slowly heat the bearing to no more than 50° C. NOTE! The motor bearing must always be replaced during motor reconditioning, to ensure continued reliable operation.

50

4)

The housing is flushed out using special cleaning fluid, see Section 03, page 21, and then blown dry; after the housing has dried an insulation test must be performed.

5)

Check that the insulation is satisfactory. Measure the resistance between the coil and stator housing, see Section 1.5.3, page 10 for the correct value. If the resistance is lower the motor must be blown clean and tested again.

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Service Manual A-Ergo — D003936, B, GBR, Translated

05 Drive unit 5.2.2.4

Assembling the traction motor 1)

Assemble in the reverse order to dismantling. Ensure that the "knob" on the bearing is positioned in alignment with the end shield.

2)

5.2.2.5

Torque The nuts on the pinion on the motor shaft should be tightened to 50

Storage of traction motor Machines in storage that will not to be used within one month must be given special attention so that problems do not occur when they are to be used again. Dust, dirt, condensation and moisture caused by large changes in temperature and problems with rust and oxidisation must be prevented. Motors should therefore be protected by waxed paper or the like, together with a moisture absorbing material, and stored indoors at room temperature, preferably in a cardboard box.

5.2.3

Gearbox

5.2.3.1

Changing the gearbox oil 1)

If the oil needs to be drained out, this is done through the plug at the bottom of the gearbox (item 1).

2)

Oil is added either through the plug (item 2) or by removing the motor.

3)

The oil level must be at the hole in the plug (item 2). Fill with oil until it just begins to run out of the hole. A suction jet pump is recommended to facilitate filling and topping up via (item 2).

Figure 20. Gearbox

5.2.3.2

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Removal and installation of the gearbox 1)

Position the truck on a pallet. The drive wheel must hang free, about 30 mm above the floor.

2)

Loosen the cable connections to the drive motor, servo motor, electric brake and steering wheel indicator. Label the cables that are not labelled to ensure correct reassembly.

3)

Remove the motor, refer to Section 5.2.2, page 49.

4)

Remove the 6 socket head cap screws from the bolted joint between the motor bed and the chassis.

5)

Carefully lower the gearbox out of the truck (see Section 5.2.4, page 52).

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05 Drive unit

NOTE! All the bolts and screws are to be tightened to the torques stated in the table, Section 1.7.1.1, page 11 6)

Drain the oil from the gearbox, see Section 5.2.3.1, page 51.

7)

As applicable: Remove the guide ring and the guide ring bearing from the old gearbox and fit them to the new one.

8)

Fit the new gearbox.

NOTE! Check that the mechanical limit switches fit into the correct positions

9)

Torque When refitting into the machine housing, the tightening torque must be applied, 47 Nm.

10) Fill with new oil, see Section 1.6, page 11.

NOTE! Do not forget to fill the gearbox with oil before starting up. The oil can be filled before the drive motor is assembled on the gearbox. To ensure the oil level is correct: open the level plug, (item 2 Figure 20, page 51), and drain off any excess oil.

NOTE! Spent oil should be taken care of and recycled according to the applicable legislation in respective countries.

5.2.4

Replacing the drive unit 1)

Disconnect the main power circuit by pulling out the battery plug.

2)

Slacken the screw clamps that hold the electrical panel, and swing it out.

3)

Disconnect the MDI and the stepper motor sensor underneath the steering wheel panel.

Lift off the steering wheel bracket by unscrewing the locking screw that is located beneath the steering wheel bracket.

4)

Remove the connections to the traction motor sensor bearings, to the S4 and S5 sensors and to the brake. Also disconnect the traction motor connections.

5)

In order to avoid damage to the S4 and S5 sensors, these can be unscrewed while the drive unit is being removed, and then refitted.

6)

Lift the truck at the centre rear by at least 350-400 mm, and then support it on a block.

7)

Remove the drive wheel.

8)

Remove the magnetic part of the brake, the rotor and hub screw, and then fit a 6 mm eye bolt into the traction motor shaft.

9)

Secure a ratchet lever hoist or a pulley block between the eye bolt and the overhead guard, and apply light tension.

10) Remove the 6 bolts securing the drive unit. First remove every alternate bolt so that the drive unit is suspended by 3 bolts. Then carefully remove the remaining 3 bolts and check that the hoist or block is holding the drive unit in place.

11) Carefully lower the drive unit and place it on its side on a thin piece of wood with the drive wheel flange upwards, so that it and the crown wheel will not be damaged. Also take care not to damage the electrical terminal connections on the motor when the

52

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Service Manual A-Ergo — D003936, B, GBR, Translated

05 Drive unit traction motor is being pulled through the motor bed. As the drive unit is being lowered, it should be carefully pulled backwards out of the truck.

12) Install in the reverse order.

When the drive unit has been lifted into place by the lifting equipment, first secure it at alternating securing holes, and once it is hanging in place the other bolts can be inserted and tightened. When refitting the sensors, these must be screwed gently all the way in by hand so that they touch the cam, and then 3/4 of a turn back before being carefully locked in place by their lock nuts.

WARNING! When refitting the steering wheel bracket and door there is a risk of pinching!

5.2.5

Reconditioning the gearbox

5.2.5.1

Replacing the drive shaft’s stuffing box 1)

Remove the gearbox, see Section 5.2.3.2, page 51.

2)

Dismantle the drive wheel.

3)

Remove the cover.

4)

Loosen the bolts that hold the crown wheel halfway, and drive out the shaft towards the drive wheel side.

5)

The bolts can be unscrewed fully when the crown wheel and bearing have come free from the axle. The shaft is pulled out from the drive wheel side. Arrange the parts in the order they were dismantled to avoid confusion.

6)

Remove the roller bearing closest to the stuffing box by tapping the axle shaft against a block of hard wood. Sometimes it is easier to remove the bearing if a sharp object is inserted between the inner ring of the bearing and the flank of the shaft. Any burrs on the axle must be removed before reassembly.

7)

Carefully clean the seat for the stuffing box in the gear housing.

8)

When assembling, place the first bearing on the drive wheel side.

9)

Fit the safety ring and the stuffing box into position. Ensure that it sits correctly.

10) Fit the guard and then carefully press in the drive shaft.

11) Now assemble the crown wheel and bearing. Start with the spacer.

12) Apply locking fluid to the shaft threads (Loctite 207) and screw together the complete drive shaft assembly with the washers and screws. Tighten the screws to the specified tightening torque in accordance with Section 1.7.1.1, page 11.

13) Fit the cover. Remember that the drain hole must be the lowest point. Use a new gasket.

Screw in the oil drain plug, with a new copper washer.

14) Fill with hypoid oil. See Section 1.6, page 11.

5.2.5.2

Assembling the gearbox 1)

Preparation of the gearbox housing (see Figure 21, page 54).

A) Thoroughly clean the gearbox housing.

B) Fit the bearings (items 1, 2 and 3) into their positions.

C) Fit the protective ring (item 1) into its position.

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05 Drive unit

Figure 21. Preparation of the gearbox housing

2)

Fit the pinion shaft (item 5) into its position (see Figure 22, page 54).

A) Press the bearing (item 6) on to the pinion shaft.

B) Fit the desired number of shims (item 7).

C) Fit the spacer tube (item 8) into place on the pinion shaft.

D) Place the gear wheel (item 9) into position.

E) Fit the pinion shaft into place and tighten its nut (item 10). The nut must be locked by “Delo 5249” or “Loctite 243”.

Figure 22. Fitting the pinion shaft.

NOTE! Always use the correct tightening torque when tightening the nut (item 10).

The nut must be locked by “Delo 5249” or “Loctite 243”.

3)

54

Fit the wheel hub (item 11) and crown wheel , item 15 (see Figure 23, page 55).

A-Ergo

Service Manual A-Ergo — D003936, B, GBR, Translated

05 Drive unit A) Press in the stuffing box (item 12).

B) Fit the desired number of shims (item 13).

C) Put the spacer ring (item 14) into place, and then the gear (item 15) into place in the gearbox.

D) Push the hub (item 11) on from the outside.

E) The hub is locked by a washer (item 16) and screw (item 17), The screw must be locked by “Delo 5249” or “Loctite 243”.

Figure 23. Fitting the wheel hub and crown wheel

NOTE! Always use the correct tightening torque when tightening the screw (item 17). The screw must be locked by “Delo 5249” or “Loctite 243”.

4)

Adjustment of the gear mesh (item 5) and (item 15).

A) Apply a paint that is suitable for the purpose on to the gear teeth.

B) Turn the gears.

C) Check the markings on the gear teeth.

D) The illustration below shows the correct meshing.

E) If the meshing pattern is as shown in the following illustration, the number of shims (item 7) on the pinion shaft (item 5) must be reduced (see Figure 22, page 54).

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05 Drive unit

F)

5)

If the meshing pattern is as shown in the following illustration, the number of shims (item 7) on the pinion shaft (item 5) must be increased (see Figure 22, page 54).

Refit the crown wheel (see Figure 24, page 56).

A) Apply liquid sealing material to the top of the gearbox.

B) Fit the crown wheel into place and tighten its screws (item 18).

C) Fit the crown wheel bearing into place and tighten.

Figure 24. Fitting the guide ring

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Service Manual A-Ergo — D003936, B, GBR, Translated

05 Drive unit 6)

Fit the cover (item 21), see Figure 25, page 57.

A) Remember that the drain hole must be the lowest point. Use a new gasket (item 20). Screw in the oil drain plug, with a new copper washer (item 22).

Figure 25. Fitting the cover

5.2.6

Drive wheel

5.2.6.1

Replace drive wheel 1)

Loosen the drive wheel nuts, without removing them.

Figure 26. Loosen the nuts on the drive wheel.

2)

Lift the front of the truck with a jack and support it on a wooden block. Remove the jack to facilitate access.

3)

Remove the wheel nuts and lift the wheel forward.

4)

Assemble the new wheel, tighten the wheel nuts by hand.

5)

Lower the truck to the floor.

6)

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Torque Tighten the nuts crosswise, to a torque of 135 Nm.

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Service Manual A-Ergo — D003936, B, GBR, Translated

05 Drive unit

5.3

Diagnostics and trouble shooting

5.3.1

Troubleshooting chart Symptom

Cause

Procedure

The wheel has a flapping sound when driving.

The tyre has separated due to an 1. impact.

2.

Change the wheel.

Examine the floor for any irregularities.

The wheel squeaks continuously Bearing is damaged. when driving.

1.

Replace bearing.

2.

Inform the driver that string and plastic etc. should be removed daily, and the floor kept clean.

The wheel is flat after long The wheel mass has become breaks, but becomes round after warm while driving and deforms driving for a while. when parked.

Try a different type of wheel.

The wheel has a deformity that A “blow out” has taken place due Change the wheel. does not disappear when driving. to overheating and changed the molecular structure of the wheel mass.

The truck seems to jerk when driving.

Hard foreign object has fastened 1. in the drive wheel.

Remove the object or change the wheel.

2.

See also items above.

The truck jumps at regular intervals, proportional to the speed, when driving.

The wheel is oval.

1.

Change the wheel.

2.

Check/adjust the brake.

3.

See also items above.

1.

Adjust to reduce the acceleration and reversing rate.

2.

Change the wheel if necessary.

The wheel has transverse The wheel has been heated. cracks, and small bits have fallen Small cracks appear with hard out of the tyre. acceleration and reversing.

The wheel has one or more small deformations.

Oil on the floor.

Locking of the brakes so that the 1. wheel slides, or loose objects on the floor that prevent the wheel 2. from rotating.

Remove objects on the floor.

Leaking seal around the drive axle.

Replace seal

•

Tell the driver to brake more smoothly.

or: •

If there are cracks in the casting the gearbox must be replaced.

Grating noise when accelerating Defective gear wheel in the drive Check the teeth by removing the or using the reversing brake. unit. cover.

Too little oil in the gearbox.

Grating noise when the truck is Faulty bearing in the traction lifted up and the drive wheel can motor. rotate freely and the motor rotates.

58

If there are cracks in the casting the gearbox must be replaced.

Dismantle and renovate the traction motor.

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Service Manual A-Ergo — D003936, B, GBR, Translated

05 Drive unit

Symptom

Cause

Procedure

The truck rolls "sluggishly".

The brakes are applied.

•

Replace brake disc.

If this does not help: •

replace the complete brake unit.

The drive unit has seized.

If there are cracks in the casting the gearbox must be replaced.

Clicking sound when driving.

Faulty wheel bearing.

Change the wheel.

Clicking sound when driving.

Loose wheel.

•

Tighten the wheel.

If this does not help: •

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Change the wheel.

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Service Manual A-Ergo — D003936, C, GBR, Translated

06 Mast system

06

MAST SYSTEM 2013B

6.1

Design and function 6.1.1 6.1.2 6.1.3 6.1.4

6.2

6.3

67

Replacing the mast/straddle legs .................................................................................... 67 Dismantling the mast ....................................................................................................... 72 Lift chains ........................................................................................................................ 77 Forks................................................................................................................................ 78 Fork carriage ................................................................................................................... 84 Fork carriage with telescopic forks (TF) .......................................................................... 85 Vertically adjustable straddle legs ................................................................................... 90 Side stabilisers ................................................................................................................ 91

Diagnostics and trouble shooting 6.3.1

A-Ergo

Mast system .................................................................................................................... 63 Fork carriage ................................................................................................................... 63 Vertically adjustable straddle legs ................................................................................... 65 Side stabilisers ................................................................................................................ 66

Repair and maintenance instructions 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7 6.2.8

63

92

Troubleshooting chart ...................................................................................................... 92

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06 Mast system

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Service Manual A-Ergo — D003936, C, GBR, Translated

06 Mast system

06

MAST SYSTEM

6.1

Design and function

6.1.1

Mast system There are four mast systems as standard versions, depending on the application or roof height, etc.

Table 17. Mast types Description

Descriptions

T

Telescopic mast

TV

Telescopic Free-view mast

TFV

Telescopic Free-lift Free-view mast

DTFV

Double Telescopic Free-lift Free-view mast

A telescopic mast consists of an outer and inner mast, fork carriage and lift cylinder. The fork carriage is lifted up and down in the inner mast, which in turn moves up and down in the outer mast. The lift cylinder first lifts the fork carriage approx. 15 cm, and then the mast system follows the lifting movement.

A mast of the double telescopic type also has, in addition to an inner and outer mast, an intermediate mast. The lifting movement is the same as for a telescopic mast, and all the masts begin to move up (or down) simultaneously.

A mast type with free-lift function works in a similar way, but with the difference that the fork carriage moves to its top position in the inner mast before the next mast section starts to lift.

Free-lift frames can be used to advantage in rooms with low ceilings or low door openings.

A mast of the free-view type implies that the distance between the mast profiles is longer, which gives better visibility.

6.1.2

Fork carriage Different fork arrangements are mounted on the back of the fork carriage. Everything from fixed forks to complex units with telescopic forks.

Fixed forks Forks with a fixed width and length.

Figure 27. Fork carriage with fixed forks

Laterally adjustable forks The forks can be adjusted to different widths.

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06 Mast system

Figure 28. Fork carriage with laterally adjustable forks

Telescopic forks (TF) The fork blades can be extended.

Figure 29. Fork carriage with extendable/telescopic forks

Overload clutch with telescopic forks (TF) AThe TF fork carriage has an overload clutch. The overload clutch is a unit that safeguards against overloading the components that drive the forks in and out.

The torque that the overload clutch can transfer is limited by the force that the pressure springs (item 1) transfer to the pressure plate (item 2), and the brake linings (item 3) to the sprocket (item 4) (see Figure 30, page 65). For the adjustment instructions see Section 6.2.6.4, page 89.

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Figure 30. Overload clutch

Fork drive motor with telescopic forks (TF) The fork drive motor is mounted on the back of the fork carriage and is used to move the forks out and in so they can reach further forward. Power is transferred from the motor to the forks via an angle gear and chain. The motor is controlled by a control on the control panel.

Refer to the plate on the motor for motor data.

6.1.3

Vertically adjustable straddle legs Vertically adjustable straddle legs means that the straddle legs can be raised sufficiently high to lift a pallet from the floor. Masts with vertically adjustable straddle legs are able to transport a pallet on the fork carriage, and if the fork carriage is raised high enough, a pallet directly on the straddle legs. This enables two pallets to be transported at the same time.

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06 Mast system

Figure 31. Vertically adjustable straddle legs

6.1.4

Side stabilisers The truck can be fitted with extendable side stabilisers to guarantee lateral stability and to eliminate the risk of tipping during high lifts. The system consists of extendable side stabilisers, which are extended by means of the standard hydraulic unit.

A limit switch, a height position switch, on the mast limits the lifting height when the stabilisers are withdrawn. When the stabilisers are extended a pressure switch gives a signal that the forks can be lifted to their maximum position.

NOTE! It is risky to drive with the side stabilizers extended.

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06 Mast system

Figure 32. Stabilizers

6.2

Repair and maintenance instructions

6.2.1

Replacing the mast/straddle legs

6.2.1.1

Detach the mast/straddle legs from the chassis

A-Ergo

1)

Remove the battery.

2)

Support the chassis on pallets.

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06 Mast system

Figure 33. Blocking up the chassis

3)

Hang up the mast so that the attachments are not loaded.

Figure 34. Suspending the mast

If the mast has vertically adjustable straddle legs:

Figure 35. Vertically adjustable straddle legs

4)

68

Screw a screw into one of the screw holes on the spacer between the guides and chassis in order to hold up the spacer while dismantling.

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Service Manual A-Ergo — D003936, C, GBR, Translated

06 Mast system

Figure 36. Spacer/guide screw

5)

Secure the guides to the mast with a tension band.

Figure 37. Secure the guides together

6)

Remove the screws attaching the mast to the chassis.

Figure 38. Upper screw attachment, mast

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7)

Remove the hydraulic connections.

NOTE! Mop up spilled surplus hydraulic oil in a suitable way.

Figure 39. Hydraulic connection

6.2.1.2

Mounting the mast/straddle legs on to the chassis 1)

Make sure that the mast is suitably supported so that it cannot move

Figure 40. Example of suspended mast

If the mast has vertically adjustable straddle legs: 2)

70

Check that the guides are level with each other in height and secure them to the mast.

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Figure 41. Secure the guides together

3)

Be sure to screw tight the spacer between the mast and chassis in the guide in one of the screw holes that are not used.

Figure 42. Spacer/guide screw

4)

Insert a suitable number of shims, 3 is the standard number.

Figure 43. Shims

A-Ergo

5)

Lower the mast so that the link arms slide in under the chassis when the mast and chassis are brought together.

6)

Connect the hydraulic couplings together.

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7)

Bring the mast and chassis together and tighten the screws.

8)

Torque The tightening torque between the mast and the machine housing when reassembling must be 277 Nm. If the mast has vertically adjustable straddle legs:

9)

Remove the tension band and screw that are holding the spacer against the guides.

Figure 44. Removing the spacer/guide screw

10) Check that the distance between the floor and the forks is correct, see Section 6.2.7.1, page 90.

6.2.2

Dismantling the mast

6.2.2.1

General The following is generally applicable for all types of masts when dismantling: •

Stand in an area with adequate ceiling height and with approved lifting devices.

The following is generally applicable for all types of masts when assembling: •

The mast is assembled in the reverse order to dismantling.

Inspecting or repairing the mast system:

6.2.2.2

72

•

Check that the thrust rollers lie against the roller surfaces on the mast. Also check that they roll easily.

•

A function test must be made after each measure/action on the mast system. The mast must not jam or run too slowly (the mast sections move in the wrong order) when lifting and lowering.

Adjustment of the side lean in the top position 1)

Lower the mast and slacken the chains.

2)

Adjust the attachment of the outer cylinders with the top nut (item 1). Adjust both cylinders equally so that the mast does not pull skew.

3)

If there is sufficient movement in the cylinder attachment, the rollers will be in contact with the running surfaces of the mast at all lifting heights.

4)

Test the operation of the lifting movement. Lift up to top position and check that the mast does not swing to the side when the end position is reached.

5)

Lock the top nut with the locking screw (item 2).

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Service Manual A-Ergo — D003936, C, GBR, Translated

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6.2.2.3

6)

Tighten the chain and check that the rollers still make contact with the running surface.

7)

The cylinder attachment should be flexible.

8)

Adjusting the mast, see Section 6.2.2.3, page 73.

Adjusting the play in the mast The lateral play is adjusted with 0.5 or 1 millimetre shims behind the thrust rollers. If there is excessive play between thrust roller and roller surface on the mast profile, the thrust roller must be replaced with a new roller with a larger diameter.

Thrust rollers are available in three different diameters (the diameter is specified on each roller): 160 mast: •

78.2 mm, 78.6 mm 79.0 and 79.4 mm.

200 mast and TF-mast: •

6.2.2.4

A-Ergo

107.0 mm, 107.5 mm 108.0 mm, and 108.5 mm.

Mast type

Permitted play between thrust rollers and roller surfaces between mast sections and fork carriage and mast

160

0.5 mm

200

0.6 mm

TF

0.6 mm

Changing the DFTV mast 1)

Lower the fork carriage onto a European pallet, or equivalent, so that the intermediate cylinder lift chain slackens.

2)

Release the lift chain from the intermediate cylinder by releasing the chain bolt, and removing the pin between the bolt and chain.

3)

Lift the mast until the fork carriage separates from the inner mast.

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4)

Place a wooden block on the straddle legs between the outer profiles so that it comes under the intermediate cylinder. Lower the inner and intermediate masts so that the inner mast rests on the wooden block and the outer chains slacken.

5)

Remove the two outer chains by removing the pins in the upper chain attachment.

6)

Release the hoses that run in the mast from the block in the outer mast, and plug them.

7)

Remove the pulley wheel for the hoses from the intermediate mast.

8)

Remove the pulley wheel for the chains from the intermediate mast.

9)

Unscrew the screw for the lifting stop.

Figure 45. Screw, lifting stop

10) Lift the inner mast straight up until the inner mast’s lower support rollers and the intermediate mast’s upper support rollers meet, and then pull the inner mast forwards to release it from the intermediate mast. If the ceiling is too low dismantle the mast, see Section 6.2.1.1, page 67, and lay it down.

Figure 46. Position for dismantling intermediate masts

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11) Remove the upper securing screws for the side cylinders.

12) Lift out the intermediate mast in the same way as the inner mast.

13)

6.2.2.5

Torque The tightening torque between the mast and the machine housing when reassembling must be 277 Nm.

Changing the TFV mast 1)

Lower the fork carriage onto a European pallet, or equivalent, so that the intermediate cylinder lift chain slackens.

2)

Release the lift chain from the intermediate cylinder by releasing the chain bolt, and removing the pin between the bolt and chain.

3)

Lift the mast until the fork carriage separates from the inner mast.

4)

Lower the mast to its bottom position.

5)

Release the hose from the outer mast and plug it. Remember to remove the cable ties.

6)

Remove the upper securing screws for the side cylinders.

7)

Lift the inner mast straight up until the inner mast's lower support roller and the outer mast's upper support roller meet, and then pull the inner mast forwards to release it from the outer mast. If the ceiling is too low dismantle the mast, see Section 6.2.1.1, page 67, and lay it down.

Figure 47. Position for dismantling intermediate masts

8)

6.2.2.6

A-Ergo

Torque The tightening torque between the mast and the machine housing when reassembling must be 277 Nm.

Replacing a TV mast 1)

Lower the fork carriage onto a European pallet, or the like, so that the lift chains slacken.

2)

Release the lift chains from the outer mast by removing the upper pins.

3)

Lift until the fork carriage separates from the inner mast.

4)

Lower the mast to its bottom position.

5)

Remove the upper securing screws for the side cylinders.

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6)

Lift the inner mast straight up until the inner mast's lower support roller and the outer mast's upper support roller meet, and then pull the inner mast forwards to release it from the outer mast. If the ceiling is too low dismantle the mast, see Section 6.2.1.1, page 67, and lay it down.

Figure 48. Position for dismantling intermediate masts

7)

6.2.2.7

Torque The tightening torque between the mast and the machine housing when reassembling must be 277 Nm.

Replacing a T mast 1)

Lower the fork carriage onto a European pallet, or equivalent, so that the intermediate cylinder lift chain slackens.

2)

Release the lift chain from the intermediate cylinder by releasing the chain bolt, and removing the pin between the bolt and chain.

3)

Lift until the fork carriage separates from the inner mast.

4)

Lower the mast to its bottom position.

5)

Secure the lift cylinder so that it cannot move sideways.

6)

Remove and plug the oil pipes.

7)

Release the upper retaining bolts on the lift cylinder from the inner mast.

8)

Remove the lower retaining screw.

9)

Carefully lift up the inner mast until it can be lifted out from the cylinder.

10) Lift the inner mast straight up until the inner mast's lower support roller and the outer mast's upper support roller meet, and then pull the inner mast forwards to release it from the outer mast. If the ceiling is too low dismantle the mast, see Section 6.2.1.1, page 67, and lay it down.

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Figure 49. Position for dismantling intermediate masts

11)

Torque The tightening torque between the mast and the machine housing when reassembling must be 277 Nm.

6.2.3

Lift chains

6.2.3.1

Replacement 1)

Remove any stop screw in the inner mast.

Figure 50. Screw, lifting stop

A-Ergo

2)

Lower the fork carriage onto a European pool pallet, or equivalent, so that the lifting chains slacken.

3)

Remove the lift chain.

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6.2.3.2

Re-fitting the chains When chains are re-fitted it is important to align them correctly, and that there is no deterioration of the clearance.

6.2.3.3

Checking the lift chains • •

Check that the chain is clean. Measure when the forks are unloaded.

Measure the chain elongation. Measure along the 25 links that go over the pulley wheel, since elongation is normally greatest here. Compare with the measurements below. If the chain has stretched by more than 2% it must be replaced.

Figure 51. Chain dimensions Chain dimensions (inches)

P (nominal) Pitch dimension (mm)

P (true) Actual pitch dimension (mm)

Measureed over 25 Maximum stretch links New chain over 25 links is (mm) 2% (mm)

1/2”-2*2

12,70

12,59

314,75

321,05

5/8”-4*4

15,88

15,875

396,88

404,81

3/4”-3*4

19,05

19,05

476,25

485,78

3/4”-4*4

19,05

18,91

472,75

482,21

1”-4*4

25,40

25,32

633,00

645,66

1 1/4”-4*4

31,75

31,54

788,50

804,27

1 1/2”-4*4

38,10

38,06

951,50

970,53

•

Measure the height of the chain's link plates, i.e. dimension G, Figure 51, page 78.

Max. wear is 5%. Measure the original height where the chain is not worn as a comparison.

Example: A chain has an original plate height of 23.2 mm. Therefore the plate height should be at least 23.2 - 5% = 23.2 x 0.95 = 22 mm.

•

Make sure than none of the pins in the plates have twisted.

Figure 52. Twisted pin

• • • •

Make sure that there are no cracks in the plates.

Look for traces of mechanical damage or rust.

Check that the chain runs easily over the pulley wheel and does not jam.

Lubricate the chain after cleaning and inspection. For the recommended types of oil and grease, see Section 1.6, page 11.

6.2.4

Forks

6.2.4.1

Adjusting the lowest height on forged forks

78

1)

The inner and outer masts should be lowered.

2)

Adjust the two outer lifting chains so that the mast just hangs a little from them.

3)

Adjust the middle chain so that the fork head is 5 ± 2 mm from the ground.

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6.2.4.2

Adjusting the lowest height on welded forks 1)

The inner and outer masts should be lowered.

2)

Adjust the two outer lifting chains so that the mast just hangs a little from them.

3)

Adjust the lifting chains so that the fork height is as shown in the table.

Fork height in lowered position: Table 18. Height of forks over floor in rest position Mast type

Min

Max (mm)

A-Ergo 160

controlled by ground clearance

89

A-Ergo 200

controlled by ground clearance

91

A-Ergo Telescopic forks (TF)

controlled by ground clearance

73

6.2.4.3

Inspection of forged forks

6.2.4.3.1

General CAUTION! Inspection of the forks must be carefully performed by trained personnel.

The purpose of the inspection is to detect damage, faults, deformation, etc. Forks showing this type of damage may not be used before they have been repaired and tested in accordance with ISO 2330.

Several test points are included in the fork inspection. A fork inspection in accordance with ISO/ 5057 must be carried out on at least one (1) occasion per year on forks that are in use; if deformation, damage or other permanent changes are discovered at any other time, an inspection must be carried out immediately. If the forks are often used for heavy lifting, the fork inspection interval may be shorter. If the forks fail to meet any of the inspection points, the machine must be taken out of service. If the customer is not prepared to do this, it should be written in the report that: "The forks do not comply with the requirements in ISO/ 5057".

When the customer subsequently signs the service order, they bear the responsibility for the defective forks.

In case of doubt, comply with the requirements set by the applicable ISO standard or by the fork manufacturer. See table.

A-Ergo

The fork blade is bent

ISO/5057

Crack formation

ISO/5057

Wear

ISO/5057

Fork tip

Fork manufacturer

Fork angle

Fork manufacturer

Difference in height between the tips of the forks

ISO/5057

Locking device

ISO/5057

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6.2.4.3.2

Worn fork hook

ISO/5057

Fork labelling

ISO/5057

The fork blade is bent

A. Ruler

B. Deformation location

The fork blade must not be bent downwards by more than a certain proportion of the length of the fork. l= fork blade length in mm. k= measurement in mm between the fork blade tips and a ruler.

Measurement when a blade must be changed: greater than k=l/33. Example: k=1150/33= 34 mm.

6.2.4.3.3

Crack formation

A. Attachment hooks

B. Heel

Use a non-destructive method to check if there are cracks in the forks. Take extra care when checking around the insides of the holes and the securing hooks. If cracks are detected, the forks must not be used.

6.2.4.3.4

Wear

Figure 53. Wear/markings A. Fork labelling.

B. Location for measuring the shank thickness.

C. Wear in the fork heel.

Check the forks for wear, especially around the heel. If 10% of the original thickness of the fork has been worn away, the fork must not be used.

Example: original thickness (n) = 40 mm -> limit for the fork not to be used = 36 mm. (n)-10% = forks must be changed.

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Worn forks must not be welded or repaired in any other way.

The original thickness is found by: • Read the markings. The markings must show the lifting capacity in kg for one fork and the centre of gravity distance in mm. The markings often also show the original thickness.

• measure the blade thickness at the centre of the shank (position B).

6.2.4.3.5

Fork tip

As soon as a fork tip is worn, it must be shortened or the complete fork changed.

6.2.4.3.6

Fork angle

Measure 500 mm along the fork blade and 500 mm along the back of the fork and mark these positions. Measure the diagonal distance between these two points and use the table.

The distance must be within the acceptable values in accordance with Table 19, page 81, otherwise the forks must not be used.

Table 19. Fork angle

6.2.4.3.7

The results

Measurement result

Optimal

707 mm

Acceptable

695-713 mm

Difference in height between the tips of the forks

A. Difference in height between the forks

The difference in height between the fork tips must not exceed 3% of the fork blade length.

Example: fork length 1150 mm - max. height difference 34 mm.

If the difference in height between the fork blades is greater than 3%, the forks must not be used.

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6.2.4.3.8

Locking device

Figure 54. Locking device

The function of the locking device is to prevent the fork from moving sideways by itself.

Check that the originally fitted locking device works as intended. If this is not the case, the forks must not be used until the fault in the locking device has been rectified.

6.2.4.3.9

Worn fork hook

Sideways forces and long periods of use can result in bent fork hooks. If this has occurred, the forks must not be used.

6.2.4.3.1 0

Fork labelling The fork markings must be clearly legible and include the lifting capacity in kg for one fork, and the centre of gravity distance in mm. If the markings are illegible, the forks must not be used. See Figure 53, page 80.

Older forks do not have these markings, but may be used anyway. The prohibition applies to forks which have markings but are damaged.

6.2.4.4

Inspection of welded and telescopic fork carriages

6.2.4.4.1

General CAUTION! Inspection of the forks must be carefully performed by trained personnel.

The purpose of the inspection is to detect damage, faults, deformation, etc. A fork carriage showing this kind of damage may not be used until it has been repaired.

6.2.4.4.2

The fork blade is bent

A. Ruler

B. Deformation location

The fork blade must not be bent downwards by more than a certain proportion of the length of the fork. If the fork blade is bent too much, the fork carriage must be straightened or replaced. l= fork blade length in mm.

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k= measurement in mm between the fork blade tips and a ruler.

Measurement when a blade must be straightened: greater than k=l/33. Example: k=1150/33= 34 mm.

NOTE! Repairs must be carried out by a licensed welder.

6.2.4.4.3

Crack formation

1.

Front welded joints

2.

Rear welded joints

Check whether the forks are cracked. Take extra care when welding joints at the front (item 1) and rear (item 2). If cracks are detected, the fork carriage must be replaced or repaired.

NOTE! Repairs must be carried out by a licensed welder.

6.2.4.4.4

Fork angle

Measure 500 mm along the fork blade and 500 mm along the back of the fork and mark these positions. Measure the diagonal distance between these two points and use the table.

The distance must be within the acceptable values in accordance with Table 20, page 83, otherwise the forks must not be used.

Table 20. Fork angle

6.2.4.4.5

The results

Measurement result

Optimal

707 mm

Acceptable

695-713 mm

Difference in height between the tips of the forks

A. Difference in height between the forks

The difference in height between the fork tips must not exceed 3% of the fork blade length.

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Example: fork length 1150 mm - max. height difference 34 mm.

If the difference in height between the fork blades is greater than 3%, the forks must not be used.

NOTE! Repairs must be carried out by a licensed welder.

6.2.4.4.6

Locking device and chain

The function of the locking device is to secure the telescopic forks to the fork carriage. Check that the locking device (item 1) works as intended.

Check that the chain (item 2) is correctly tensioned and in good condition. Adjust by means of the adjusting screw (item 3) as necessary.

Check that the thrust rollers (item 4) spin freely and are not jammed.

The fork carriage must not be used until any faults have been rectified.

6.2.5

Fork carriage

6.2.5.1

Adjusting the fork carriage 1)

The thrust rollers have a specific clearance to the roller surfaces.

2)

The lateral play is adjusted by adjusting the number of shims behind the load rollers, and by replacing the rollers.

For the amount of permitted play, see Section 6.2.2.3, page 73.

6.2.5.2

Dismantling the fork carriage 1)

Lower down the fork carriage on to a Euro pallet, or equivalent.

2)

Remove the lift chain.

3)

Lift up the inner mast with truck’s standard hydraulic system until the fork carriage is released.

CAUTION! Observe great caution!

4)

84

Reverse the truck away.

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6.2.6

Fork carriage with telescopic forks (TF)

6.2.6.1

Dismantling the TF fork carriage The fork carriage only needs to be lifted out of the frame when replacing fork carriage rollers.

To lift out, see the instructions for dismantling the type of frame the truck is equipped with.

1)

Lift the fork carriage to a suitable height to dismantle the over-cogging protection on the back of the fork carriage (see Figure 55, page 85).

Figure 55. Over-cogging protection

A-Ergo

2)

Lower the fork carriage to a suitable height to achieve a comfortable working position; make sure that the forks are fully withdrawn.

3)

Pull the battery plug out from the electrical panel plug to disconnect the current to the truck’s electrical system.

4)

Release the flexible cable to the fork drive motor by loosening the two nuts that hold the motor’s end head, and then remove the cables connections to the motor.

5)

Release the bolts (item 1) enough to be able to adjust the chain tensioning bolt (item 2).

Screw the bolt to the left so that the chain slackens and the chain lock (item 3) can be removed (see Figure 56, page 86).

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Figure 56. Chain tensioning bolt

6)

Remove the bolts completely and lift off the drive assembly.

7)

Loosen the screws on the forks and pull off the forks (see Figure 57, page 86).

Figure 57. Fork bracket

8)

86

Release the chain adjuster (item 1, see Figure 58, page 87).

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Figure 58. Chain adjustment

9)

Remove the chain lock (item 2) and remove the chains (item 3, see Figure 58, page 87).

10) Remove the sprockets from the tips of the roller joists.

11) Remove the side thrust rollers (see Figure 59, page 87).

Figure 59. Side thrust rollers

12) Remove the outer lock rings holding the side bearings for the shaft (item 1, see Figure 60, page 88).

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Figure 60. Outer lock rings for side and centre bearings

13) Remove the centre bearing (item 2, see Figure 60, page 88). Drive the shaft to one side so that the side bearing is pressed out from the fork carriage. Remove the bearing and lift the shaft out from the fork carriage.

14) Note the order in which the gear, circlips and spacers are fitted, and then work them off.

6.2.6.2

6.2.6.3

Assembling the TF fork carriage 1)

Fit the sprockets in the tips of the roller joists. Lightly grease the bearing inside and outside before fitting.

2)

Fit the rear shaft with sprocket, stop rings and bearing housing. Check that the shaft is not tensioned skew by rotating it by hand at least one turn in each direction.

3)

Fit and adjust the fork chains so that they run parallel with the sprockets, and so that they give 2-4 mm in the middle. Lock the sprockets, stop rings and chain tensioners.

Lightly grease the chains along their entire length.

4)

Fit the over-cogging guard.

5)

Fit and adjust the roller attachments by using a fork, so that the play is less than 0.3 mm. Ensure that the forks are centred on the roller joists. Remember to lock with the screws.

6)

Lightly grease all the roller surfaces along their entire length, and fit the forks.

7)

Fit the complete motor. Fit and adjust the lower motor chain so that it runs parallel between the sprockets, and so that it gives 2-4 mm in the middle. Lock the motor attachment and the sprocket. Lightly grease the chain along its entire length.

8)

Remove the plug in the gearbox and check the oil level, which should reach to the centre of the output shaft. Replenish if necessary.

Checking the TF fork carriage after assembly Test run the fork carriage and check that:

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6.2.6.4

•

the forks do not jam.

•

the forks go fully in and out.

•

the chains run parallel between the sprockets.

•

there is no abnormal noise.

•

the overload clutch slips in the end positions.

Adjusting the overload clutch (TF) The spring tension is not adjustable, since the tensioning nut (item 1) must be fully screwed in and locked with stop screws. The bearing (item 2) and sprocket (item 3) must be lightly lubricated with cold-resistant grease (-35°C), see Figure 61, page 89.

WARNING! There must not be any grease on friction surfaces. If there is any damage to the overload clutch, it must be completely replaced.

Figure 61. Overload clutch

6.2.6.5

Replacing the fork drive motor (TF) 1)

Release the cable bracket and the cover over the engine, and lift them off.

2)

Note the connection of the electric cables, and release them.

3)

Remove the bolts.

4)

Lift the motor straight up.

Figure 62. Fork drive motor and gearbox

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6.2.6.6

6.2.6.7

Replacing the coupling between the fork drive motor and the gearbox (TF) 1)

Remove the motor, refer to Section 6.2.6.5, page 89.

2)

Release the coupling by unscrewing the stop screw and pulling off the coupling.

3)

Push on a new and tighten it with the stop screw.

4)

Loosen and pull off the coupling half located in the gear, and fit a new one.

5)

Fit the motor, connect the cables, and test drive.

Replacing the fork drive motor wiring (TF) 1)

Lift the forks approx. one metre above the floor.

2)

Release the bracket holding the electric cable at the motor.

3)

Remove the cover over the drive motor end, where the electric cable goes in.

4)

Remove the panel over the component box, including all the clips holding the cable.

5)

Check the markings and positioning of the electric cables.

6)

Release the cable and pull it out.

7)

Move the springs over to the new cable, put it in place, and connect it.

8)

Fit the cover and bracket over the drive motor.

9)

Clamp the cable securely and lift the forks a number of times to check that it is not trapped, catches, or rubs against anything.

10) Fit the panels.

6.2.7

Vertically adjustable straddle legs

6.2.7.1

Adjusting the vertically adjustable straddle legs 1)

Place the truck on a level surface and lower the forks and straddle lift.

2)

heck that the distance between the floor and top of the forks corresponds with Table 21, page 91. Measure at four places: • •

90

at each fork tip on each side behind the forks

3)

Check that the distance is the same between mast and guides. If necessary adjust to obtain equal distances by means of the adjusting screws, both at the top and bottom.

4)

The side play of the mast must not exceed 0-0.5 mm. Because of the tolerance in the linearity of the mast section a maximum amount of play of 1.5 mm is permitted at the “worst point”, with the mast raised or lowered. This means that if for example the play is 0.5 mm with the straddle lift raised, the play with the straddle lift at its lower position should be max 1.5 mm, and vice versa.

5)

Check the play between the roller surfaces on the mast and the guides. For the amount of permitted play, see Section 6.2.2.3, page 73.

6)

Check that the forks are horizontal.

7)

If the fork tips point upwards, shims above the pressure plate should be removed (assuming that the forks are straight).

8)

If the fork tips point downwards, shims should be added above the pressure plate (assuming that the forks are straight).

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Figure 63. Positioning of shims

9)

When the forks are parallel, check the height. The cylinders can be extended if it is not high enough.

10) Test lift, and check that the straddle legs do not lift skew. If so, adjust the length of the cylinders until the best lifting movement is obtained.

11) Check measure, and if necessary make further adjustments.

Table 21. Measuring the height of the vertically adjustable straddle legs/forks Truck with vertically adjustable straddle legs Distance to the fork upper surface

Max 95 mm

Distance to top of straddle leg

Max 90 mm Min 85 mm

6.2.7.2

Dismantling and assembling of the vertically adjustable straddle legs 1)

Lift up the straddle legs with the truck. Place a block under the fork tips and lower down the straddle legs, whereby the load wheel is lifted from floor level.

2)

Tap out the retaining pin through the shaft and drive out the shaft that holds the fork wheel.

3)

Tap out the retaining pin at the pressure link arm and pull out the load wheel, pull rods and pressure link arm as a complete assembly.

4)

Tap out the shafts from the ends of the pull rods.

5)

Check for wear and replace damaged parts if necessary.

6)

Refit in the reverse order.

7)

Check the lifting movement. If the straddle lift pulls at an angle it must be adjusted, see Section 6.2.7.1, page 90.

6.2.8

Side stabilisers

6.2.8.1

Checking the side stabiliser

A-Ergo

1)

Position the truck on a level surface.

2)

Fix a tape measure with the zero at the top edge of one fork. Lift until the stabiliser switch in the mast breaks, i.e. until the mast stops, and measure the height. The lift height should be at 3000 mm +/- 25 mm.

3)

Extend the stabilisers until the motor stops. Check that the wheels are pressed against the floor and check the residual suspension. See Table 22, page 92.

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06 Mast system

Table 22. Check values for side stabilisers When the stabilizers are extended at full speed, the spring should be compressed by 4-9 mm when the pump motor has stopped. Irregularities in the floor are absorbed by the spring in the top of the cylinder (see Figure 64, page 92).

Residual suspension with fully extended stabilizers and a level floor surface.

5-10 mm

Figure 64. Check points for side stabilisers

6.2.8.2

Longitudinal adjustment of the side stabilizers •

Mechanical adjustment is performed by adjusting the upper or lower end of the cylinder.

6.3

Diagnostics and trouble shooting

6.3.1

Troubleshooting chart Table 23. Symptom/Action table Symptom

92

Possible cause

Procedure

Play in the mast

Insufficient shims for the mast rollers

Repeat the shimming procedure

The mast lowers unevenly and jerks

Mast rollers shimmed too tight

Repeat the shimming procedure

The mast squeaks

No lubricating grease on the mast roller Grease the roller surfaces surfaces

No lubricating grease on the mast roller Grease the roller surfaces surfaces

A-Ergo

SERVICE MANUAL Machine:

A-Ergo

Manual No:

005975

Edition 2002B

7 Steering Design and function ....................................................................................................... 7.3 General ................................................................................................................ 7.3 Steering ............................................................................................................... 7.3 Regulator, steering servo motor .......................................................................... 7.4 Repair instructions ........................................................................................................ 7.5 Steering wheel, step motor sensor ...................................................................... 7.5 Replacement .................................................................................................................. 7.5

Steering servo motor with gearbox ...................................................................... 7.5 Dismantling ..................................................................................................................... 7.5

Replacing the steering servo sensor ................................................................... 7.6 Diagnosis and trouble shooting ................................................................................... 7.7

ATLET SERVICE MANUAL A-ERGO

7.2

ATLET SERVICE MANUAL A-ERGO

Steering / Design and function / General

7.3

Edition 2002B

7 Steering Design and function General The steering movement is transferred completely electronically, without mechanical connection between the steering wheel and wheel. The system consists of steering wheel, regulator, steering servo unit and servo motor. A monitoring system is built into the steering servo unit, which stops the truck if an electrical fault occurs in the regulator.

Steering The steering wheel is mounted in a vertically adjustable panel to allow the best possible adjustment. The steering wheel has no mechancial contact with the wheel. All the steering takes place by means of a sensor in the form of a step motor under the steering wheel. The sensor gives a signal to the servo steering regulator, which converts the signal to a drive voltage for the steering servo motor to turn to the right or left, depending on the direction of rotation of the steering wheel, see section 10.

The steering servo motor is of the 3-phase induction motor type. The turning movement is limited by means of two limit switches, S4 and S5. These are placed in the motor bed and stop the turning movement before the mechanical end stop is reached.

To maintain control of the acceleration during hard turns there is also a 45° sensor, S8, on some trucks, placed in the motor bed..

S8 S4, S5

07_004_SM_A-Ergo_S4S5S8.eps

Figure 7.1 Limit switch S4 and S5.

SMA-Ergo_07_2002B.fm

ATLET SERVICE MANUAL A-ERGO

7.4

Steering / Design and function / Regulator, steering servo motor

Regulator, steering servo motor For information concerning regulators, see section 10.

ATLET SERVICE MANUAL A-ERGO

Steering / Repair instructions / Steering wheel, step motor sensor

Repair instructions Steering wheel, step motor sensor Replacement

07_003_SM_A-ERGO_RattPulsgiv.eps

Figure 7.2 Position of step motor sensor

1.

Remove the steering wheel panel and turn it upside down, see section 4 for instructions.

2.

Remove the cables to the steering wheel sensor.

3.

Unscrew the steering wheel sensor.

4.

Lift over the fixed components to the new steering wheel sensor.

5.

Connect the steering wheel sensor and refit the panel.

Steering servo motor with gearbox Dismantling 1.

Move away the power panel, see section 10.

2.

Remove the cables to the steering servo motor.

ATLET SERVICE MANUAL A-ERGO

7.5

7.6

Steering / Repair instructions / Replacing the steering servo sensor

3.

Unscrew the steering servo motor from the motor bed..

07_001_SM_A-ERGO.eps

Figure 7.3

4.

Unscrew the steering servo motor gearbox and carefully release it; the component gears are loose.

Important!

Carefully release the gearbox, the component gears are loose.

Replacing the steering servo sensor See section 10.

ATLET SERVICE MANUAL A-ERGO

Steering / Diagnosis and trouble shooting / Replacing the steering servo sensor

Diagnosis and trouble shooting See section 10 for trouble shooting of the steering servo system.

ATLET SERVICE MANUAL A-ERGO

7.7

7.8

Steering / Diagnosis and trouble shooting / Replacing the steering servo sensor

ATLET SERVICE MANUAL A-ERGO

Service Manual A-Ergo — D003936, C, GBR, Translated

08 Hydraulic system

08

HYDRAULIC SYSTEM 2013B

8.1

Design and function 8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 8.1.6 8.1.7

8.2

8.3

109

Hydraulic system ........................................................................................................... 109 Hydraulic oil, changing/draining......................................................................................110 Air filter, replacing ........................................................................................................... 111 Oil filter element, replacement........................................................................................ 111 Checking the hydraulic oil level ......................................................................................112 Lowering brake valve......................................................................................................112 Hose rupture valve .........................................................................................................114 Control valve...................................................................................................................115 Adjusting the level limit position switch (ALL).................................................................119 Hydraulic pump motor ....................................................................................................119 Hydraulic pump motor ALL ............................................................................................ 120 Stabiliser cylinders......................................................................................................... 122 Installation instruction for pipe couplings....................................................................... 123

Diagnostics and trouble shooting 8.3.1

A-Ergo

General.......................................................................................................................... 101 Hose rupture valve ........................................................................................................ 101 Lowering brake valve..................................................................................................... 101 Mechanical control valve ............................................................................................... 102 Electric proportional valve ............................................................................................. 102 Level limit position switch (ALL) .................................................................................... 102 Hydraulic diagram.......................................................................................................... 103

Repair and maintenance instructions 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6 8.2.7 8.2.8 8.2.9 8.2.10 8.2.11 8.2.12 8.2.13

101

125

Symptom and Action ..................................................................................................... 125

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08 Hydraulic system

08

HYDRAULIC SYSTEM

8.1

Design and function

8.1.1

General

8.1.1.1

Lift The driver operates a lift lever or alternatively a proportional electrical lever which actuates a microswitch, which in turn actuates the lift motor by means of a contactor. The motor drives the built-in hydraulic pump, which pumps hydraulic oil to the lift cylinders. The lift/electrical lever controls at the same time a control valve which steers an oil flow to the cylinder that is to carry out the work.

In the control valve there is a pressure limiting valve which limits the maximum hydraulic oil pressure. The pressure of the hydraulic oil is built up when the cylinder goes towards its end position. The relief valve opens if the maximum system pressure is reached and leads the oil from the pump back to the tank. The opening pressure of the relief valve is set at the factory, so that the machine will be able to handle the load it is designed for.

WARNING! The relief valve must only be adjusted by authorised and trained personnel, since it is a safety part. All work with the hydraulic system must be carried out in a pressureless state, and in a clean environment.

8.1.1.2

Lower As the lowering is controlled manually with the aid of a lever, there is a lowering brake valve located between the control valve and the cylinder, which regulates the lowering speed by restricting the return flow of hydraulic oil.

In cases where the lifting and lowering movements are controlled by an electrical control valve, there is a lowering brake valve integrated into the control valve. When lowering commences, oil is led from the cylinder through the control valve back to the tank and the cylinder is pressed together by the weight of the fork carriage.

On certain cylinders there is also a hose rupture valve, which provides protection from accidents during uncontrolled oil discharge.

8.1.2

Hose rupture valve Hose rupture valves, the purpose of which is to prevent the forks from dropping down out of control if, for example, a hydraulic hose ruptures, are fitted in most of the lift and stabilizer cylinders. They are placed in front of the nipples that are connected for the supply of hydraulic oil. There is usually a lowering brake valve in the free lift cylinder.

8.1.3

Lowering brake valve The lowering brake valve regulates the lowering speed and is mounted in a valve housing, located in the lower section of the mast. It controls the lowering speed of the cylinders (TV, TFV, DTFV cylinders). In the case of free lift there is a lowering brake valve in the bottom of the free lift cylinder (T cylinder).

The valve is set at the factory, but may be subsequently adjusted. Check the lowering speed in relation to the table, see Table 24, page 113 before repairing or adjusting.

There is no external lowering brake valve on trucks equipped with electrical control valves, instead it is integrated as a function in the control valve, see Section 8.1.5, page 102 ; in this case there must be a hose rupture valve.

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8.1.4

Mechanical control valve

8.1.4.1

General The control valve controls the lifting and lowering movements on the truck. The lifting and lowering rates are proportional to the amount of control lever movement.

8.1.4.2

Lifting function The pump provides pressure to the lift cylinders through the open control valve. If the lift cylinders are obstructed, have an excessive load, or if there is a fault in the control valve so that it does not open, the oil will return to the tank through the pressure limiting valve.

8.1.4.3

Lowering function The control valve opens to release the oil from the lift cylinders. When the fork carriage presses down the lift cylinder, the oil flow goes through the lowering brake valve, which regulates the lowering speed, see table Table 24, page 113.

8.1.5

Electric proportional valve

8.1.5.1

General The control valve controls the lifting and lowering movements on the truck. The lifting and lowering rates are proportional to the amount of control lever movement.

8.1.5.2

Lifting function The pump supplies a pressure to the control valve, which in turn closes the pressure chamber completely. This pressure also opens the non-return valve and then continues through the open proportional valve to the lift cylinders If the lift cylinders are obstructed, have an excessive load, or if there is a fault on the proportional valve so that it does not open, the oil will return to the tank through the pressure limiting valve.

8.1.5.3

Lowering function The control valve opens to release the oil from the lift cylinders. Since the non-return valve is closed, the only way out for the oil is through the pressure chamber. The flow through the pressure chamber is in turn controlled by the pressure difference over the feed restriction in the proportional valve, since the control valve does not receive pressure from the pump.

8.1.5.4

Lowering brake function The pressure chamber is the heart of the electrical control valve.

NOTE! It is set at the factory and should NEVER be altered.

The feed restriction in the proportional valve has a stroke length limit, which can be set from outside. The stroke length limit governs the maximum lowering speed.

The pressure chamber maintains a constant pressure drop over the feed restriction in the proportional valve during lowering. This enables the lowering speed to remain constant regardless of the load, and therefore no external lowering brake valves are required.

8.1.6

Level limit position switch (ALL) The function of the electrical level limit position switch is to switch off the hydraulic motor when the fork carriage reaches its top position. This will protect the hydraulic motor from overheating. For adjustments, see Section 8.2.9, page 119.

102

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08 Hydraulic system

8.1.7

Hydraulic diagram Descriptions

A-Ergo

Page

Hydraulic schematic diagram, Manual proportional valve 104014 (–2008w45)

Figure 68, page 104

Hydraulic schematic diagram, Manual proportional valve 104014 (2008w46–)

Figure 69, page 105

Hydraulic schematic diagram, Electric proportional valve 104005 (–2008w45)

Figure 70, page 106

Hydraulic schematic diagram, Electric proportional valve 104005 (2008w46–)

Figure 71, page 107

Hydraulic schematic diagram ALL, 104913

Figure 72, page 108

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08 Hydraulic system

Figure 68. Hydraulic schematic diagram, Manual proportional valve 104014 (–2008w45)

104

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08 Hydraulic system

Figure 69. Hydraulic schematic diagram, Manual proportional valve 104014 (2008w46–)

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08 Hydraulic system

Figure 70. Hydraulic schematic diagram, Electric proportional valve 104005 (–2008w45)

106

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08 Hydraulic system

Figure 71. Hydraulic schematic diagram, Electric proportional valve 104005 (2008w46–)

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08 Hydraulic system

Figure 72. Hydraulic schematic diagram ALL, 104913

108

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Service Manual A-Ergo — D003936, C, GBR, Translated

08 Hydraulic system

8.2

Repair and maintenance instructions

8.2.1

Hydraulic system General rules NOTE! Cleanliness during all work with hydraulic components is of the greatest importance for the operating safety and service-life of the system. The following should be taken into consideration: • • • • • • • • • • •

Dirt particles must not get into components.

Do not use cloths that release fibres or particles.

Only use clean tools.

Carefully clean tanks, pipes and hoses before installation.

Welded or hot-bent pipes must be pickled (cleaned in an acid bath) and washed before they are built in.

The oil tank must be closed and provided with an efficient air filter to prevent dirt contaminating the hydraulic oil.

Sealing compounds such as flax, cement or thread tape are not permitted.

Take into consideration the specified operating data.

Do not exceed the permitted pressures and volume flows.

Do not exceed or go below the specified temperature range.

Pay attention to specified electrical voltages and power consumption.

NOTE! All work with the hydraulic system should be carried in a pressureless state and in a clean environment.

Installation To prevent dirt and corrosion in the hydraulic system all hydraulic components must be provided with plastic plugs blocking the connections before they are delivered. Only remove these plugs just before the component is to be installed in the machine. Retaining screws and connections must correspond with those on the drawing. Retaining screws should not be tightened with a higher torque than what is specified on the drawing. If such information is missing, the torque should not exceed that specified in Section 1.7.1.1, page 12.

Connections Couplings must be fitted in accordance with the tightening torques specified in the table at Section 1.7.1.2, page 13. We recommend couplings with elastic seals. Such couplings are necessary for control valves. Ring couplings do not seal at the low torque generally applicable for proportional valves.

Connect pipes and hoses in accordance with the hydraulic diagram. Pay attention to the connection designations. Do not use force, and avoid building-in tensions in pipes, etc, Start up Check that everything is connected in accordance with the hydraulic diagram. Set the relief valves down to a very low pressure if they are not sealed. Start-up with low pressure and volume flows.

Test the function and tightness of the system. Clean the system by allowing oil to pass over the filter for a while, without loading the system (replace the filter insert at the recommended change intervals).Check the oil level. Slowly increase the pressures and volume flows to their appropriate values. If measuring equipment is fitted, check this continuously. Pay attention to the noise level since abnormal noise implies defects. Test during variable loads that components are correctly fitted, and that the system is tight.

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08 Hydraulic system

In the event of returning equipment to the manufacturer, protect polished surfaces from damage and dirt by covering them with foil and protective paper. Fit plastic plugs in all connections. Send the complete components, not loose parts.

8.2.2

Hydraulic oil, changing/draining

8.2.2.1

Properties of the hydraulic oil The hydraulic oils that are recommended in this manual have properties that promote a long service life and good functionality, and these are the oils that should be used in the truck.

The hydraulic oil used in the UniCarriers trucks should comply with the UniCarriers quality requirements: • • • • • • • • •

Smooth action.

Long service-life.

High viscosity index with wide range of temperature applications.

Good low-temperature properties.

High filterability.

Good air and water separating capacity.

Good wear protection.

Good oxidation stability.

Minimum foaming.

• •

Provide protection from rust and corrosion.

Good adhesive capacity.

NOTE! Never mix oils of different types or brands! Environmentally adapted oils must not be used without the approval of UniCarriers if the warranty it to be valid.

NOTE! For recommended oil and grease types, see Section 1.6, page 11.

8.2.2.2

Equipment that is required • • •

8.2.2.3

New oil, or purifying equipment for the old oil.

A tray to collect the oil in.

A clamp or plug for the suction pipe.

Procedure: 1)

Lower the forks and disconnect the battery electrical.

2)

Lift up the steering wheel panel and open out the machine housing cover.

3)

Check how much oil needs to be filled by marking the existing level. e.g. with a strip of tape.

4)

Place the tray on the floor behind the truck.

5)

Clamp the suction pipe between the pump and tank, release the suction hose from the pump and lead it to the tray, and then release the clamp so that the oil runs out.

NOTE! Make sure that the oil does not overflow in the tray. Spent oil must be taken care of and recycled in accordance with the applicable legislation in respective countries.

When changing the oil the filters must always be replaced!

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08 Hydraulic system

6)

Replace the suction pipe, and fill up with new oil through the hydraulic oil filter to the same level as before. If there has been any leakage it will be necessary to fill to a higher level. To obtain the correct oil level all the cylinders should be run to their end positions, and check that the pump does not suck air.

7)

Run in the cylinders and check that the oil tank does not overflow.

NOTE! The hydraulic oil should be filtered when filling, by pouring the oil through the filter.

8)

8.2.3

Wipe up any oil spillage, close the machine housing cover, and lower the steering wheel panel.

Air filter, replacing The air filter is located on the side of the hydraulic tank filler cap.

Figure 73. Air filter on the hydraulic tank

8.2.4

A-Ergo

1)

Unscrew the top of the filter housing.

2)

Take out the filter.

3)

Wipe the filter housing clean with a cloth that does not leave fibres.

4)

Insert a new filter and screw on the top.

Oil filter element, replacement 1)

Lower the forks and electrically disconnect the battery.

2)

Open the machine housing cover.

3)

Remove the cover that is located on the top of the hydraulic oil tank.

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Figure 74. Oil filter

8.2.5

4)

Lift up the filter element, wait briefly until the oil has had time to run off the element, and then lift it out.

5)

Pull the filter away from the rod.

6)

Clean the magnet on the rod, the purpose of which is to capture swarf.

7)

Insert a new filter.

8)

Put the filter back into the hydraulic oil tank, fit a new O-ring and screw the cover back on.

9)

Close the machine housing cover.

Checking the hydraulic oil level 1)

Carefully raise the fork carriage to its topmost position.

2)

Check that the hydraulic pump is not drawing in air. This can be recognised by the function in operation moving jerkily, or by an abnormal screeching noise.

3)

If the hydraulic pump is drawing in air, move all the hydraulic functions to their lowest positions, open the machine housing cover, and check the oil level in the hydraulic tank.

4)

Fill with hydraulic oil of the grade recommended in Section 8.2.2.1, page 110 so that the level rises a few cm. Then perform the “test lift” and check as above.

5)

Repeat this procedure until a normal function is obtained.

8.2.6

Lowering brake valve

8.2.6.1

Dismantling and assembling

112

1)

Lift the forks so that the inner mast is raised by about 30 cm. Place a wooden block under the inner mast, and carefully lower the inner mast until it rests on the block.

Continue lowering until the system is pressure-less.

2)

Disconnect and push out the battery to improve access.

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Service Manual A-Ergo — D003936, C, GBR, Translated

08 Hydraulic system

3)

Place protective paper under the truck, release the hose from the valve housing (item 1) and plug it.

4)

Unscrew and remove the lowering brake valve (item 2) and plug the valve housing (item 1).

5)

If a fault is suspected on the valve, it should be checked. There are specific dimensions for the spring length, depending on which cylinder it is to protect. See the setting value in Table 24, page 113.

6)

Adjust the valve, or replace with a new one, and fit it in the valve housing.

7)

Refit the hose and push the battery back in.

Figure 75. Lowering brake valve

8)

Test run.

Figure 76. Location of the lowering brake valve

Table 24. Setting the lowering brake valve

A-Ergo

Machine type

Marking

s mm

v s/m

Q l/min

A Vertically adjustable straddle leg

SB09C/3402

7,5

9,6

10

A 160 T

SB25C/3342

13,5

1,8

37

A 160 TV

SB25C/3342

13,5

1,8

37

A 160 TFV

SB27C3345

16

1,8

45

A 160 DTFV

SB25C3342

13,5

1,8

37

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08 Hydraulic system

Machine type

Marking

s mm

v s/m

Q l/min

A TF/200 TFV

SB27C/3345

16

2,0

45

A TF/200 DTFV

SB27C/3345

16

2,0

45

Figure 77. Cross-sectional view of the lowering brake valve

8.2.7

Hose rupture valve

8.2.7.1

Dismantling and assembling 1)

Lower the forks and relieve the pressure in the hydraulic system.

2)

Place protective paper under the cylinder to be repaired.

3)

Loosen the pipe or hose that goes to the cylinder, and plug it.

4)

Remove the nipple placed in the cylinder.

5)

Unscrew the hose rupture valve (item 1, see Figure 78, page 114) that is screwed into the cylinder.

Figure 78. Hose rupture valve

114

6)

If a fault is suspected, check the length of the spring in relation to the table or data sheet. Adjust, or fit a new valve.

7)

Fit the nipple, connect the pipes, and wipe clean.

8)

Test run.

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Service Manual A-Ergo — D003936, C, GBR, Translated

08 Hydraulic system

Figure 79. Hose rupture valve

Table 25. Setting value for the hose rupture valve Machine type

Marking

s

Q

mm

L/min

A 160 T

LB3C/3791

2,4

80

A 160 TV

LB3C/9175

1,2

50

A 160/200/TF TFV Free lift

LB3C/3791

2,4

80

A 160/200/TF TFV Final stroke

LB3C/9185

1,2

50

A 160/200/TF DTFV Free lift

LB4C/3694

2,0

125

A 160/200/TF DTFV Final stroke

LB3C/3691

2,0

67

8.2.8

Control valve

8.2.8.1

General instructions when working with the control valve

8.2.8.2

A-Ergo

1.

Cleanliness • Dirt particles must not be allowed to get into components.

• Cloths must not shed fibres and particles.

• Tools must be clean.

• Tanks, pipes and hoses must be carefully cleaned before installation.

• Welded or hot-bent pipes must be pickled and cleaned before they are built-in • The oil tank must be closed and provided with an efficient breather filter that prevents the penetration of dirt.

2.

Sealing compound • Sealing compounds such as flax, mastic or thread tape are not permitted.

3.

Operating data • Do not exceed the permitted pressures and volume flows.

• Do not go beyond the specified temperature range.

• Pay attention to specified electrical voltages and maximum power consumption.

Removal and installation of the manual proportional valve 1)

Lower down the forks and relieve the pressure in the hydraulic system.

2)

Fold up the armrest to provide access to the valve. See Section 4.2.2.1, page 41 for how to remove the armrest.

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Figure 80. Location of the manual proportional valve

3)

Place protective paper under the valve and release the electric cables to the microswitch(s).

4)

Loosen all the oil pipes connected to the valve and plug them.

5)

Loosen the valve from the truck, and lift it out.

6)

When fitting, first place the valve in the truck but do not tighten until all the oil pipes are connected. Tighten the valve and then the oil pipes.

7)

Adjust the relief valve to the rated weight in accordance with the machine plate.

8)

Seal the setting.

Figure 81. Hand lever operated valve

8.2.8.3

116

Electrically operated control valve, removal and installation 1)

Lower down the forks and relieve the pressure in the hydraulic system.

2)

Switch off the power lock.

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08 Hydraulic system

3)

Open the machine housing cover and fold up the hand rest to gain access to the valve.

Figure 82. Location of the electric proportional valve

4)

Place protective paper under the valve and release the electric cables to the microswitch(s).

5)

Loosen all the oil pipes connected to the valve and plug them.

6)

Loosen the valve from the truck, and lift it out.

7)

Torque When fitting, first place the valve in the truck but do not tighten until all the oil pipes are connected. Tighten the valve and then the oil pipes, to a maximum of 60 Nm.

8)

Adjust the relief valve to the rated weight in accordance with the machine plate.

9)

Seal the setting.

Figure 83. Electrically operated proportional valve

8.2.8.4

Checking the lowering speed The lowering speed of the fork carriage depends on the load on the forks which is stated on the truck’s machine plate.

Check the actual lowering speed with the table below.

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NOTE! According to EN 1726, a load must not be lowered at a rate exceeding 0.6 m/s.

Mast type

Lowering speed m/s

A 160

max 0.6

A 200/TF

max 0.5

If the correct lowering speed cannot be achieved, the electrical signal from the control unit to the solenoid valves must be checked first, in accordance with Section 8.2.8.5, page 118.

The hydraulic valve is then adjusted in accordance with Section 8.2.8.6, page 118.

8.2.8.5

Adjusting the electric valve regulator See Section 10, page 137.

8.2.8.6

Adjusting the lowering speed valve in the electrical hydraulic valve As a first step all the settings of the control unit should always be checked before a hydraulic adjustment.

See Section 10, page 137.

If the correct lowering speed has not been achieved (see Section 8.2.8.4, page 117 ) adjust the lowering speed valve mounted on the hydraulic valve, (see item 1, Figure 84, page 118 ), until the correct lowering speed is obtained.

Figure 84. Electrically operated proportional valve

8.2.8.7

118

Adjusting the working pressure 1)

Place a maximum rated load on the forks. (The maximum rated load is specified on the truck’s machine plate.)

2)

Unscrew the adjusting screw, (item 2) two turns counterclockwise.

3)

At the same time as activating the fork lift truck lifting function, screw in the adjusting screw (clockwise) until the forks begin to lift the load off the floor. Then turn the adjusting screw a further 1/4 turn inwards and lock it.

4)

Continue to turn the adjusting screw clockwise until the machine just manages to lift the maximum load to its highest permitted value.

5)

Finally, perform repeated lifting operations to ensure that the lifting capacity is sufficient.

6)

Seal.

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Service Manual A-Ergo — D003936, C, GBR, Translated

08 Hydraulic system

8.2.8.8

Emergency lowering valve The emergency lowering valve is used to lower the forks in the case of a power failure.

WARNING! Ensure that the forks can be lowered unobstructed before opening the emergency lowering valve.

8.2.9

1)

Open the emergency lowering valve (see item 3, Figure 84, page 118) with a 2.5 mm Allen key.

2)

Close the emergency lowering valve once the forks have been lowered.

Adjusting the level limit position switch (ALL)

Figure 85. Adjusting pressure

1)

Unscrew the connector securing screw (indicated by the arrow).

2)

The pressure can be adjusted with the connector still connected using an Allen key (size 2) through the hole were the screw in point 1 is fitted.

3)

Put the maximum rated load on the forks and make fine adjustments to the limit position switch setting to allow continuous movement during lifting and to stop the movement directly when the top position is reached.

8.2.10

Hydraulic pump motor

8.2.10.1

Removing the hydraulic pump motor 1)

Lift the forks to their highest position to lower the hydraulic oil level in the tank, thus reducing oil leakage at the pump shaft when the motor is removed.

WARNING! Do not work under the forks.

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2)

Electrically disconnect the battery.

3)

Open the machine housing cover and disconnect the wiring to the hydraulic motor.

4)

Slacken the two retaining bolts that secure the pump to the hydraulic motor.

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5)

Loosen and remove the bolts that hold the clamp round the hydraulic motor.

6)

Remove the loosened retaining bolts and detach the pump from the hydraulic motor, and then lift off the hydraulic motor.

NOTE! Check that the connector is turned in the correct direction and that the motor and pump journals are at 90° in relation to each other.

Figure 86. Hydraulic pump motor

7)

Install in the reverse order.

NOTE! Grease in the pump journal before fitting!

8.2.11

Hydraulic pump motor ALL

8.2.11.1

General If the performance of the electric motor changes it should be inspected internally. One of the most common sources of faults is wear on the carbon brushes in the motor.

The brushes can wear out, or stick in the brush holders. In both cases inadequate contact between the brushes and the commutator can lead to serious damage on the commutator surface.

8.2.11.2

When should the brushes be replaced?

•

•

8.2.11.3

If a carbon brush cannot move freely in the brush holder. To check this the brush holder must be released from the brush rigging. The force from the brush spring should then press out the brush from the brush holder as far as is permitted by the cable.

If a carbon brush is approaching the end of its usable length. The length of the brushes must never be less than 10 mm (a new brush has a length of 17 mm). Since this is difficult to measure there is an alternative method. Measure the difference between the cable and the groove in the brush holder. The difference must be at least 1 mm. Even if the difference is only slightly more, it is recommended that the brushes are changed anyway, since their remaining service life may be shorter than the interval to the next inspection.

Replacing the brushes The brushes themselves cannot be changed, as they are part of an assembly consisting of the brush, brush holder and spring. Installation is in accordance with the following instructions.

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Figure 87. Replacing the brushes

1)

Release the cables from the terminals on the motor (item 1, Figure 87, page 121).

2)

Remove the through bolts from the rear end of the motor (item 2, Figure 87, page 121).

3)

Lift out the electric motor from the truck.

4)

Place the electric motor on the drive end.

5)

Remove the nuts from the terminals, (item 3, Figure 87, page 121). If the motor has an earth return, the earth connection on the rear end of the motor should also be detached (item 4, Figure 87, page 121).

6)

Remove the rear end (item 5, Figure 87, page 121). Make sure that the terminals remain in their positions.

Figure 88. Replacing the brushes

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7)

Disconnect all four carbon brushes by releasing the screws (item 6, Figure 88, page 121) - A. Then press each brush towards the commutator. - B. Remove the brush set from the brush rigging – C. The old brush set is replaced with a new set by the reverse procedure. It is recommended to replace each brush separately to avoid confusion.

Make sure that each brush set is replaced with the correct part, i.e. one that has the cable on the correct side. (The service kits consist of two matching pairs of brush sets!)

8)

Torque Tighten the screw (item 6, Figure 88, page 121), to approx. 1.3-1.8 Nm. 121

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9)

Replace the terminals in the grooves in the rear end, and replace it back on the motor.

Check that there is a washer between the rotor and the end (item 12, Figure 88, page 121) and that the attachment is held in place by a lug and a slot on the casing and end.

10)

Torque Insert the through bolts and replace the electric motor in the truck. Tighten the bolts to approx. 4.8-6.8 Nm.

11)

Torque Tighten the terminal nuts to 10-14 Nm (item 3, Figure 87, page 121).

12) Replace the cables to the motor terminals.

8.2.11.4

Tips for prolonging the service-life of the motor •

• •

• •

• • •

The rapid wearing of carbon brushes and the commutator is often caused by oil. Oil or grease is burned by the sparks produced at the brushes, and leaves a residue of abrasive ash. If oil or grease is detected in the motor the reason for this must be eliminated immediately.

Never overload the motor. Brushes that have been severely overheated expand permanently and can fasten in the brush holders.

The service-life of the brushes does not only depend on the loading, but also on how worn the commutator is. The commutator should have smooth, level and greyish black surface. A worn commutator must be machine milled (never use abrasive paper, grindstone or a file!) to a surface finish of Ra = 0.8-1.8µm and a maximum runout of 0.03 mm (with the rotor resting in the bearing seats). The service-life of the commutator is prolonged if it is machined a little and often, rather than seldom and a lot. The minimum permitted diameter of the commutator is 40.8 mm.

The motor must not be exposed to full load immediately after changing the brushes.

Look for signs of overheating on the windings, dark patches, brittle or burned insulation, and damage to the soldering on the commutator. The electric motor should be replaced if such damage is found.

If possible, remove dust and dirt from inside the motor with compressed air.

A dirty commutator should always be cleaned with a cloth moistend with petrol (do not used cotton rags since these shred fibres), and carefully blown dry with compressed air.

If the bearing cup looks as if it has run out of oil (i.e. if there is a lot of oil on the rotor washer or brush holder) lubricate it with a little bearing grease.

8.2.12

Stabiliser cylinders

8.2.12.1

General The stabiliser cylinders have in their upper end a flexible attachment, the purpose of which is to compensate for minor irregularities in the floor.

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Figure 89. Stabilizer Cylinder

8.2.12.2

8.2.12.3

Removal and installation of the stabilizer cylinders 1)

Fully extend the stabilizers.

2)

Remove the split pin from the upper attachment. Take hold of the cylinder in one hand and then pull out the HCB bolt. This is because of the pre-tensioning of the spring package.

3)

Lift up the stabilizers slightly to release the tension in the spring package.

4)

Pull out the battery plug.

5)

Release the hoses and plug them.

6)

Remove the lower bolt that goes through the piston rod end.

Dismantling and assembling, gaskets 1)

Unscrew the piston rod guide and pull the piston rod out of the cylinder tube.

2)

Brace the piston rod in the vice in the end that normally sits in the straddle leg; use protective jaws on the vice.

3)

Remove the nut and remove the gasket holder, together with the piston seals.

NOTE! Before fitting, all seals should be lubricated with hydraulic oil.

4)

8.2.13

Assemble in the reverse order.

Installation instruction for pipe couplings To achieve a safe and tight connection when installing pipe couplings in the hydraulic system, the following points should be taken into consideration: CAUTION! Do not cut the pipe, as this could mean that metal chips would get into and damage the hydraulic system.

1)

Small pipe dimensions can be fitted directly in the coupling connected to the machine part. Screw the nut by hand until it lies flush with pipe olive, press the pipe towards the shoulder in the coupling cone, and tighten the nut a ¾ turn.

NOTE! The pipe must not follow round.

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2)

The pipe olive will now have gripped the pipe, which no longer needs to be pressed against the shoulder. Complete the fitting with an additional ¾ turn of the nut. Marking the nut simplifies complying with the prescribed torque (see Figure 90, page 124).

Figure 90. A mark on the nut simplifies the specified torque

3)

Larger pipe dimensions and couplings in free pipes are preferably fitted by placing the coupling body in a vice. The U-ring spanner length should be 15 times the nut width (the spanner can be extended with a piece of pipe). Otherwise fit according to point 3.

If several couplings of the same type are to be fitted, make sure that each pipe end goes in the same coupling cone it was previously fitted in. Final fitting is facilitated if the nut is loosened a little and oil is applied between the friction surfaces.

4)

After fitting, release the cap nut and check that the pipe olive has pressed up a visible swelling in the area in front of it (see Figure 91, page 124). If not, give it another short turn. It is of no importance whether the pipe olive can still be turned.

Figure 91. A visible swelling should have formed after tightening

After a visible swelling has formed the nut should be fitted without extension of the U-ring spanner, and without excessive force.

NOTE! Refitting: After a visible swelling has formed the nut should be fitted without extension of the U-ring spanner, and without excessive force.

5)

If the pipe is to be bent after a coupling, the straight pipe end should have a length of at least 2 nut heads, H. Long and heavily loaded pipes should be provided with pipe clips.

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Figure 92. Straight pipe length between bend and coupling

6)

The final assembly must be done with at least 1 turn of the nut from the point where it can no longer be turned by hand.

8.3

Diagnostics and trouble shooting

8.3.1

Symptom and Action A number of fault symptoms have been listed in the table below, with a number of possible faults and repair procedures. It is therefore possible for other faults to have occurred in addition to the ones listed.

Symptom

Possible fault

Procedure

The lift motor runs, but the fork carriage does not lift.

The lowering valve has jammed and is open.

1.

Close the valve.

2.

Adjust, or remove any dirt from the valve.

The lift motor runs, but the fork carriage lifts very slowly.

The machine is overloaded.

Lighten the load.

The overflow valve is defective.

Adjust the valve to the rated weight.

A foreign object has partially Take apart and clean. blocked a hose, hydraulic pipe or valve.

Hydraulic hose has been clenched.

The lift motor emits a screeching The oil level is too low in the noise just before the fork hydraulic tank. carriage reaches the top.

The fork carriage will not lower.

Valve does not open on return because of foreign object in the system.

Rearrange the hose and clamp secure.

1.

Fill with hydraulic oil. When the tank is almost full, try with 0.1 litre at a time to avoid overfilling.

2.

Find out the reason for the low level, and rectify the fault.

Dismantle the valve and clean it.

The hose rupture valve is closed Limit the lowering speed. because the lowering speed is too high.

The hose rupture valve is closed Replace the hose rupture valve. because the spring in the valve is defective.

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Symptom

Possible fault

The fork carriage lowers too slowly.

Lowering valve or lowering brake 1. valve is dirty or defective.

Run the lift motor for a maximum of 1 minute to see if the dirt releases.

2.

If not, dismantle the valve and clean, or replace defective parts.

The fork carriage lowers too quickly.

Procedure

The oil filter is blocked and dirty.

Change filter.

The lowering brake valve is defective.

Replace the lower brake valve.

The lowering brake valve is incorrectly adjusted.

Adjust the lowering brake valve.

Hydraulic oil flows out via the air Oil level too high. filter.

Reduce the oil level to correct level.

The oil foams.

Change the oil with oil that has the correct properties.

Condensation water in oil tank.

Empty the tank of oil and fill with new hydraulic oil to correct level.

The fork carriage rocks when lifting.

Air in the hydraulic system.

Bleed the system via the air cylinders.

The hydraulic oil has a bad smell, sulphur.

The oil separators in the hydraulic oil are ruined.

1.

Change the oil and filter.

2.

Flush the complete system with new hydraulic oil.

Motor oil has been used and caused the hydraulic oil to emulsify with water and become contaminated.

The lift motor continues to run The pressure switch is not despite the fork carriage being at adjusted correctly. the top and against the mechanical stop. NOTE! Only The pressure switch cannot be applies to ALL trucks. adjusted.

Lower the pressure in the pressure switch, see Section 8.2.9, page 119.

The lift motor stops when the The pressure switch is not maximum load or a lesser load is adjusted correctly. to be lifted. NOTE! Only applies to ALL trucks.

The pressure switch cannot be

Increase the pressure in the pressure switch, see Section 8.2.9, page 119.

Change the pressure switch.

Change the pressure switch.

adjusted so that the pump stops when at the top position.

The lift motor runs intermittently when ender load. NOTE! Only applies to ALL trucks.

126

The limit values between the overflow valve and the pressure switch are too close to each other.

Check and if necessary adjust the overflow valve towards maximum load and then adjust the pressure switch in accordance with the instructions.

If this still does not work, change the pressure switch.

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09 Lift cylinders

09 9.1

LIFT CYLINDERS Design and function 9.1.1

9.2

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General.......................................................................................................................... 131

Repair and maintenance instructions 9.2.1 9.2.2 9.2.3 9.2.4

131 131

General.......................................................................................................................... 131 Free lift cylinder TFV/DTFV ........................................................................................... 132 Lifting cylinder TV/TFV/DTFV........................................................................................ 133 Lift cylinder T ................................................................................................................. 135

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09 Lift cylinders

09

LIFT CYLINDERS

9.1

Design and function

9.1.1

General The lift cylinders consist of single-acting hydraulic cylinders, where hydraulic oil is pumped into the cylinder, pressing out the piston rod.

When the driver activates the lowering function the cylinders are pressed together through a control valve releasing oil out from the cylinders. They are then pushed together by the weight of the forks, at the same time as the oil returns to the hydraulic tank.

As opposed to the lift cylinders, the side stabiliser cylinders are double-acting. This implies that a hydraulic oil also acts in the opposite direction and pushes the cylinder together.

9.2

Repair and maintenance instructions

9.2.1

General

9.2.1.1

Bleeding of the hydraulic cylinders with the air bleed screw WARNING! When bleeding, the air screw must be opened no more than approx. a half turn. If the air screw is opened completely the oil will spurt out and the forks crash uncontrollably to their bottom position. The hose rupture valves do not function in this phase.

Figure 95. Example, air screw.

9.2.1.2

1)

Open the air bleed screw about half a turn.

2)

Check that there is sufficient oil in the hydraulic tank and that the pump does not suck air.

3)

Carefully run the cylinder repeatedly between its end positions.

4)

When oil without air bubbles comes out, the cylinders have been bled.

5)

Adjust the oil level in the hydraulic tank.

6)

Repeatedly lift from bottom to top position.

7)

Check that the forks do not bounce. If they do, bleed the air one or more times.

Bleeding of the hydraulic cylinders without a bleed air screw Cylinders without bleed air screws are bled by running the cylinder repeatedly between its end positions.

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NOTE! Check the oil level regularly.

9.2.2

Free lift cylinder TFV/DTFV

9.2.2.1

Dismantling and assembling

9.2.2.2

1)

Remove the retaining screw that holds the lower end of the cylinder.

2)

Lower the forks, e.g. on a pallet, so that the chains slacken. Remove the chain pin that goes through the chain bolt on the cylinder, and place the chain over the back of the fork carriage.

3)

Release the fork carriage from the mast by lifting up the inner mast with the hydraulic pump. Reverse the truck away.

4)

Lower so that all the cylinders are pushed together completely.

5)

Loosen the bolts that hold the clamp at the top end of the cylinder, without removing it.

6)

Disconnect the oil pipe.

7)

Remove the clamp, and lift out the cylinder.

8)

Plug the oil pipe.

9)

Install in the reverse order.

Dismantling and assembling 1)

Brace the lower end of the cylinder in a vice.

CAUTION! Risk of deformation, use moderate force.

2)

Remove the circlip (item 1) and remove the yoke, (item 2).

3)

Place a container for oil spillage under the cylinder.

4)

Remove the top nut (item 3) with a suitable tool and take it off the piston rod.

5)

Pull out the piston rod.

6)

Remove the seals (item 4) and guide rings (item 5) from the piston. Use a thin tool that will not scratch.

7)

Remove the seal (item 6) and scraper (item 7) from the top nut and O-ring (item 8).

8)

Clean all parts and check for damage. Replace if necessary.

NOTE! Always use original spare parts for maximum safety and service-life.

9)

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Assemble in the reverse order. Oil in all parts with hydraulic oil before fitting.

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09 Lift cylinders

Figure 96. Free lift cylinder TFV / DTFV

9.2.3

Lifting cylinder TV/TFV/DTFV

9.2.3.1

Dismantling and assembling

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1)

Lift the forks until the inner mast is raised approx. 20 mm. Place wooden blocks under the inner mast, and lower it down onto the blocks.

2)

Remove the upper securing screws (item 1).

3)

Lower the cylinder to its compressed position.

4)

Loosen, disconnect, and plug the oil pipe.

5)

Remove the retaining screw (item 2).

6)

Lift out the cylinder.

7)

Install in the reverse order.

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9.2.3.2

Dismantling and assembling 1)

Make a nore of how far the adjusting screw (1) is screwed into the piston rod end (this will be needed when reassembling).

2)

Unscrew the adjusting screw (item 1).

3)

Support the lower end of the cylinder in a vice.

CAUTION! Risk of deformation: use moderate force.

4)

Place a container for oil spillage under the cylinder.

5)

Unscrew and remove the top nut (item 2). Pull out the piston rod (item 3).

6)

Remove the sealing rings and guides (item 4) from the top nut.

7)

Remove the guide rings (item 5) from the piston rod.

8)

Clean all parts and check for damage. Replace if necessary.

NOTE! Always use original spare parts for maximum safety and service life.

9) 134

Install in the reverse order. Lubricate all parts with hydraulic oil before fitting.

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09 Lift cylinders

9.2.4

Lift cylinder T

9.2.4.1

Dismantling and assembling

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1)

Lower the forks, e.g. on a pallet, so that the chains slacken. Remove the split pin bolt (item 1) that sits in the top end of the cylinder.

2)

Remove the chain and place it over the back of the fork carriage.

3)

Release the fork carriage from the mast by lifting up the inner mast with the hydraulic pump. Reverse the truck away.

4)

Place a wooden block, 10-15 cm thick, under the inner mast, and carefully lower the inner mast until it rests on the block.

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9.2.4.2

5)

Secure the cylinder so that it cannot drop out of the mast! Remove the circlip (item 2) and remove the lower securing screw (3).

6)

Lower carefully so that the piston rod comes out of the yoke (item 4). When the piston rod is fully pushed in, remove the oil pipe and return pipe. Tilt the cylinder forward and lift it out.

7)

Install in the reverse order.

Dismantling and assembling 1)

Place the cylinder on a bench with the chain attachment facing down.

2)

Slacken and remove the top nut (1) with a hook spanner.

3)

Pull out the piston rod (item 2) and place it carefully on the bench to avoid damaging it.

4)

Remove the parts (items 3, 5, 6, 7 and 8).

5)

Clean all parts and check for damage. Replace if necessary.

NOTE! Always use original spare parts for maximum safety and service life.

6)

136

Install in the reverse order. Lubricate all parts with hydraulic oil before fitting.

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10 Electrical system

10

ELECTRICAL SYSTEM

10.1 General 10.1.1 10.1.2 10.1.3

Safety procedures ......................................................................................................... 141 Safety checks ................................................................................................................ 141 Hand terminal operation ................................................................................................ 142

10.2 Design and function 10.2.1 10.2.2 10.2.3 10.2.4 10.2.5

145

General functional description of the controllers ........................................................... 145 Multifunction Display Indicator (MDI)............................................................................. 148 Traction motor controller, AC1 ....................................................................................... 150 Steering servo controller, EPS-AC ................................................................................ 162 Wiring diagram .............................................................................................................. 167

10.3 Repair and maintenance instructions

168

10.3.1 10.3.2 10.3.3 10.3.4

Calibration, Speed controller ......................................................................................... 168 Calibrating the lifting and lowering controls ................................................................... 171 Save the parameters in the hand terminal's memory .................................................... 173 Downloading parameters from the hand terminal.......................................................... 175

10.3.5 10.3.6 10.3.7 10.3.8

Check the error codes ................................................................................................... 176 Changing the traction motor controller/steering servo controller ................................... 178 MDI replacement ........................................................................................................... 178 Changing the steering servo sensor.............................................................................. 179

10.4 Diagnostics and trouble shooting 10.4.1 10.4.2 10.4.3 10.4.4

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141

180

Safety ............................................................................................................................ 180 Trouble shooting aids .................................................................................................... 180 Practical trouble shooting .............................................................................................. 180 Error codes .................................................................................................................... 182

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10

ELECTRICAL SYSTEM

10.1

General

10.1.1

Safety procedures

10.1.1.1

General WARNING! Working with electrical vehicles can result in personal injury.

•

•

10.1.1.2

During all work on the truck’s electrical system, or in its immediate vicinity, rings, watches and other metal objects must be removed since the battery capacity is such that a short circuit through such an object can result in very serious burn injuries.

Working with electrical vehicles can result in personal injury. All testing, trouble shooting and adjusting must be carried out by authorised personnel. The drive wheel should run free of the floor and be able to rotate freely during work.

Electronic controllers • •

All the electronic controllers in the truck have multiple safety systems.

When replacing or repairing the electronic controllers, or removing cables, the battery should always be disconnected.

NOTE! Incorrectly connected battery cables can destroy the electronic controllers.

WARNING! During all work on the truck the drive wheel must be lifted up from the floor to prevent accidents occurring. In order to avoid burn injuries, wrist watches and other metal objects must be taken off.

After the power has been disconnected to the controller and work or trouble shooting is to be conducted, there can be residual voltage in the capacitors for a few minutes, so take care when using current-conducting tools during these minutes.

10.1.2

Safety checks

10.1.2.1

Servo controlled steering system NOTE! Checks on the external component functions in the servo controlled steering system must be carried out after every service and after work has been carried out on the electrical system. All functional tests of the safety system must be carried out with the truck speed controller in its neutral position.

The servo controlled steering system embodies a number of safety monitors, partly to check the controller circuits, but also such external circuits and components as the steering wheel sensors, steering motor and end position sensors.

Functional testing of the servo controlled steering system safety functions must result in an inability to activate the steering or drive systems and the brake not being able to go into its unbraked state.

The monitoring system for the steering wheel sensors and their wiring is checked by disconnecting the steering wheel sensor connector; this will result in an error code, see Section 10.4.4.3, page 186.

The steering motor monitoring system is checked by disconnecting one of the wiring connections to the motor, either at the motor or its controller. An error code must then be shown if the steering wheel is moved, see Section 10.4.4.3, page 186.

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10 Electrical system A dangerous condition arises if the end position switches for the steering function are activated without the steered wheel being at the particular end position. This is monitored by the controller sensing whether the sensor is activated even though the wheel is moving away from the sensor. Test this by placing a jumper between pins 2 and 3 of the end position sensor connector, see S4 and S5 respectively in the connections schematic diagram “Wiring Diagram Handbook” and steering away from the respective sensor; check that an error code is shown, see Section 10.4.4.3, page 186.

Figure 97. S4 and S5 connectors, seen from the wiring side

10.1.2.2

Traction motor system The monitoring system checks that starting takes place in the correct order, i.e. that the speed controller does not send an output signal when the truck is started by the key switch.

This function is tested by switching the key switch off, holding the speed control in the affected position and switching the key switch back on again. The truck should not in that case move until the speed controller has been in the neutral position.

A test of the motor circuit is not possible, since it is a 3-phase motor, but it is not necessary anyway.

There are different systems to reduce the maximum speed of the truck, the lifting height of the forks and the load. These systems are tested by lifting the forks above the microswitch breaking height and loading with more than the preset weight. A tortoise is then shown on the MDI display, refer to Section 10.2.2, page 148.

10.1.3

Hand terminal operation The hand terminal is connected to the controllers via a 9-pole connector, connector "C". This is normally covered by a rubber plug, which must be put back after the hand terminal has been disconnected.

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Figure 98. Hand terminal/programming tool for adjusting the controller settings

All adjustments to the controller settings are made by means of the hand terminal.

With the aid of the six buttons on the hand terminal the settings of the traction motor controller and steering servo controller respectively can be checked and adjusted.

See table 10.1 below for instructions on how the terminal is used in the menus.

Desired function

Buttons to use

To step down through the menus:

ROLL (1)

To step up through the menus:

ROLL (2)

To enter a menu option: ENTER (3)

To increase the currently SET (5) set value:

To reduce the currently set value:

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SET (6)

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Desired function To exit a menu option and save the changed

Buttons to use OUT (4) + ENTER (3) OUT (4) + OUT (4)

value To exit a menu option without saving the changed value:

To select “CONFIG MENU”

ROLL (1) + SET (5)

To also present all error messages by using the hand terminal, see Section 10.4.4, page 182.

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10.2

Design and function

10.2.1

General functional description of the controllers

10.2.1.1

Overview of the communication routes

Figure 99. Overview of the electrical system communication routes 1. Traction motor controller 3. Steering servo controller 5. Speed Controller 7. Lift control 9. Hydraulic pump 11. Hydraulic lift cylinder 13. Steering servo motor

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2. CAN bus link 4. Multifunction Display Indicator (MDI) 6. Traction motor 8. Electrical panel 10. Hydraulic valve 12. Steering wheel

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Communication between the controllers

Figure 100. Communication between the controllers

The brain of the system is the traction motor controller (1) which via the CAN link communicates with the controller for the steering servo motor (3) and the Multi Function Display (MDI) (4).

The control units include self-diagnostic sections which can generate error codes. These error codes are presented on the MDI (4) and on the hand terminal (se Section 02, page 17). The MDI also presents the total time during which the truck has been in operation and the battery status.

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Service Manual A-Ergo — D003936, B, GBR, Translated

10 Electrical system 10.2.1.3

Traction motor controller

Figure 101. Overview of the traction controller for the traction motor.

When the speed control lever (5) is moved, the traction motor controller (1) sends a drive voltage to the traction motor (6). A pulse transducer in the upper bearing of the traction motor feeds back the motor rotation speed to the regulator, which alters the drive voltage to produce a speed which is equivalent to the speed control.

Figure 102. Overview of the traction motor controller, hydraulic pump motor, lifting valve and lift cylinder

A-Ergo

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Service Manual A-Ergo — D003936, B, GBR, Translated

10 Electrical system When the control lever for the electrically controlled lifting movement (7) is moved, the traction motor controller (1) sends a voltage to the lift motor contactor (8) which starts the lift motor (9). The traction motor controller also sends information via the CAN link (2) to the MDI (4) concerning how large the control movement is, and the lifting rate is then controlled by the MDI, which gives a proportionally equally high control voltage to the control movement to the control valve (10), which in turn gives a proportionally equally high hydraulic flow to the lift cylinder (11), which provides the variable lifting and lowering rates.

On trucks with manual hydraulic valves the valve output is directly controlled by the position of the lifting lever.

10.2.1.4

Steering servo controller

Figure 103. Overview of the steering servo controller, steering wheel and steering servo motor

When the steering wheel is turned, a signal is sent via a stepping motor on the steering wheel (12) to a controller for the steering servo motor (3) which in turn transmits a proportional drive voltage to the steering servo motor (13) which turns the drive wheel at the desired speed and direction.

10.2.2

Multifunction Display Indicator (MDI)

10.2.2.1

Display description Battery charging is indicated by means of five LEDs, four green and one red. When the battery is fully charged all the green LEDs are on. The LEDs go off as the battery becomes discharged, and when the battery charge has reached a level that requires the battery to be recharged the red LED (steady) goes on.

148

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Service Manual A-Ergo — D003936, B, GBR, Translated

10 Electrical system

Figure 104. Multifunction Display Indicator (MDI) 1.

3.

5.

7.

9.

10.2.2.2

Steady red light: Less than 10% battery capacity Flashing red light: Error code indicating 50% battery capacity 100% battery capacity

2.

25% battery capacity

4.

6.

Error code shown/Service necessary (Spanner) Alphanumeric display

8.

75% battery capacity A flashing hourglass indicates that the hour counter is active (Hourglass) Reduced top speed (Tortoise)

Functionality The display consists of a field with alphanumeric symbols and three different figurative symbols.

The operating time, error codes and MDI software version are indicated by means of the alphanumeric display: • • •

The operating hours counter indicates the number of hours the truck has been in operation.

The error codes are indicated by means of a pre-defined code and by the flashing of the red LED. The software version is shown briefly on start up – EPXXX, where XXX represents the version.

Other symbols: • • •

A-Ergo

A tortoise shows that the maximum speed is reduced.

The spanner is shown when an error code is indicated, or when a pre-programmed service must be carried out.

The hourglass flashes when the hour counter is active.

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10 Electrical system

10.2.3

Traction motor controller, AC1

10.2.3.1

General

Figure 105. Overview of the traction motor and hydraulic motor

10.2.3.2

Operation, traction motor controller AC1.

In an alternating current based regulation system it is important that the rotation of the motor is synchronised by the traction controller. To enable this, a sensor, an incremental encoder, is located in the motor, with two phases displaced by 90°. If these signals are disturbed or lost, there will be no synchronisation between the motor and the traction controller. This results in the motor running very slowly and drawing maximum current. Avoid running the motor in this situation.

10.2.3.3

Connector, specification, traction motor controller AC1 The traction motor controller has three connectors with input and output signals for valves, sensors, switches, programming tools, etc. Each connector pin is specified below with, where appropriate, the voltage level in the connected condition.

Connector E1 (the figure shows the connector from the wiring side).

Table 25. Connector E1 traction motor controller AC1

150

Pin

Descriptions

Remarks

E1.1

Controlling the Drive contactor.

Controlled to B-

E1.2

Supply to Drive contactor

+24V

E1.3

Controlling the electric brake

Controlled to B-

E1.4

Controlling the pump contactor

Controlled to B-

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Service Manual A-Ergo — D003936, B, GBR, Translated

10 Electrical system

Pin

Descriptions

Remarks

E1.5

Supply to pump contactor

E1.6

Control of vertically adjustable straddle legs valve

Controlled to B-

E1.7

CAN communication

CAN Low

E1.8

Neg. supply to lifting/lowering control

B-

E1.9

Pos. supply to traction motor encoder

+4-5 V

E1.10

Neg. supply to traction motor encoder

B-

E1.11

Pos. supply to instruments

+24 V

E1.12

Neg. supply to instruments

B-

E1.13

Input from speed reduction switch

From pressure switch, see note below (*)

E1.14

Input for lifting vertically adjustable straddle legs

+24V on activation

E1.15

Input for lowering vertically adjustable straddle legs

+24V on activation

E1.16

+12V supply to instruments

+12 V

E1.17

CAN communication

CAN High

E1.18

Signal from lift control

Neutral = approx. 2.5V Maximum lifting rate = approx. 4.5 V Maximum lowering rate = approx. 1.0 V

E1.19

Input A from traction motor encoder Synchronises the motor movement with phase shifted pulses from the encoder

E1.20

Input B from traction motor encoder

(*)

The input from the pressure switch is filtered so that pressure fluctuations will not trip the speed reduction. A change in the input value must be present for at least 1 second before it will be accepted. During lifting and lowering movements, no change in the input value will be accepted.

Connector E2 (the figure shows the connector from the wiring side).

Table 26. Connector E2 traction motor controller AC1

A-Ergo

Pin

Descriptions

Remarks

E2.1

Supply from electric lock

+24 V

E2.2

Supply to external units

+24 V

E2.3

Input from brake switch

+24 V required for driving

E2.4

Not used in the A models

E2.5

Not used in the A models

E2.6

Not used in the A models

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10 Electrical system

Pin

Descriptions

Remarks

E2.7

Prop. valve: Stabilizers up Man. valve:

Accessories: Input from control switch

Stabilizers up and down E2.8

Prop. valve: Stabilizers down Manual valve:

Accessories: Input from control switch

Starting the pump motor E2.9

Acceleration reduction

Reduction of steered wheel deflection B- gives a reduction.

Lamp L1 must be working to obtain correct operation

E2.10

Input signal from speed control

Neutral = approx. 2.5 V Maximum in the direction of the forks = approx. 1.0 V Maximum in the opposite direction = approx.

4.5 V

E2.11

Neg. supply to speed control

B-

E2.12

Positive supply to speed and lift controls

+5 V

Connector C is used for connection of the "Hand terminal" programming tool.

Figure 106. Connector C (the illustration shows the connector on the controller)

The battery and motor connections are located separately on the motor controller.

Figure 107. Connect the battery and motor

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Table 27. Separate wiring connections Pin

10.2.3.4

Descriptions

-BATT

Negative supply from the battery.

+BATT

Positive supply from the battery.

U; V; W

Motor connections, connected to the equivalent markings on the traction motor.

Menu tree, traction motor controller AC1 The following headings can be found in the traction motor controller's menu tree. Use the hand terminal to see the menus, see Section 10.1.3, page 142.

Table 28. The main flow of the hand terminal menus, Traction motor controller Display window

Display window

AC1 ZAPI Vx.x 24V 250A 00000

MAIN MENU PARAMETER CHANGE MAIN MENU TESTER MAIN MENU SAVE PARAMETER MAIN MENU RESTORE PARAMETER MAIN MENU ALARMS MAIN MENU PROGRAM VACC MAIN MENU MOTOR DATA

Table 29, page 154

CONFIG MENU

Table 31, page 157

CONFIG MENU

Table 32, page 158

CONFIG MENU

SET MODEL

SET OPTION

ADJUSTMENTS

(Not available) Table 35, page 158 Table 36, page 160

Table 33, page 158 Table 34, page 158 (Not available) (Not available)

To see what is included in each menu choice, look at the table referred to after each display window.

Sub-menu specification for PARAMETER CHANGE

A-Ergo

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10 Electrical system

Table 29. Delivery settings of the Zapi AC 1 Traction motor controller at A in the truck.

(Parameter Change Menu) FUNCTION

154

A Std

A Std Increased speed. 10 km/h

ATF+ Speed reduc. Speed reduc. EXPLANATION ALL With With assistance stabilizers from the out less than pressure 2m switch

ACCELERATION DELAY

3

3

3

3

3

Acceleration ramp. A lower value gives faster acceleration

EXTRA ACC DELAY

5

5

5

5

5

Lengthened acceleration ramp with deflected drive wheel

RELEASE BRAKING

6

6

6

6

6

Braking torque at speed control to neutral position

INVERSE BRAKING

8

8

8

8

8

Braking torque in reversing direction

PEDAL BRAKING

7

7

7

7

7

Must not be changed without verifying that the braking distance meets the EU standards

SPEED LIMIT BRAKING

7

7

7

7

7

Braking torque during reduced throttle

BRAKE CUTBACK

5

5

5

5

5

Braking torque at beginning of speed reduction

MAX SPEED FORW

94

119

94

94

94

Maximum speed in the machine housing direction. May not be increased after delivery.

MAX SPEED BACK

94

94

94

94

94

Maximum speed in the forks direction.

May not be increased after delivery.

CUTBACK SPEED 1

100

100

100

*1

0

Reduced speed.

CUTBACK SPEED 2

70

70

100

70

70

Reduced speed to 5 km/h above the free lift stroke

H&S CUTBACK

10%

10%

10%

10%

10%

Not used in the A models

FREQUENCY CREEP

0.30

0.30

0.30

0.30

0.30

Lowest speed when the truck starts off

MAXIMUM CURRENT

9

9

9

9

9

Equivalent to the controller's maximum current to the motor

INCHING SPEED

0

0

0

0

0

Not used in the A models

A-Ergo

Service Manual A-Ergo — D003936, B, GBR, Translated

10 Electrical system

FUNCTION

A Std

A Std Increased speed. 10 km/h

ATF+ Speed reduc. Speed reduc. EXPLANATION ALL With With assistance stabilizers from the out less than pressure 2m switch

INCHING TIME

0

0

0

0

0

Not used in the A models

AUXILIARY TIME

10

10

10

10

10

Must not be changed from this setting

LIFT CUTBACK

75

75

75

75

75

Adaptation of valve operation for the lift mode

MIN VALVE 1

5

5

5

5

5

The minimum opening of the proportional valve

MIN VALVE 2-4

0

0

0

0

0

The minimum opening of the On/Off valves

MAX VALVE 1

70

70

70

70

70

Maximum voltage to the proportional valve

MAX VALVE 2

255

255

255

255

255

Maximum voltage to the lift stop valve

MAX VALVE 3 and 4

100

100

100

100

100

Maximum voltage to the other valves

VALVES VOLTAGE

24

24

24

24

24

System voltage to the valves

OPENING RAMP V1-V4

0.2

0.2

0.2

0.2

0.2

Opening ramp for the valves

CLOSING RAMP V1-V4

0

0

0

0

0

Closing ramp for the valves

Changes from the standard are indicated by bold text *1 = Set to the value that is specified in KO. Each parameter value can be altered in ten steps, see Table 30, page 155 below for the available alternatives.

Table 30. Available parameter values, Traction motor controller PARAMETER

A-Ergo

UNIT

PARAMETER LEVEL IN STEPS OF 10 0

1

2

3

4

5

6

7

8

9

ACCELERATIO Sec. N DELAY (*)

1,0

1,5

2,0

2,5

3,0

3,5

4,0

4,5

5,0

5,5

EXTRA ACCEL. (**) DELAY (**)

1,5

1,8

2,1

2,4

2,7

3,0

3,5

4,0

4,5

5,0

RELEASE BRAKING (***)

Sec.

5,5

5,0

4,5

4,0

3,5

3,0

2,5

2,0

1,5

1.0

INVERSE BRAKING (***)

Sec.

5,5

5,0

4,5

4,0

3,5

3,0

2,5

2,0

1,5

1.0

PEDAL BRAKING (***)

Sec.

5,5

5,0

4,5

4,0

3,5

3,0

2,5

2,0

1,5

1,0

SPEED LIMIT BRAKING (***)

Sec.

8.9

8.3

7.7

7.1

6.6

6.0

5.5

4.9

4.4

3.8

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Service Manual A-Ergo — D003936, B, GBR, Translated

10 Electrical system

PARAMETER

UNIT 0

1

2

3

4

5

6

7

8

9

BRAKE Sec. CUTBACK (***)

5,5

5,0

4,5

4,0

3,5

3,0

2,5

2,0

1,5

1,0

MAX SPEED FW

Hz

67

72

78

89

94

99

109

114

119

124

MAX SPEED BW

Hz

67

72

78

89

94

99

109

114

119

124

CUTBACK SPEED 1

% Max Sp

10

20

30

40

50

60

70

80

90

100

CUTBACK SPEED 2

% Max Sp

10

20

30

40

50

60

70

80

90

100

H&S CUTBACK % Max Sp

10

15

20

25

37

50

62

75

87

100

FREQUENCY CREEP

Hz

0,3

0,6

0,9

1,2

1,5

1,8

2,1

2,4

2,7

3,0

MAXIMUM CURRENT

% IMax

47

53

58

64

70

76

82

88

94

100

INCHING SPEED

Hz

0

2

4

6

8

10

12

14

16

18

INCHING TIME Sec.

0,3

1,0

2,0

2,8

3,63

4,5

5,4

6,2

7,1

8,0

AUXILIARY TIME

0,0

0,4

0,8

1,4

2,0

3,0

4,0

6,0

8,0

10,0

10

15

20

25

37

50

62

75

87

100

Sec.

LIFT CUTBACK %

156

PARAMETER LEVEL IN STEPS OF 10

MIN VALVE 1

This parameter can be adjusted in steps of 1, from 1 to 255

MIN VALVE 2

This parameter can be adjusted in steps of 1, from 1 to 255

MIN VALVE 3

This parameter can be adjusted in steps of 1, from 1 to 255

MIN VALVE 4

This parameter can be adjusted in steps of 1, from 1 to 255

MAX VALVE 1

This parameter can be adjusted in steps of 1, from 1 to 255

MAX VALVE 2

This parameter can be adjusted in steps of 1, from 1 to 255

VALVE 3 VOLTAGE

%V

12

20

25

40

50

60

70

80

90

100

VALVE 4 VOLTAGE

%V

12

20

25

40

50

60

70

80

90

100

VALVES VOLTAGE

V

12

24

36

48

60

72

80

96

120

V1 OPENING RAMP

Sec.

0,2

0,4

0,6

0,8

1,0

1,2

1,4

1,6

1,8

2,0

V2 OPENING RAMP

Sec.

0,2

0,4

0,6

0,8

1,0

1,2

1,4

1.6

1,8

2,0

V3 OPENING RAMP

Sec.

0,2

0,4

0,6

0,8

1,0

1,2

1,4

1.6

1,8

2,0

V4 OPENING RAMP

Sec.

0,2

0,4

0,6

0,8

1,0

1,2

1,4

1.6

1,8

2,0

V1 CLOSING RAMP

Sec.

0,2

0,4

0,6

0,8

1,0

1,2

1,4

1.6

1,8

2,0

V2 CLOSING RAMP

Sec.

0,2

0,4

0,6

0,8

1,0

1,2

1,4

1.6

1,8

2,0

A-Ergo

Service Manual A-Ergo — D003936, B, GBR, Translated

10 Electrical system

PARAMETER

UNIT

PARAMETER LEVEL IN STEPS OF 10 0

1

2

3

4

5

6

7

8

9

V3 CLOSING RAMP

Sec.

0,2

0,4

0,6

0,8

1,0

1,2

1,4

1.6

1,8

2,0

V4 CLOSING RAMP

Sec.

0,2

0,4

0,6

0,8

1,0

1,2

1,4

1.6

1,8

2,0

(*)

The acceleration time is the time from 0 to 100 Hz; this is an average ramp that in practice can be affected by different settings and loads

(**)

EXTRA ACCEL. DELAY gives a multiple of the level set at ACCELERATION DELAY Example: • ACCELERATION DELAY=LEVEL 2

(***)

•

EXTRA ACCEL. DELAY= LEVEL 5

•

Gives a delay of 2.0 s * 3.0 = 6.0 s

The braking affect is based on the deceleration ramp and is the time that elapses between the controller pulses from 100 to 0 Hz, and is an average ramp that can be affected by different settings and loads

Sub-menu specification for TESTS. Table 31. Sub-menu "TESTS", Traction motor controller TEST

UNIT/STATUS

BATTERY VOLTAGE

V

Voltage to the electric lock

MOTOR VOLTAGE

%

Voltage to the motor as a percentage of the battery voltage.

VOLTAGE BOOSTER

%

Voltage to the motor as a percentage of the battery voltage while under load.

FREQUENCY

Hz

Pulse frequency of the voltage and current to the motor

ENCODER

Hz

The motor speed, measured as a frequency from the encoder bearing in the motor

SLIP VALUE

Hz

Motor slippage, the difference between the controlling frequency and the motor frequency

COS PHI

A-Ergo

DESCRIPTIONS

cos(φ) for the motor, the phase shift between current and voltage

CURRENT RMS

A

The rms (root mean square) value of the motor current

BATTERY CURRENT

A

Calculated current from the battery

BATTERY CHARGE

%

The battery's charging condition as a percentage

TEMPERATURE

°C

Temperature of the controller's heat sink

ACCELERATOR

V

Voltage from the speed controller shown as a voltage to the left and a percentage to the right

LIFTING CONTROL

V

Voltage from the lift potentiometer shown as a voltage to the left and a percentage to the right

LIFTING SWITCH

ON/OFF

Lift controller status

DESCENT SWITCH

ON/OFF

Lowering control status

FORW. SWITCH

ON/OFF

Status of the speed controller, forward direction

BACK. SWITCH

ON/OFF

Status of the speed controller, reverse direction

SEAT SWITCH

ON/OFF

Not used

H&S CUTBACK

ON/OFF

Not used

BRAKE SWITCH

ON/OFF

Foot pedal status ("if Input #4" option is set as "Brake").

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10 Electrical system

TEST

UNIT/STATUS

DESCRIPTIONS

CUTBACK SWITCH #1 ON/OFF

Status for input "Speed reducing 1"

CUTBACK SWITCH #2 ON/OFF

Free lift switch status

DIGITAL INPUT #1

ON/OFF

Lift switch status

DIGITAL INPUT #2

ON/OFF

Status of the lowering switch during lowering ("If Input #2" is set as "Present #1").

Table 32. Sub-menu "SAVE PARAMETER", Traction motor controller SAVE PARAMETER

With this menu all the set parameters can be saved in the hand terminal's memory

Table 33. Sub-menu "RESTORE PARAMETERS", Traction motor controller RESTORE PARAMETERS

With this menu all the set parameters saved in the hand terminal's memory can be downloaded to the controller's memory

Table 34. Sub-menu "ALARMS", Traction motor controller This menu presents the following: CODE = Error code h = time (which operating hour) that the error code occurred

ALARMS

N° = how many times this particular error code has occurred °C = temperature of the controller when the error code was generated

The sub-menu that is obtained by pressing both buttons 1 and 5 on the hand terminal simultaneously is specified below: • •

See Table 35, page 158 see Table 36, page 160.

Table 35. Sub-menu "SET OPTION", Traction motor controller FUNCTION HYDRAULICS

TILLER SWITCH SET INPUT #1 CUTB DLY

SELECTION

DESCRIPTIONS

0

Manual valve

1

Proportional valve with or without side stabilizers or vertically adjustable straddle legs

2

Proportional valve with the combination of side stabilizers and vertically adjustable straddle legs

HANDLE

Pin E2.3 is used as an input from the foot brake switch.

SEAT

Pin E2.3 is used as an input from the seat switch.

PRESENT

Pin E1.13 is used as a speed reducing input.

OPTION #1

Pin E1.13 is used as a hand brake input.

PRESENT OPTION #1

SET INPUT #2

PRESENT OPTION #1

SET INPUT #3

PRESENT OPTION #1

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FUNCTION SET INPUT #4

SELECTION

DESCRIPTIONS

BELLY

Pin E2.7 is used as an input from the belly switch.

BRAKE

Pin E2.7 is used as a brake input.

EXCLUSIVE HYDRO

Pin E2.7 is used as an "EXCLUSIVE HYDRO", hydraulic brake, input.

RUNNING

The hour meter records running hours

KEY ON

The hour meter records hours spent with the key switched on

ON

The battery indicator is active, and when the battery has discharged by over 90% an alarm is generated and the current to the traction motor is limited to half the maximum.

OFF

The battery indicator is active, but no alarm or reduction takes place in the case of major discharge.

HYDRO KEY ON

ON/OFF

If this function is set to ON, the Traction motor controller controls a hydraulic contactor when the key is switched on if the function "aux output #1" is set to "hydrocontactor" or "exclusive hydro"

STOP ON RAMP

ON/OFF

The ramp stop function is activated with the time that has been set in the "auxiliary time" parameter; after this time the function is affected by the parameter "aux output #1" (See also Table 37, page 161).

OFF

The ramp stop function is not activated (See also Table 37, page 161).

HOUR COUNTER

BATTERY CHECK

AUX OUTPUT#1

HYDROCONTAC Pin E1.3 controls a hydraulic function when a TOR directional, brake pedal is active or the truck is moving (See also Table 37, page 161) BRAKE

Pin E1.3 controls the electric brake (See also Table 37, page 161).

EXCLUSIVE HYDRO

Pin E1.3 drives a hydraulic function when “exclusive hydroinput” is active (See also Table 37, page 161).

AUX FUNCTION #1

PRESENT, with delay.

This function controls the delay to the stabilizers when a double-acting hydraulic function is used. Otherwise ABSENT, without no delay is desired. delay.

PEDAL BRAKING

ANALOG, Option The mechanical brake has a potentiometer installed, "Set input #4" set which means that when the speed control is released to "Belly": the controller will apply a braking force that is related to the amount of force with which the brake pedal is depressed. The minimum braking force is determined by the "Release braking" parameter (for gentle braking). The greatest braking force is determined by the "Pedal braking" parameter.

ANALOG, Option As for “Option BELLY” above, but with the addition that "Set input #4" set the mechanical brake, as well as having a to "Brake": potentiometer, also has a switch installed.

QUICK INVERSION

A-Ergo

DIGITAL

No analogue foot brake function

NONE

The mechanical brake, does not have either a potentiometer or a switch installed.

BELLY

The function is activated but not timer-controlled

TIMED

The function is timer-controlled

NONE

The function is switched off.

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10 Electrical system

FUNCTION

SELECTION

DESCRIPTIONS

AUX VOLTAGE #1

100 %

The drive voltage to the emergency contactor and electric brake as a percentage of battery voltage

PERFORMANCE

OPTION #1

Set the power to "Low Performance".

OPTION #2

Set the power to "High Performance".

AUX FUNC1

PRESENT OPTION #1

VALVE 1 TYPE

OPTION #1

Electrically operated valve 1 is of the On/Off type

OPTION #2

Electrically operated valve 1 is of the proportional type

OPTION #1

Electrically operated valve 2 is of the On/Off type.

OPTION #2

Electrically operated valve 2 is of the proportional type.

VALVE 3 TYPE

OPTION #1

Electrically operated valve 3 is of the On/Off type

VALVE 4 TYPE

OPTION #1

Electrically operated valve 4 is of the On/Off type

VALVE 2 TYPE

See Table 36, page 160 below for the specification of the sub-menu “ADJUSTMENTS”. The sub-menu is accessed via buttons 1 and 5 on the hand terminal.

Table 36. Sub-menu "ADJUSTMENTS", Traction motor controller FUNCTION

VALUES

EXPLANATION

Options

Basic setting

MIN LIFT

...V

-

Saves the lowest value from the lift potentiometer when the lift switch is activated

MAX LIFT

...V

-

Saves the highest value from the lift potentiometer when the lift switch is activated

MIN LOWER

...V

-

saves the lowest value from the lowering potentiometer when the lowering switch is activated

MAX LOWER

...V

-

saves the highest value from the lowering potentiometer when the lowering switch is activated

SET BATTERY TYPE

24V/ 36V/ 48V

24 V

select battery voltage

ADJUST BATTERY

...V

23,8 V

fine adjustment of the measured battery voltage

THROTTLE 0 ZONE

...%

THROTTLE X ZONE

...%

54

changes the speed controller characteristic

THROTTLE Y ZONE

...%

25

parameter to change the speed controller characteristic

ADJUSTMENT #02

1-9

9

Sets the lower level for battery discharging

ADJUSTMENT #01

1-9

5

sets the upper level of battery discharging

CHECK UP DONE

ON/OFF

-

Acknowledgement that Service has been carried out

* See also Section 10.3.2, page 171

sets the deadband for the speed controller

CHECK UP TYPE

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10 Electrical system

FUNCTION

VALUES

EXPLANATION

Options

Basic setting

NONE

0

-

Service reminder indicator switched off

OPTION #01

0

-

"Alarm99" at 300 hours of operation

OPTION #02

0

-

"Alarm99" + red LED lit on the MDI at 340 hours of operation

OPTION #03

0

-

"Alarm99" + red LED lit on the MDI at 340 hours of operation and the truck is stopped

OPTION #04

0

-

OPTION #05

0

-

On setting “AUX OUTPUT” and “RAMP ON/OFF” in the “SET OPTION” menu, different functions are obtained at the E1:3 pin output. The combinations are specified in Table 37, page 161 below.

Table 37. “Aux Output” set in combination with “Ramp On/Off, Traction motor controller Aux Output Brake

Hydr. Cont

Excl. Hydro

A-Ergo

Pin E1.3 Driver: Magnetic brake

A hydraulic unit contactor

A hydraulic unit contactor

Stop on ramp

Truck action when stopped on a ramp gradient

On

The truck is held stationary with the aid of the traction motor until the time set by the "auxiliary time" parameter has elapsed, when the electric brake is activated and the control signal to the traction motor is terminated. Only use this combination if the negative brake is installed.

Off

The truck is held in place with the aid of the traction motor, but slowly descends the ramp until the time set by the "auxiliary time" parameter has elapsed, when the electric brake is activated and the control signal to the traction motor is terminated. Only use this combination if the negative brake is installed.

On

The truck is held stationary with the aid of the traction motor until the time set by the "auxiliary time" parameter has elapsed, when the truck slowly descends the ramp until it reaches level ground

Off

The truck is not braked electrically but just rolls slowly down a ramp until it reaches level ground.

On

The truck is held stationary with the aid of the traction motor until the time set by the "auxiliary time" parameter has elapsed, when the truck slowly descends a ramp until it reaches level ground.

Off

The truck is not braked electrically but just rolls slowly down a ramp until it reaches level ground.

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10.2.4

Steering servo controller, EPS-AC

10.2.4.1

General

Figure 108. Steering servo controller

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10 Electrical system 10.2.4.2

Function, steering servo controller EPS-AC

Figure 109. Function overview of the steering servo system 1. Steering wheel 2. Stepping motor sensor 3. Stepping motor sensor wiring, 6 wires 4. Steering servo controller 5. Motor wiring 6. Steering servo motor 7. Wiring for safety control of traction motor brake 8. Traction motor brake 9. Traction motor 10. Drive wheel 11. End position sensor

A stepping motor sensor is connected to the steering wheel, which sends a signal to the steering servo controller when the steering wheel is moved. The steering servo controller sends a drive voltage to the steering servo motor which turns the drive wheel to the desired direction at the desired speed. If anything wrong is indicated, the controller will remove the drive signal from the drive motor and allow the drive motor brake to be applied and thereby stop the truck.

Figure 110. End position switches S4 and S5

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10 Electrical system The drive unit's end positions are indicated by inductive sensors, S4 and S5. When a sensor is activated, the turning movement in that direction is halted. In order to supervise that the turning movement is not stopped by the sensor before the drive unit has reached its end position, the steering servo controller detects if the drive unit moves away from the sensor without releasing the end position indication.

A third sensor, S8, detects whether the steered wheel has turned by more than 45 degrees from the straight ahead direction. If this is the case, the drive motor's acceleration is reduced so as to minimise the tipping torque that arises from sideways acceleration. The reduction in acceleration is set by the parameter “EXTRA ACCEL DELAY” in the menu “PARAMETER CHANGE” with the aid of the hand terminal (see Section 02, page 17).

Figure 111. Sensor locations, truck seen from above

10.2.4.3

Connector, specification, steering servo controller EPS-AC The steering servo controller has three connectors with inputs and outputs for sensors, programming tools, etc. Each connector pin is specified below with, where appropriate, the voltage level in the connected condition.

Connector E3 (figure shows connector from the cabling side).

Table 38. Connector E3 steering servo controller Pin

164

Descriptions

E3.1

Not used in the A models

E3.2

Not used in the A models

E3.3

CAN communication

E3.4

Not used in the A models

E3.5

Speed reduction

E3.6

Not used in the A models

E3.7

From the steering wheel sensor

E3.8

Not used in the A models

E3.9

Not used in the A models

E3.10

From the steering wheel sensor

Comment

CAN High

Stepper motor

Stepper motor

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10 Electrical system

Pin

Descriptions

Comment

E3.11

Control signal from speed control

Neutral = approx. 2.5 V Maximum in the direction of the forks = approx. 4.5 V Maximum in the opposite direction = approx. 1.0 V

E3.12

Not used in the A models

E3.13

CAN communication

E3.14

Not used in the A models

E3.15

Not used in the A models

E3.16

Not used in the A models

E3.17

Not used in the A models

E3.18

Not used in the A models

E3.19

Not used in the A models

E3.20

From the steering wheel sensor

CAN Low

Stepper motor

Connector E4 (the figure shows the connector from the wiring side).

Table 39. Connector E3 steering servo controller Pin

Descriptions

Remarks

E4.1

Output from the safety relay

+24 V that is disconnected in the case of a fault in the steering servo

E4.2

Not used in the A models

E4.3

From the steering wheel sensor

E4.4

From the steering wheel sensor

E4.5

Not used in the A models

E4.6

End position signal

Stops clockwise steering direction

E4.7

Input signal to the safety relay

+24 V

E4.8

Not used in the A models

E4.9

From the steering wheel sensor

E4.10

Not used in the A models

E4.11

Not used in the A models

E4.12

End position signal

Stops counterclockwise steering direction

Connector C is used for connection of the "Hand terminal" programming tool.

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Figure 112. Connector C (the figure shows the connector from the wiring side)

The battery and motor connections are located separately on the steering servo motor controller.

Table 40. Separate wiring connections Pin

Descriptions

-BATT

Negative supply from the battery.

+BATT

Positive supply from the battery.

U; V; W

Motor connections.

Figure 113. Battery and motor connections

10.2.4.4

Menu tree, steering servo controller EPS-AC The following headings can be found in the steering servo controller's menu tree. Use the hand terminal to see the menus, see Section 10.1.3, page 142.

Table 41. The main flow of the hand terminal menus Display window

Display window

AC1 ZAPI V0.0 12V 250A 00000

MAIN MENU PARAMETER CHANGE

166

Table 42, page 167

CONFIG MENU SET MODEL

MAIN MENU

CONFIG MENU

TESTER

SET OPTION

MAIN MENU

CONFIG MENU

SAVE PARAMETER

ADJUSTMENTS

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10 Electrical system

Display window

Display window

MAIN MENU RESTORE PARAMETER MAIN MENU ALARMS (Not available)

MAIN MENU PROGRAM VACC MAIN MENU MOTOR DATA MOTOR DATA

(Not available)

Under the menu selection “PARAMETER CHANGE”, certain parameters that are important for turning are set, see Table 42, page 167.

Table 42. Sub-menu "PARAMETER CHANGE", steering servo controller PARAMETER/ BASIC SETTING

EXPLANATION

SPEED LIMIT

7

sets the maximum turning rate for controlling the drive wheel

AUX FUNCTION 3

2

sets the compensation of the steering wheel deflection sensitivity at a high rate

SENSITIVITY

3

sets the steering wheel deflection sensitivity

CREEP SPEED

7

power reinforcement at small turning movements

PURSUIT RAMP

-

not used

COMPENSATION

2

sets the compensation for voltage drop in wiring and transistors

DESENSITIVITY

-

not used

POS ACCURACY

-

not used

AUXILIARY RAMP

-

not used

AUXILIARY TIME

1

sets the time for which the steered wheel is held in the locked direction after the steering wheel has ceased to be affected

ANTIROLLBACK

40 %

sets the power that holds the wheel in the locked direction after the steering wheel has ceased to be affected

AUX FUNCTION 2

HOUR COUNTER

RUNNING the time is counted as being while the system is active and steering is possible

MICRO CHECK

PRESENT The connected supervision system MUST NEVER BE DISCONNECTED

ENCODER CONTROL

10.2.5

OFF

there is no encoder in this system

FEEDBACK DEVICE

OPTION 1 not used

DIRECTION GAUGE

OPTION 1 not used

AUTO INPUT ACTIVE

1

not used

AUX FUNCTION 1

0

not used

Wiring diagram All the wiring diagrams can be found in a separate “Wiring diagram handbook”, contact Atlet for further information.

The relevant wiring diagrams for A_Ergo are specified in the table below.

A-Ergo

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Descriptions

Machine

Reference

Document code

Wiring diagram

A-ERGO

104100

Circuit diagram

A-ERGO

104101

10.3

Repair and maintenance instructions

10.3.1

Calibration, Speed controller The drive motion is controlled by a linear lever that is supplied with approx. 5 V. In the neutral position, the lever delivers about 2.5 V. When the level is moved to drive forward, the output signal from the sensor increases towards 4.5 V, and reduces towards 1.0 V when the lever is moved backwards.

In order to calibrate the start position and the maximum position, the Hand terminal is used, see Section 10.1.3, page 142 for the user instructions.

1)

Connect the Hand terminal, the display shows: AC1 ZAPI V x.x 24V 250A 00000

2)

After starting, press both the upper outer buttons.

Figure 114. Keyboard

CONFIG MENU SET MODEL 3)

Step down to the Adjustment menu.

CONFIG MENU ADJUSMENT

168

4)

Press ENTER to access the menu.

5)

Step to ACCELER MIN.

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10 Electrical system

ADJUSTMENT ACCELER MIN 6)

Press ENTER.

7)

The display then shows the current value.

ACCELER MIN ...V

8)

Move the control to a position that is suitable for starting the driving movement in the "drive wheel direction". If the control is too far from neutral, the controllability is reduced, a change towards the voltage neutral value by about 0.2 V may be suitable. (As the control is affected by the direction away from the forks, the voltage increases. And as the control is affected by the direction towards the forks, the voltage decreases)

9)

Press OUT.

10) Press ENTER if the value is to be saved.

Press OUT if the value is NOT to be saved.

11) The display now shows: CONFIG MENU ADJUSTMENT 12) Press ENTER to access the menu.

13) Step to ACCELER MAX.

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ADJUSTMENT ACCELER MAX 14) Press ENTER.

15) The display then shows the current value.

ACCELER MAX ...V 16) Move the control to the maximum speed position in the "drive wheel direction".

17) Press OUT.

18) Press ENTER to save.

19) Step to SET ACC REV MIN and repeat the procedure from step 8 to step 12 in the forks direction. Then step to SET ACC REV MAX and repeat the procedure from step 14 to step 18, also in the forks direction.

20) Press ENTER if the value is to be saved.

Press OUT if the value is NOT to be saved.

21) The display now shows: CONFIG MENU ADJUSTMENT 22) To return to the main menu, press “OUT”.

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10 Electrical system The speed controller is now calibrated in both directions. Test the sensitivity, and if any parameter does not feel good, recalibrate that particular function.

10.3.2

Calibrating the lifting and lowering controls This function stores the minimum and maximum values for the lifting and driving controls.

The minimum value is the lever position where the respective movement will start, and the maximum value is that where the movement has reached maximum speed.

The lifting and lowering movements are controlled by a linear lever that is supplied with 5 V. In the neutral position, the lever delivers about 2.5 V. When the level is moved to the lift position, the voltage increases towards 4.5 V, and reduces towards 1.0 V during lowering.

In order to calibrate the start position and the maximum position, the Hand terminal is used.

1)

Connect the Hand terminal, the display shows: AC1 ZAPI Vx.x 12V 250A 00000

2)

After starting, press both the upper outer buttons.

Figure 115. Keyboard

CONFIG MENU SET MODEL 3)

Step down to the Adjustment menu.

CONFIG MENU ADJUSTMENT 4)

Press ENTER to access this function.

5)

Step to MIN LIFT.

ADJUSTMENT MIN LIFT 6)

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Press ENTER.

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7)

The display then shows the current value.

MIN LIFT ...V

8)

Move the control to a position that is suitable for starting the lifting movement.

9)

Press OUT.

10) Press ENTER if the value is to be saved.

Press OUT if the value is NOT to be saved.

11) The display now shows: CONFIG MENU ADJUSTMENT 12) Press ENTER to access this function.

13) Step to MAX LIFT.

ADJUSTMENT MAX LIFT 14) Press ENTER.

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10 Electrical system 15) The display then shows the current value.

MAX LIFT ...V 16) Move the control to the maximum lift position.

17) Press OUT.

18) Press ENTER if the value is to be saved.

Press OUT if the value is NOT to be saved.

19) The display now shows: CONFIG MENU ADJUSTMENT 20) Repeat the procedure for “MIN LOWERING” and “MAX LOWERING” respectively.

21) To return to the main menu, press “OUT”.

The lifting and lowering controls are now calibrated.

10.3.3

Save the parameters in the hand terminal's memory This function saves the set parameters in the hand terminal's memory.

These parameters can then be loaded into a different controller by using the “RESTORE” function.

The following data can be saved by using “SAVE PARAMETERS”: 1.

2.

3.

All parameter values ("PARAMETER CHANGE").

Options (“SET OPTIONS”).

Battery level (“BATTERY LEVEL”).

1)

Connect the Hand terminal, the display shows: AC1 ZAPI Vx.x 24V 250A 00000

2) A-Ergo

After starting, press the button 3, ENTER to access the “MAIN MENU”.

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MAIN MENU PARAMETER CHANGE 3)

Step to SAVE PARAM.

MAIN MENU SAVE PARAM. 4)

Press ENTER to access the menu.

5)

If this function has been used before, that is indicated by a two-digit reference.

SELECT: Mod. 00 FREE

6)

Step up, button 2, or down, button 1, until the window indicates FREE.

SELECT: Mod. 01 FREE 7)

Press ENTER to save.

8)

The display shows what has been saved, beneath what has been done.

READING...

ACCELER DELAY (ECC)

9)

When all is ready the window shows: MAIN MENU SAVE PARAM.

10) Press OUT to return to the start window.

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AC1 ZAPI Vx.x 24V 250A 00000

10.3.4

Downloading parameters from the hand terminal This function allows the parameters saved in the hand terminal's memory to be downloaded to the controller.

The following data can be downloaded by using “RESTORE PARAMETERS”: 1.

2.

3.

All parameter values ("PARAMETER CHANGE").

Options (“SET OPTIONS”).

Battery level (“BATTERY LEVEL”).

NOTE! All the values in the controller's memory will be overwritten by the parameters saved in the hand terminal.

1)

Connect the Hand terminal, the display shows: AC1 ZAPI Vx.x 24V 250A 00000

2)

After starting, press the button 3, ENTER to access the “MAIN MENU”.

Figure 116. Keyboard

MAIN MENU PARAMETER CHANGE 3)

Step to RESTORE PARAM.

MAIN MENU RESTORE PARAM.

A-Ergo

4)

Press ENTER to access the menu.

5)

The display will show the models that are saved by a two-digit code.

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SELECT: Mod. 00 AC1 ZAPI V1 6)

Step up, button 2, or down, button 1, until the desired model is shown.

SELECT: Mod. 01 AC1 ZAPI V1 7)

Press ENTER to start the transfer.

8)

The display asks if you are sure.

ARE YOU SURE? YES = ENTER NO = OUT

9)

The display shows what has been saved, beneath what has been done.

STORING...

ACCELER DELAY

10) When all is ready the window shows: MAIN MENU RESTORE PARAM. 11) Press OUT to return to the start window.

AC1 ZAPI Vx.x 24V 250A 00000

10.3.5

Check the error codes The controller remembers the five most recent errors that have occurred. For each error that has been saved, the error code itself, the number of times this particular error has occurred, the hour meter reading at the time of each error and the controller's temperature are shown.

1)

176

Connect the Hand terminal, the display shows:

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AC1 ZAPI Vx.x 24V 250A 00000 2)

After starting, press the button 3, ENTER to access the “MAIN MENU”.

MAIN MENU PARAMETER CHANGE 3)

Step to ALARMS.

MAIN MENU ALARMS ALARMS 4)

Press ENTER to access the menu.

5)

The display will show the error code, the number of times this particular error has occurred and the temperature of the controller at the time the error occurred.

CODE 00005 #02 20ºC

6)

Step up, button 2, to see the next error, or step down, button 1, to see previous errors.

CODE 00007 #03 18ºC 7)

To exit the ALARM window press OUT.

8)

The question of whether to reset the error code list to zero will be shown.

CLEAR LOGBOOK? YES = ENTER NO = OUT

9) A-Ergo

Press ENTER for yes and OUT for no.

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10) To exit the ALARM window press OUT.

AC1 ZAPI Vx.x 24V 250A 00000

10.3.6

Changing the traction motor controller/steering servo controller 1)

If possible, save the current parameter settings, see Section 10.3.3, page 173, before removal.

2)

Remove electrical power from the truck.

3)

Open out the electrical panel to gain access to the controller.

4)

Disconnect the motor wiring and supply wiring.

5)

Pull out the operating wiring, connectors E1 and E2, and E3 and E4 respectively.

6)

Unscrew the controller.

7)

Steering servo controller: Scrape clean the contact surface between the controller and its attachment plate.

8)

Steering servo controller: Apply a layer of heat-conducting paste between the controller and the attachment plate.

9)

Fit the controller.

10) Connect the operating wiring, connectors E1 and E2, and E3 and E4 respectively.

11) Connect the motor wiring and supply wiring.

12) Download the parameter settings that the previous controller had (assuming that item 1 above was carried out), see Section 10.3.4, page 175 .

10.3.7

178

MDI replacement 1)

Switch off the current to the truck and pull out the battery plug.

2)

Raise the control panel, see Section 07, page 93 for the procedure.

3)

Disconnect connector E5.

4)

Release the securing hook and pull out the MDI.

5)

Refit in the reverse order.

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10.3.8

Changing the steering servo sensor

10.3.8.1

General

Figure 117. Location of the steering servo sensor, truck seen from above

Figure 118. Fitting the steering servo sensor

10.3.8.2

10.3.8.3

Removing the steering servo sensor 1)

Remove electrical power from the truck.

2)

Remove the locking nut (item 1, Figure 118, page 179) from the sensor.

3)

Screw out the sensor (and follow up with the wiring, so it des not get twisted).

Fitting the steering servo sensor 1)

Screw in the sensor (item 1, Figure 118, page 179) and follow up with the wiring, so it des not get twisted, until it meets the cam.

2)

Unscrew the sensor1 turn and secure it with the nut.

3)

Lock the nut with thread locking fluid.

NOTE! The nut must be locked with thread locking fluid. Ensure that no thread locking fluid enters the threaded hole.

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10.4

Diagnostics and trouble shooting

10.4.1

Safety NOTE! See Section 10.1.1, page 141 before any work starts on the truck electrical system.

10.4.2

Trouble shooting aids

10.4.2.1

Circuit diagram The circuit diagram is the basis for the work of trouble shooting, as it provides an overview of the electrical system functions; from this it is possible to locate faults.

A wiring diagram is supplied with each truck, or can be found in a separate “Wiring diagram handbook”.

10.4.2.2

Wiring diagram A connections schematic diagram is used to translate the theoretical solutions of the circuit diagram into practical connections in the truck.

A connections diagram is supplied with each truck, or can be found in a separate “Wiring diagram handbook”.

10.4.2.3

Error codes Error codes are read on the MDI, see Section 10.2.2, page 148, and on the hand terminal, se Section 10.1.3, page 142 The meanings of the error codes are specified in the following section: • • •

10.4.2.4

Traction motor controller, see: Section 10.4.4.2, page 183.

Steering servo controller, see: Section 10.4.4.3, page 186.

Error codes in the display, see: Section 10.4.4.1, page 182.

Multimeter When using a multimeter, all the measurements must use B- as a reference.

The most reliable trouble shooting method is obtained with the negative supply wire connected as close to the battery as possible, but an exception is when for example voltage levels from the speed control are to be measured; in this case it is best to use B- at the respective controller.

10.4.2.5

Input and output specifications Connector pin numbering, see • • • •

Table 25, page 150 Table 26, page 151 Table 38, page 164 Table 39, page 165

10.4.3

Practical trouble shooting

10.4.3.1

General For all trouble shooting in the electrical system it is recommended to first connect the Hand terminal to the appropriate controller and see if this is producing any error message, which is translated in the tables, see Section 10.4.4, page 182.

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10 Electrical system Faults which at first sight seem to be associated with a controller may actually be due to a fault in another unit, so first look for error messages in all units, if the first does not show one that applies.

10.4.3.2

Error in the drive function 1)

Connect the hand terminal to the traction motor controller and read off any error message; these appear automatically once the hand terminal has logged on to the traction motor controller.

2)

If no error message is present, operate the brake switch and the speed control to see if an error message appears. If one does not, go over to the test menu and read off the brake switch function (Brake switch Table 31, page 157) and the output signal from the speed controller (ACCELERATOR).

•

• 3)

Also check the positions of the speed reduction switches by using "SPEED SWITCH 1 and 2" in the test menu.

•

4)

see Table 31, page 157

Also check the current to the motor "CURRENT RMS". If there is current to the motor but it does not move, or only moves slowly, this can be due to a fault in the encoder signal from the motor, which can be studied by using "ENCODER" in the test menu.

• •

5)

see Section 10.3.1, page 168 There is no separate direction switch, the direction is determined by the throttle voltage from the speed control. In the test menu, however, the choice of direction can be studied by means of the "FORW SWITCH" and "BACK SWITCH" (indications that the system has identified the direction of travel) see Table 31, page 157

see Table 31, page 157 If the encoder is faulty, the encoder bearing in the drive motor must be changed, see Section 05, page 47.

At over +75 °C in the traction motor controller the maximum motor current is gradually reduced with increasing temperature. At 100 °C it is reduced to zero.

This is presented as a "HIGH TEMPERATURE" error message on the hand terminal, and as 16A61 on the instrument display (MDI).

6)

If the error message "VACC NOT OK" is shown on the hand terminal, or 16A78 on the instrument display (MDI), the fault may be that the speed control is incorrectly calibrated.

•

10.4.3.3

10.4.3.4

A-Ergo

To calibrate the speed control, see Section 10.3.1, page 168.

Fault in the servo steering system 1)

Connect the Hand terminal to the controller.

2)

Read off any error messages, and read the cause and solution in Section 10.4.4, page 182.

Fault in the lifting/lowering system 1)

Connect the Hand terminal to the traction motor controller and read off any error messages, see Section 10.4.4, page 182.

2)

Check the system settings against Table 29, page 154.

3)

Use the Test menu, see Table 31, page 157, to study the following:

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10.4.3.5

•

Input voltage from the lifting/lowering control with:

"LIFTING CONTROL"

•

If the system is getting the lift demand with:

"LIFTING SWITCH"

•

If the system is getting the lower "DESCENT SWITCH" demand with:

Fault symptoms, Traction motor controller Table 43. Fault symptoms Symptom

Possible cause

Procedure

Low voltage to the traction motor Battery voltage is below the set limit value

Charge the battery

The system does not start

The electric lock must be energised before the speed control can be moved

10.4.4

Error codes

10.4.4.1

MDI error codes

1.

3.

Incorrect start up sequence

Indication of which controller is generating an 2. alarm.

A=Alarm

Alarm number

The controller that is generating an alarm can be identified by means of the two first digits in the error code, see Table 44, page 182.

Table 44. Indication of which controller is generating an alarm Controller code

Explanation

Error codes

02

Traction motor controller

See Section 10.4.4.2, page 183.

06

Steering servo controller

See Section 10.4.4.3, page 186.

16

Multifunction Display

See Table 45, page 183.

Certain error codes are set uniquely by the MDI, see Table 45, page 183.

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Table 45. Error codes presented in the Multi Function Display, MDI MDI fault code 16A67

10.4.4.2

Hand terminal error code CAN BUS KO

Explanation

Control/Procedure

CAN bus connector link poor.

1.

Check the wiring and connections.

2.

If OK, change controller.

16A70

HW OVER CURR

Valves connected to E5.4 and/or E5.6 short circuited.

Check the current consumption.

Change the valve when the current consumption exceeds 2 A.

16A74

DRIVER SHORTED

The MDI PRC has detected a short Check the current consumption circuit at the ON/OFF valves. of the ON/OFF valves. Change the valve when the current consumption exceeds 2 A.

16A75

CONTACTOR DRIVER

Internal fault in the MDI.

Change MDI.

16A89

PEPV NOT OK

There is either no or low positive voltage to the valves.

Check that the voltage at E5.1 = B+. If OK, change the MDI.

16A90

NEVP1 NOT OK

Problem with one of the proportional valve controls.

Traction motor controller error codes The following error codes are set by the traction motor controller, Table 46, page 183.

Table 46. Traction motor controller AC1 error codes Error code indicating MDI

Explanation

Control/Procedure

Hand terminal

02A00

BATTERY LOW

If the "BATTERY Charge the battery.

CHECK" function is activated and the battery has less than 10% remaining, the current will be reduced to half the set level and at the same time an error code will be shown.

02A08

WATCHDOG

This is an internal test that is performed both during driving and when stationary; it is the logic that is tested.

Change the controller.

02A13

EEPROM KO

Error in the area that includes adjustable parameters.

Switch the key on and off once: • If the error code has disappeared, note that all the settable parameters have returned to their default values and that new settings must be made.

•

02A16

A-Ergo

If the error remains, change the controller.

AUX OUTPUT When the key is switched Change the controller.

KO on, check the μP Drive contactor, the driver for the electric brake. If the answer is not correct, an error code will appear.

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Service Manual A-Ergo — D003936, B, GBR, Translated

10 Electrical system

Error code indicating

Control/Procedure

MDI

Hand terminal

02A17

LOGIC FAILURE #3

A fault in the hardware Change the controller. section that handles the overcurrent protection to the different motor phases.

02A18

LOGIC FAILURE #2

A fault in the hardware section that handles the voltage supply to the different motor phases.

Change the controller.

02A19

LOGIC FAILURE #1

Reports that the over/undervoltage protection has been activated.

1.

an actual over/undervoltage has occurred.

2.

change the controller.

3.

Check the plugs.

4.

look for burnt pins.

This test is done during start-up and when stationary.

1.

problem with wiring to the motor, connections, motor windings or earth connection.

2.

change the controller.

02A30 / VMN LOW/ 02A31 VMN HIGH

02A37

CONTACTOR Drive contactor closed on 1.

CLOSED start-up.

2.

Check the contactor and wiring

02A38

CONTACTOR The logic has sent a 1.

OPEN voltage to the main 2. contactor coil, and this is expected to close, but the contacts have not closed.

break in the wiring to the coil.

STBY in HIGH Check that the current is 1. zero when the truck is 2. stationary If not, stop the truck.

defective current sensor.

02A53

Change the traction motor controller. main contactor defective.

change the controller.

02A55

PROG LIFT LEVER

This error code reports that there is an error in the program for the lifting/lowering controls.

Error in the program for the lifting/lowering controls.

02A60

CAPACITOR CHARGE

Internal fault in the controller.

Change the controller.

02A61

HIGH TEMPERATU RE

Heat sink temperature 1. above 75°C. The current 2. is limited in relation to the excessive temperature.

3.

The controller shuts down completely at 100°C.

02A67 02A70

184

Explanation

CAN-BUS KO Monitoring of CAN bus.

ENCODER ERROR

Incorrect signal from the rotation speed feedback sensor in the traction motor (Encoder).

Check the fan on the electrical panel.

No action if the truck does not show any other symptoms.

At reduced traction, improve the cooling.

1.

Check the wiring.

2.

change the controller.

1.

Check the encoder signal with the hand terminal.

2.

Check the wiring between the traction motor encoder and the traction motor controller.

A-Ergo

Service Manual A-Ergo — D003936, B, GBR, Translated

10 Electrical system

Error code indicating MDI 02A71

Control/Procedure

Hand terminal HANDBRAKE The truck will not start because the foot brake switch has not been operated.

1.

Faulty switch.

2.

The driver has followed the wrong sequence during start up.

3.

Faulty wiring.

4.

If the error remains, change the controller.

02A73

THERMIC SENSOR KO

Incorrect value from the Change the controller. sensor which controls the temperature of the controller.

02A74

DRIVER SHORTED

Internal fault in the controller.

Change the controller.

02A75

CONTACTOR Internal fault in the DRIVER controller.

Change the controller.

02A76

COIL SHORTED

02A78

02A79

02A80

A-Ergo

Explanation

VACC NOT OK

INCORRECT START

FORW + BACK

When the key is switched 1. on, check the μP Drive contactor for FF SR. If the answer is not correct, 2. an error code will appear; in the case of this fault, change the controller. FF SR performs a hardware check on the current to the drive contactor coil, and if this is too high the drive contactor opens and an error code is shown.

Check for a possible short circuit in the wiring, and that the coil has the correct resistance.

This test is done when 1. stationary. The reason for 2. the alarm is that the 3. voltage from the speed control is 1 Volt higher than the minimum value that has been programmed in the PROGRAM VACC function.

speed control not properly calibrated.

This alarm reports that an incorrect start has taken place.

1.

speed control incorrect.

2.

the driver has followed the wrong sequence during start up.

3.

faulty wiring.

4.

if the error remains, change the controller.

1.

the driver has followed the wrong sequence during start up.

2.

faulty wiring.

3.

if the fault remains, change the controller.

This test is performed continuously and means that two different drive directions have been "requested" simultaneously.

Change the controller.

speed control incorrect. check the lift control.

02A86

PEDAL WIRE This error code reports Check the wiring to the speed control.

KO that there is a fault in the wiring to the speed control potentiometer.

02A89

PEV NOT OK The voltage at the "PEV" Change the controller. output is incorrect.

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Service Manual A-Ergo — D003936, B, GBR, Translated

10 Electrical system

Error code indicating

10.4.4.3

Explanation

Control/Procedure

MDI

Hand terminal

02A93

INPUT ERROR #2

This alarm is detected only during starting.

Meaning: The battery voltage has deviated more than 20% from its nominal value.

Check with a multimeter if the actual battery voltage is above or below the stated limit value. If not, use the Zapi console and check "BATTERY VOLTAGE" n the test menu.

If a deviation is found between the actual battery voltage and the battery voltage on the Zapi console, an adjustment is required: Go to the adjustment menu. Check that "SET BATTERY TYPE" is 24 V and then adjust the parameter "ADJUST BATTERY" to the correct value. Then switch off and switch on the truck again.

02A94

CURR.SENS KO

Fault in the current feed system.

Change the controller.

02A99

INPUT ERROR #1

The speed control has • two output signals, a • primary that is centred around 2.5 Volts and increases when driving in the machine housing direction, and reduces in the forks direction, and a secondary that is also centred around 2.5 Volts but goes in the opposite direction when driving.

This is used as a checking signal and goes to the steering servo pin E3.11. From there it goes via the CAN system to the traction motor controller and is compared with the primary signal. If they do not agree, the system will go into its neutral state and the brake will be activated.

Check the speed control and its wiring.

Poor connection to the speed control.

•

Check at connector E3 that there are good contact surfaces.

•

Check measure E3.11.

Measure the voltage levels.

Steering servo controller error codes The following error codes are set by the steering servo controller, Table 47, page 187

186

A-Ergo

Service Manual A-Ergo — D003936, B, GBR, Translated

10 Electrical system

Table 47. Steering servo controller EPS error codes Error code indicating MDI

Control/Procedure

Hand terminal

06A08

MICRO SLAVE

Internal fault in the steering servo controller.

if the error remains, change the controller.

06A13

EEPROM KO

Internal fault in the steering servo controller.

Perform a “CLEAR EEPROM” • Use the hand terminal, press on both the SET buttons (5+6) at the same time to enter the “ALARM CONFIG MENU” •

Step forward to “CLEAR EEPROM”

•

Press “ENTER” (3+3) twice. If the error remains, change the controller.

06A16

LOGIC Internal fault in the steering FAILURE #4 servo controller. High rest voltage between the U and W phases.

if the error remains, change the controller.

06A17

LOGIC Internal fault in the steering FAILURE #3 servo controller. High rest voltage between the V and U phases.

if the error remains, change the controller.

06A18

LOGIC Arises when the desired FAILURE #2 voltage between the U and W phases is different from the measured value.

if the error remains, change the controller.

06A19

LOGIC Arises when the desired FAILURE #1 voltage between the U and V phases is different from the measured value.

if the error remains, change the controller.

06A28

S.P OUT OF Arises when the potentiometer • RANGE for the desired steering angle has a poor electrical contact.

•

Check the steering angle potentiometer's connections and wiring.

F.B OUT OF Arises when the potentiometer • RANGE for feedback of the steering angle has a poor electrical • contact.

Check the steering angle potentiometer's connections and wiring.

06A29

A-Ergo

Explanation

If no fault is found, change the potentiometer.

If no fault is found, change the potentiometer.

06A32

VMN NOT OK

Arises when the initial rest if the error remains, change the controller. voltage between at least one phase and signal earth is high.

06A37

KM CLOSED

Arises when the safety contact • closes early.

Check the electrical installation, pins E4.1 and E4.7.

•

Check the functions of any switches and relays in the circuit.

•

If no fault is found, change the controller.

Arises when the safety contact • opens late.

Check the functions of any switches and relays in the circuit.

•

If no fault is found, change the controller.

06A38

KM OPEN

06A39

KS CLOSED Arises when the safety contact • closes early.

Check the electrical installation, pins E4.1 and E4.7.

•

Check the functions of any switches and relays in the circuit.

•

If no fault is found, change the controller.

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10 Electrical system

Error code indicating

Control/Procedure

MDI

Hand terminal

06A40

KS OPEN

06A48

MAIN CONT Arises on initiation of the CAN OPEN bus system synchronization with the traction motor controller AC1 if the main contactor does not close.

Probably an alarm from the traction motor controller AC1.

06A53

STBY in HIGH

Change the controller.

06A61

HIGH Temperature controller over 76 Switch off the truck and allow the unit to cool.

TEMPERAT °C. URE

06A67

KEYOFF

06A68

188

Explanation

Arises when the safety contact • opens late.

Check the functions of any switches and relays in the circuit.

•

If no fault is found, change the controller.

Rest voltage too high.

A warning that the Sicus module is giving a “key off” command via the CAN bus.

The error code disappears if the Sicus module removes the command.

One of the drive unit position • limit switches (S4 or S5) is closed when it should be open. • Arises if the current amplifier's output signal gives a higher value than the Imax level for longer than one second.

Check the operation of both position limit switches.

Adjust the switches S4 and S5.

06A70

HIGH CURRENT

if the error remains, change the controller.

06A71

POWER Arises in the case of a loss of FAILURE #3 phase in the steering servo motor U, V, W.

Check measure the steering servo motor and its wiring.

06A72

POWER Arises in the case of a loss of FAILURE #2 phase in the steering servo motor U, V, W.

Check measure the steering servo motor and its wiring.

06A73

POWER Arises in the case of a loss of FAILURE #1 phase in the steering servo motor U, V, W.

Check measure the steering servo motor and its wiring.

06A81

DATA ACQUISITI ON

Arises when the operator alters Switching the key off and on resets the alarm.

“ADJUSTMENT #1” to level 1.

06A94

MICRO SLAVE KO

The steering wheel deflection set point and the actual value from the drive wheel do not agree.

Check the connections - stepping motor sensor - steering servo motor - steering position limit switch if the error remains, change the controller.

A-Ergo

Service Manual A-Ergo — D003936, B, GBR, Translated

10 Electrical system

Error code indicating MDI

Hand terminal

06A95

D LINE SENSOR KO

Explanation

Control/Procedure

Arises when the signal from the 1. stepping motor sensor. pin 2.

E4.3 EPS, is open.

Check the stepping motor wiring.

3.

06A96

Q LINE SENSOR KO

Arises when the signal from the 1. stepping motor sensor. pin 2.

E4.9 EPS, is open.

3.

A-Ergo

Measure the resistance between pin E4.3 and signal earth (should be close to 30 Ω) if the error remains, change the stepping motor sensor.

Check the stepping motor wiring.

Measure the resistance between pin E4.9 and signal earth (should be close to 30 Ω) if the error remains, change the stepping motor sensor.

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190

A-Ergo

SERVICEMANUAL Machine:

A-Ergo

Manual No:

005975

Edition 2009B

11 Speed control and Brake system Design and function ..................................................................................................... 11.3 Electric brake ......................................................................................................11.3 Repair and maintenance instructions ........................................................................ 11.4 Electric brake ......................................................................................................11.4 Adjusting the electric brake (–2006w46) ...................................................................... 11.4 Adjusting the electric brake (2006w47–) ...................................................................... 11.4 Replacing the magnetic part, electric brake (–2006w46) ............................................. 11.4 Replacing the brake disc (2006w47–) .......................................................................... 11.5 Emergency release ...................................................................................................... 11.7

Speed controller .................................................................................................11.8 Replacing the speed controller ..................................................................................... 11.8 Adjusting the speed controller ...................................................................................... 11.8 Checking the foot pedal ................................................................................................ 11.8

ATLET SERVICE MANUAL A-ERGO

11.2

ATLET SERVICE MANUAL A-ERGO

Speed control and Brake system / Design and function / Electric brake

11.3

Edition 2009B

11 Speed control and Brake system Design and function Electric brake A-Ergo is fitted with an electric brake. The electric brake is a safety brake with two friction surfaces. The brake torque that can be adjusted using an adjuster screw on the older model (–2006w46), is generated by spring pressure. The brake is activated when the voltage across the coil is cut, i.e. the truck brakes when it has no power supply.

When the brake is actuated the springs press on the plate, which is pressed axially to the rotor. When the brake is to be released the coil is supplied with battery voltage.

The magnetic field created between the plate and the magnetic part allows the rotor to rotate freely.

The brake is actuated in four different ways (see also the wiring diagram): 1.

Via the drive motor regulator when the regulator indicates a serious fault.

2.

Via the steering servo regulatorn, which disconnects the brake coil supply to the plus terminal of the battery if a serious fault is indicated.

3.

Via the foot pedal, which disconnects the brake coil supply to the plus terminal of the battery when the driver is not longer actuating it.

SMA-Ergo_11_2009B.fm

ATLET SERVICE MANUAL A-ERGO

11.4

Speed control and Brake system / Repair and maintenance instructions / Electric brake

Repair and maintenance instructions Electric brake Adjusting the electric brake (–2006w46) Adjusting is carried out in the following order.

1.

Adjusting of A dimension:

1.

Fit the electric brake and tighten the bolts.

2.

Check the gap, see figure11.1, between the magnetic part and the plate (the A dimension should be: A = 0.2 mm

3.

If the gap needs adjusting, release the bolts holding the brake and turn the adjusting sleeves.

4.

Tighten the brake and check that the gap is the same all round.

A dimension: A = 0.2 mm

2.

Test the brakes by driving and test braking.

T

A

SM104.1

Figure 11.1 Electric brake

Adjusting the electric brake (2006w47–) Electric brake in new design (from 2006 w47) is adjusted at the factory and cannot be adjusted later.

Replacing the magnetic part, electric brake (–2006w46) 1.

The T dimension should be checked before replacing the magnetic part!

ATLET SERVICE MANUAL A-ERGO

Speed control and Brake system / Repair and maintenance instructions / Electric brake

2.

11.5

When refitting the magnetic part adjust the T dimension to the same dimension as before by means of a hook spanner, see figure 11.1.

Warning!

Remember to lock any adjustments!

Warning!

Check that you have a safe braking capacity.

Warning!

The friction lining must be at least 1 mm, otherwise it must be replaced.

Note!

When you install a new brake, remember to remove the transport lock.

Replacing the brake disc (2006w47–)

C B Figure 11.2 Electric brake (2006w47–)

1.

Disconnect the electrical connections to the magnetic part.

2.

Undo the three retaining screws, pos B in figure11.2.

3.

Dismantle the brake by unscrewing 3 screws, pos C.

4.

Lift out the brake disc and clean the magnetic part and brake plate.

5.

Mount the new brake disc and refit the magnetic part. Tighten the three retaining screws at 9.5 Nm.

ATLET SERVICE MANUAL A-ERGO

11.6

Speed control and Brake system / Repair and maintenance instructions / Electric brake

6.

Reconnect the electrical connections to the magnetic part.

Warning!

Check that you have a safe braking capacity.

ATLET SERVICE MANUAL A-ERGO

Speed control and Brake system / Repair and maintenance instructions / Electric brake

11.7

Emergency release The brake can be released manually where necessary.

Note!

If the brake is released manually, there is no working parking or emergency brake.

Never leave a truck with a manually released brake!

Figure 11.3

To manually release the brake, screw in two screws (M6x55) in the two marked holes.

(Figure 11.3).

ATLET SERVICE MANUAL A-ERGO

11.8

Speed control and Brake system / Repair and maintenance instructions / Speed controller

Speed controller Replacing the speed controller 1.

Lift up the arm rest, see section 4.

04_003_SM_A-ERGO_ArmstDem.eps

Figure 11.4 Lift up arm rest

2.

Release the cabling to the speed controller.

3.

Unscrew the two screws holding the controller in place, and take out the controller.

Adjusting the speed controller See section 10.

Checking the foot pedal The foot pedal can be checked in two different ways, either by measuring the resistance or by measuring it connected in the system and supplied with voltage.

We recommend measuring the switch connected in the system and supplied with voltage.

1.

Lift up the drive wheel and secure the truck with blocks.

2.

Connect a voltmeter over the foot switch connectors.

3.

Press down the foot switch.

4.

Read-off the value, it should be less than 0.1 Ohm.

5.

Release up the foot switch and read-off the value, it should be approx. battery plus.

The resistance of the switch should be measured if it is lower.

ATLET SERVICE MANUAL A-ERGO