BT 25 30 30L 35 CBE AC Power E Range Service Manual 036-0409-02 - PDF DOWNLOAD

Service Manual

CBE 25 30 30L 35

E Range

036-0409-02

01/2004

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Electric 036-0409-02

2.5-3.5 ton AC

SERVICE MANUAL

page 3

CESAB S.p.a. reserves all rights of reproduction of this handbook

The text and the numbering system may not be used in other printed matter, reprinted or translated, whether entirely or in part, without written authorization

from CESAB reserves the right to make any necessary modifications without obligation to promptly update this handbook.

Copyright by

CESAB S.p.A via Persicetana Vecchia, 10 40132 Bologna - Italy Tel. (0039) 051.20 54 11 Fax (0039) 051.72 80 07 E-mail: cesab@cesab.it

BOLOGNA’S FACTORY, AFTER SALES SERVICE

INDEX GENERAL INFORMATIONS

page

5

CHASSIS

page

9

MOTORS

page

17

TRASMISSION AND DRIVE GEAR

page

21

BRAKES & WHEELS

page

27

STEERING SYSTEM

page

33

ELECTRIC & ELECTRONIC SYSTEM

page

41

HYDRAULIC SYSTEM

page

127

LIFTING MASTS

page

139

MAINTENANCE TABLES

page

155

SAFETY DIRECTIONS

page

163

SERVICE MANUAL GENERAL INFORMATION

GENERAL INFORMATION INDEX TECHNICAL DATA

page

7

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SERVICE MANUAL TECHNICAL DATA

2.5-3.5 ton AC page 7

2.5-3.5 ton AC page 8

SERVICE MANUAL

Electric 036-0409-02

SERVICE MANUAL CHASSIS

CHASSIS INDEX OPERATORS SEAT

page 11

PEDALS

page 11

DRIVE DIRECTION LEVER ON STEERING COLUMN

page 11

STEERING COLUMN PUSH BUTTONS

page 12

LOAD HANDLING COMMANDS

page 13

BATTERY COVER

page 13

DASHBOARD

page 14

PLATES

page 15

LIFTING THE TRUCK

page 16

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SERVICE MANUAL

036-0409-02

2.5-3.5 ton AC page 11

OPERATOR'S SEAT PEDALS FOOT DRIVE DIRECTION (Standard version) - Forward direction (D) - Backward direction (E) - Service brake pedal (C) - Parking and emergency brake pedal (A) A

C

D

E

F

DRIVE DIRECTION LEVER ON STEERING COLUMN (Alternative version)

1 o

2

Direction selector lever (F) é 1 Forward direction o 0 Neutral ê 2 Backward direction

Single drive pedal (G)

G

Key (H) Emergency push button (P) Parking brake release lever (B)

P

H

B

Q

The steering wheel position can be adjusted forward or backward.

In order to do it, unloose the lever (Q) then secure the steering column in the desired position. Do not adjust the steering wheel while the truck is moving.

2.5-3.5 ton AC

SERVICE MANUAL

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Electric 036-0409-02

STEERING COLUMN PUSH BUTTONS

1 2

It is strongly recommended to avoid operating both push buttons when the truck is running.

Selected setting push button (1): L (low), P (programmable), H (high) Low speed push button (2)

1)

2)

Setting selector: at the truck start up the default settingis P (programmable); H (high) or L (low) settings can be selected pulling the push button several times. On the dashboard, three leds, as indicated at page 14 paragraph 10, will show the selected condition.

P:

- Maximum drive speed.

- Acceleration and braking action are optimised for low energy consumption.

- Parameter change function enabled.

H:

- Maximum drive speed.

- Strong acceleration and braking action.

- Parameter change function disabled.

L:

- Reduced drive speed.

- Soft acceleration and braking action.

- Parameter change function disabled.

Low speed selector: it limits the maximum drive speed of the truck by the set percentage ( from 10% up to 90% ). See on page 69 (Parameter change function, AC3 traction unit) paragraph “CUTBACK SPEED”. As indicated at page 14 paragraph 11, on the dashboard, one led, will show the selected condition (when the reduction speed is selected the led light is on).

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SERVICE MANUAL

036-0409-02

2.5-3.5 ton AC page 13

LOAD HANDLING COMMANDS N

A

M L

There can be three types of commands for load handling CONTROL VALVE VERSION (A) JOYSTICK VERSION (B) FINGERTIPS VERSION (C)

K

Levers unit K) Lifting control lever (yellow cap) L) Tilting control lever (green cap) M) Sideshift control lever (red cap) N) Device control lever (optional) (black cap)

B

Functions

C

BATTERY COVER

Battery cover lifting I

Press the lever (J), lift the cover using the appropriate handle (I); complete lifting is facilitated by the use of an air spring.

After opening the battery cover, it is possible to remove the rear compartment cover.

J

H

Battery connector (H) Inside the battery cover

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SERVICE MANUAL

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Electric 036-0409-02

DASHBOARD 1 6

8

9

2 7 3

4

5

12

11

10

1) Battery charge indicator 2) Parking brake ON warning light 3) Low brake fluid level warning light 4) Lifting speed reduction due to flat battery 5) Dead man device warning light 6) Drive motor temperature warning light 7) Lifting motor temperature warning light 8) Electronic hour meter 9) Diagnostic code display (see Alarm function chapter).

10)Selected setting display: L (low), P (programmable), H (high) 11)Low speed light (when the reduction speed is selected the light is on) 12)Forward/backward indication

DASHBOARD CONTROLS 1

1)

Battery charge indicator (adjustable with the analizer see pages 9697). This consists of 3 green LEDS, 4 orange LEDS and 3 red LEDs, With battery charged the right green LED becomes on and while the battery discharges, the LEDS will be separately on from right side to left side. When the battery is 80% discharged, the first red LED on the left begins to flash showing that the battery must be recharged (reserve).

There is an indication on the display (9). The battery indicator rearms only below the 70% of the full charge.

2

2)

Parking brake ON warning light

3

3)

Brake fluid low warning light

4

4)

Lifting speed reduction due to flat battery

5

5)

“dead man device” pilot light the pilot light comes ON, when the driver leaves the driving seat

6

6)

Drive motor temperature warning light lights up when the temperature is 150°C

7

7)

Lifting motor temperature warning light lights up when the temperature is 150°C

8

8)

Electronic hour meter It is activated by insertion of the ignition key.

It shows the hours and the tenth

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2.5-3.5 ton AC

SERVICE MANUAL

036-0409-02

page 15

PLATES

A

IDENTIFICATION PLATE

B

LOAD PLATE

According to the dimension of the truck the plate A can be located in different places

ATTACHMENT OR SPECIAL CONDITION OF USE MODEL Type

MOTOR

RATED CAPACITY kW

SERIAL N°

kg

TYRES

DRAW-BAR PULL (1h) LIFT HEIGHT mm

N BATTERY MASS kg min.

MANUFACT. YEAR

SERVICE MASS Without Battery kg

kg max.

TENSION

SERIAL N°

CENTER OF LOAD DISTANCE mm

A B

Cod. 0312004

Cod. 0312005

V

DERATED CAPACITY Kg CARRELLI ELEVATORI S.p.A. via Persicetana vecchia, 10 40132 - Bologna - Italia

CESAB LDT Bevan Way Smethwick - Warley West Midla 1ds B66 1BZ

IDENTIFICATION PLATE It identifies the lift truck technical data

CAPACITY PLATE

LOAD PLATE It identifies the load capacity with a load center of 500 mm (except for different indications)

2.5-3.5 ton AC

SERVICE MANUAL

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Electric 036-0409-02

LIFTING THE TRUCK

é

If the carriage is equipped with mudguard extensions, chains can only be hooked by previously disassembling the extensions themselves.

HOOKS ATTACHMENT POINTS FOR LIFTING THE TRUCK B The hooking points are shown on the carriage with the symbol shown on the side (see figure).

TRUCK WITH OVERHEAD GUARD To lift the truck the following equipment must be used: A- CHAINS: dia. 10 mm - Degree 8 UNI EN 818-2 C

C

B- HOOKS: for 3,2 t - UNI/ISO 7597 LIFTING OF THE FORKLIFT TRUCK WITH CABIN To lift the truck the following equipment must be used: A- CHAINS: dia. 10 mm - Degree 8 UNI EN 818-2 B- HOOKS: for 3,2 t - UNI/ISO 7597 C- N° 2 upper brackets to hold the chains.

It is important to remember that the chain length must be sufficient to lift the truck in a horizontal position, with the lifting angles (ß) ≤ 45° with respect to the vertical lifting line.

Ensure that the chains is protected where it comes into contact with edges and adjust the chains on the truck so that it remains in a horizontal position during all the lifting operations.

Make sure that there are no personnel in the vicinity of the truck, before carrying out the lifting operation.

If any maintenance operations need to be performed on the truck in a raised position, the vehicle must be rested on appropriate supports, sufficient to bear the overall weight of the vehicle, keeping the chain taut.

SERVICE MANUAL MOTORS

MOTORS INDEX ELECTRIC MOTORS

page 19

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SERVICE MANUAL

2.5-3.5 ton AC page 19

ELECTRIC MOTOR

TRACTION MOTOR V 50 (nominal) Kw 14 Frequency 40 Hz Rpm nominal max.

1140 (rpm/min) Service S2=60’ Classe IS F N° poles 4

LIFTING MOTOR (2.5-3.0 ton) V 50 (nominal) Kw 14 Frequency 80 Hz Rpm nominal max.

2300 (rpm/min) Service S3=20% Classe IS F N° poles 4 Dimension 370mm Lifting pump 19 l/m’

LIFTING MOTOR (3.0L-3.5 ton) V 50 (nominal) Kw 20 Frequency 80 Hz Rpm nominal max.

2300 (rpm/min) Service S3=20% Classe IS F N° poles 4 Dimension 420mm Lifting pump 19 l/m’

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SERVICE MANUAL TRANSMISSION & DRIVE GEAR

TRANSMISSION ANB DRIVE GEAR INDEX TRACTION UNIT

page 23

OIL CHANGE INSTRUCTIONS

page 24

TIGHTENING TORQUES

page 25

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SERVICE MANUAL

2.5-3.5 ton AC page 23

TRACTION UNIT 1

2 3

4

5

The traction gear unit is consisted of: 1) Right hand reduction gear 2) Oil bath brakes 3) Differential gear 4) Electrical motor 5) Left hand reduction gear

2.5-3.5 ton AC

SERVICE MANUAL

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Electric 036-0409-02

Disassemble the reduction unit - Park the lift truck on a level ground.

- Engage the parking brake and disconnect the battery; - Disassemble the mast; - Lift the front part of the lift truck and set the special shims under the side panels of the chassis; - Remove the front wheels; - Disconnect the tie rods of the parking brake, the service brake oil pipe, the motor cables etc; - Keep the reduction unit in lifted position; - Remove the fastening screws located on the chassis (tightening torque setting of 45 daNm).

7 screws

OIL CHANGE Type of oil MOBIL-FLUID 422 or equivalent (see oil table).

After the first 50-100 hours - change the oil.

Every 250 hours - remove the front wheels.

Check the oil level, when it is cold.

E

Every 1.000 hours or 12 months - change the oil.

E F

F

OIL CHANGE C

-

-

INSTRUCTIONS

Place the lift truck on a flat floor with the parking brake on.

Lift the front part of the lift truck and remove the wheels.

Disconnect the battery connector.

Changing the oil in the reduction gears.

Carefully clean the area around the oil filling (E) and draining caps (F); place a suitable container below the drain cap and then remove both the filling and the draining caps and allow the oil to drain out completely.

Clean any ferrous residues from the magnetic cap (F) and replace it.

Pour fresh oil into the hole (E) until it starts overflowing from (E). After a short functioning period, check the oil level again.

The oil quality for each reduction is approximately 1 L. Breather (C).

Electric 036-0409-02 TIGHTENING TORQUES

SERVICE MANUAL

2.5-3.5 ton AC page 25

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SERVICE MANUAL BRAKES & WHEELS

BRAKES AND WHEELS INDEX BRAKES

page 29

SERVICE BRAKE SYSTEM DIAGRAM

page 30

PARKING BRAKE SYSTEM DIAGRAM

page 31

PARKING BRAKE RELEASE INSTRUCTIONS

page 31

STANDARD TYRES

page 32

Electric 036-0409-02

SERVICE MANUAL

2.5-3.5 ton AC page 29

BRAKES

DISKS AND COUNTER DISKS DIFFERENTIAL BRAKE

BRAKE COUNTER DISK

EXTERNAL BRAKE DISKS

CENTRAL BRAKE DISKS

SERVICE BRAKE OIL INLET

PARKING BRAKE LEVER

External brake disks thickness Central brake counter disk thickness Max wear on each side Brake counter disks thickness Differential brake disk thickness Differential brake counter disk thickness

2,75 ÷ 2,85 3,60 ÷ 3,70 0,45 2,95 ÷ 3,05 1,57 ÷ 1,63 1,37 ÷ 1,43

mm mm mm mm mm mm

(n° 2) (n° 1) (n° 1) (n° 2) (n° 2)

2.5-3.5 ton AC

SERVICE MANUAL

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Electric 036-0409-02

SERVICE BRAKE SYSTEM DIAGRAM H

B

C

A

A) Reduction gear (right) and braking unit B) Parking brake command C) Bleeding screw D) Electric drive motor E) Brake pump F) Tank G) Service brake pedal H) Reduction gear (left)

D

G

E

SERVICE BRAKE CONTROL The disk brake is in an oil bath and it acts on both of the front wheels; the brake uses the same oil as the drive reduction unit.

F

F

OIL BRAKE TANK (F)

Gioco

CHECK SERVICE BRAKE

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SERVICE MANUAL

036-0409-02 I

page 31

PARKING BRAKE SYSTEM DIAGRAM

L O M

P

2.5-3.5 ton AC

N

I) Release lever L) Parking brake pedal M)Microswitch N) Brake block anchor O) Pedal adjusting screw P) Release adjusting screw PARKING BRAKE CONTROL AND ADJUSTMENT Every 500 hours - Check the clearance shown on the drawing A with the parking brake pedal released - Check the parking brake stroke which should correspond to 4 notches ( L pedal). If it necessary, act on the adjusting screw (O) - With the front wheels lifted adjust the cable so that the same ones at 1st notch are free, on the contrary, at the 2nd notch are blocked.

Press the parking brake pedal some times and check if the clearance is still the same.

A

The dimension of the parking brake is sufficient to guarantee blocking of the truck.

Leva.tif

PARKING BRAKE RELEASE INSTRUCTIONS

A

-

B

Parking and emergency brake pedal (A) Parking brake release lever (B)

To block the truck with the parking brake it is necessary to press the Parking brake pedal (A).

The system remain blocked disabling also all the electrical functions of the truck.

To release the parking brake system it is necessary to pull the Parking brake release lever (B).

Remove the foot from the pedal and release the lever.

2.5-3.5 ton AC

SERVICE MANUAL

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Electric 036-0409-02

STANDARD TYRES THE SAFETY OF RIMS AND WHEELS FOR FORKLIFT TRUCKS “PNEUMATIC” tyres must be replaced when the tread is less than 1.6 mm. “SUPERELASTIC” tyres must be replaced when the tread reaches the “60J” indicator printed on the side.

Replacement of “CUSHION” tyres is recommended when they reach a thickness of 20 or 30 mm.

C

CUSHION →

→

SE

SUPERELASTIC

→

PN

PNEUMATIC→

→ PNEUMATIC TYRES PRESSURES Front 10 BAR Rear 10 BAR

SERVICE MANUAL STEERING SYSTEM

STEERING SYSTEM INDEX STEERING CONTROL

page 35

POWER STEERING SEAL CONTROL AND CLEANING

page 35

POWER STEERING HYDRAULIC LAYOUT

page 36

POWER STEERING HYDRAULIC DIAGRAM

page 37

STEERING AXLE

page 38

BEARING ADJUSTMENT

page 39

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SERVICE MANUAL

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2.5-3.5 ton AC page 35

STEERING CONTROL The steering uses the same oil as the lifting by means a priority valve, so that a sufficient oil flow to the power steering is always assured.

The oil capacity is checked by the Ls signal (load - sersing) coming from the steering unit and it occurrs so that the oil capacity sent to the power steering is equal to its actual request.

The exceeding oil is sent to the control valve for other functions.

When the steering wheel is turned the steering unit “measures” a volume of oil proportional to the above rotation and sends it into the steering cylinder.

The steering unit returns automatically in it neutral position when the manoeuvre is finished (see hydraulic diagram page 37).

POWER STEERING SEAL CONTROL AND CLEANING

B

G

Every 250 hours - check the entire system to identify any leak; any intervention must be carried out without pressure in the system.

Every 4 000 working hours - replace hoses (G) connecting the orbitrol device to the steering jack.

Every 10 000 hours - replace the hydraulic pipe system.

Power steering pressure setting The max power steering pressure must be 90-100 Bar

In order to set the power steering pressure, the following operation are necessary: 1 - Fit a manometer on point (A) of the motor; 2 - In order reach the adjusting screw (B) remove the cap (by allen wrench) positioned in the upper side of the orbitrol (power steering unit); - screw in to incroase the pressure - screw out to decrease the pressure

PRESSURE SETTING

90-100 BAR A

2.5-3.5 ton AC page 36

Electric

SERVICE MANUAL

036-0409-02

POWER STEERING HYDRAULIC LAYOUT

R

L

L

ì

è

ORBITROL

L

R

ì

é

R

Electric 036-0409-02

2.5-3.5 ton AC

SERVICE MANUAL

page 37

POWER STEERING HYDRAULIC DIAGRAM STEERING CYLINDER

ORBITROL

TO THE CONTROL VALVES

PRIORITY VALVE A

PUMP

FILTER

2.5-3.5 ton AC

Electric

SERVICE MANUAL

page 38

036-0409-02

STEERING AXLE Steering axle check Every 500 hours - lubricate the steering gear joints using the appropriate grease nipples (D), (E), (F) and (G); - check the steering angles.

Every 2.000 hours - check and if it is necessary, adjust the wheel hub bearings.

Every 500 ore check the angles Max steering angle (internal wheel ≅ 80°) End stroke setting (adjustment): take the cylinder to the internal end stroke, then operate on the special screws putting them on the spindles. Then screw in the adjusting screws till when you obtain the desired steering angle B = 80° If any abnormal consumption of the wheel tread is observed, the following controls should be made: - check the parallelism of the steered wheels; - check that the steering angle of the wheels is the same in both directions.

B = 80° Standard 85° Max angle accepted ANGLE MEASURED BY THE AXLE FRAME TO THE INTERNAL WHEEL THROUGH A SPECIAL DEVICE

D E

F D

END STROKE SETTING SCREW

GREASE NIPPLE (G)

STEERING AXLE

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SERVICE MANUAL

2.5-3.5 ton AC page 39

BEARING ADJUSTMENT Steering wheel bearings require an adjustment once a year.

Steering wheels lift the steering wheels remove cap (1); remove check pin (4); fasten the nut with a torque setting of 6 dNm; turn the hub of 2-3 turns in both senses; unfasten nut (3) and retighten with a 2-1 daNm torque; check that the wheels slide correctly (max. rolling final torque: 0.2 dNm) and that there is no side play (maximum axial play of 0.05 mm); reassemble the check pin; reassemble the cap (1); lower the wheels again and check that all bolts fixing the wheel disk (5) to hub (2) are well tightened.

5 2 4

1 3

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SERVICE MANUAL ELECTRICAL & ELECTRONICAL SYSTEM

ELECTRIC & ELECTRONIC SYSTEM INDEX ELECTRICAL COMPONENTS LOCATION COMPONENTS DESCRIPTION FUSES BOX CONVERTER BATTERY AND BATTERY CHARGER OPERATIONAL FEATURES DIAGNOSIS GENERAL PRECAUTIONS PROTECTIONS ELECTRONIC PANELS TECHNICAL FEATURES ELECTRIC BLOCK DIAGRAM ELECTRIC MOTORS ENCODER ELECTRICAL CIRCUIT CONNECTION CAN-BUS AND ONBOARD COMMANDS DIAGRAM CAN - BUS DESCRIPTION ARM CARD LIGHT CARD I/O CARD MHYRIO CARD POTENTIOMETER CONFIGURATION CONSOLE FUNCTION GENERAL DESCRIPTION PARAMETER CHANGE FUNCTION TESTER FUNCTIONS ALARMS FUNCTIONS PARAMETER SETTING TABLE MAPS FOR USING THE CONSOLE TRACTION LIFTING MHYRIO WIRING DIAAGRAM

page page page page page page page page page page page page page page page page page page page page page page page page page page page page page page

43 44 45 46 47 48 48 49 49 50 51 51 53 55 57 58 60 61 62 63 67 69 71 74 82 84 85 99 111 121

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2.5-3.5 ton AC

SERVICE MANUAL

036-0409-02

page 43

ELECTRICAL COMPONENTS LOCATION

1

2 14 3 13

15

4 12

5

11

6 9

7 8

10 1 2 3 4 5 6 7 8 9

FIGERTIP JOYSTICK COMMAND (WITH ARM CARD INSIDE) ELECTRIC CONTROL VALVE MECHANIC CONTROL VALVE 24 V FUSES BOX ORBITROL I / O CARD MHYRIO UNIT CONTACTORS LIFTING MOTOR

10 11 12 13 14 15

TRACTION MOTOR TRACTION MODULE LIFTING MODULE BACK LIGHTS BOARD DC/DC CONVERTER 80 V FUSES

Electric

2.5-3.5 ton AC

SERVICE MANUAL

page 44

036-0409-02

COMPONENTS DESCRIPTION

E

A) B) C) D) E) F) G)

F

G

A

Traction module Lifting module Contactors Panel cooling fan Module power fuses 80 V fuses back lights board

B

D C

E

ACCELERATOR PEDAL Set the potentiometer Position the tester set in OHM between the green and the red wire.

Set the potentiometer from 5.13 to 6.27 KOHM (pedal released) from 1.087 to 1.32 KOHM (pedal pressed) ↑

180 mm ↓

Height adjustment screw

Electric

SERVICE MANUAL

036-0409-02

2.5-3.5 ton AC page 45

FUSES BOX 24 VOLT FUSES

1

2

This box is located under the dashboard and it is used for all the 24 V fuses only.

1 Connector for the wiring.

2 Connection bars transfer the positive pole to all fuses.

The horn fuse is the only one available in the box. If other fuses have to be connected to be sure that the relevant free wires are supplied with 24Volt.

3 Direction lights intermittence connector.

3

80 VOLT FUSES 1

2

This box is located over the logic units and it is used for all the 80 V fuses only.

3

1 Ignition key fuse.

2 80/24V DC/DC converter fuse.

3 80 Volt diode.

4 5 3 2 1

1 2 3 4

CAN-BUS for logic units.

CAN-BUS for I/O card.

CAN-BUS for joysticks card.

Connector for stop, reverce lights and 24 volt (924) negative signal.

5 Connector for 80V and 24V positive signals.

24 V CONNECTION

2

1 +24 V pole.

2 Negative pole.

80/24V DC/DC CONVERTER The DC/DC converter is fixed on the counterweight.

1 Panel cooling fan connector.

2 In 80 V and out 24 V connector.

3 Panel cooling fan fuse.

1

=>

1

CONNECTOR DESCRIPTION

=>

2

3

2.5-3.5 ton AC page 46

SERVICE MANUAL

Electric 036-0409-02

CONVERTER

DC-DC CONVERTER

INPUT 80 VOLT

OUTPUT 24 VOLT

The Converter DC-DC reduce the battery voltage from 80 Volt to 24 Volt.

The truck is provide to a different kind of converter DC/DC according to the equipment used.

EQUIPMENT STD. MACHINE ROTARY BEACON WIPER WORKING LIGHTS COMPLETE LIGHTENING EQUIPMENT WIPER+ROTARY BEACON STREET LIGHTENING SYSTEM WIPER+WORKING LIGHTS WIPER+COMPLETE LIGHTS SYSTEM WIPER+STREET LIGHTENING SYSTEM WORKING LIGHT+ROTARY BEACON WIPER+ROTARY BEACON+ WORKING LIGHTS ROTARY BEACON+ COMPLETE LIGHTENING SYSTEM WIPER+HEATHER WIPER+HEATHER+ COMPLETE LIGHTENING EQUPIMENT WIPER+HEATHER+ STREET LIGHTENING SYSTEM WIPER+HEATHER+WORKING LIGHTS

CONVERTER Electric Distributor

CONVERTER Mechanic Distributor

240 W 360 W 360 W 360 W 360W 360 W 720 W 720 W 720 W 720 W 720 W

140 W 240 W 240 W 360 W 360 W 360 W 720 W 720 W 720 W 720 W 360 W

720 W

720 W

720 W 720 W

720 W 720 W

720 W

720 W

720 W 720 W

720 W 720 W

Electric 036-0409-02

SERVICE MANUAL

BATTERY AND BATTERY CHARGER General indications for battery maintenance Every 50 working hours - measure electrolyte density.

Approximate density data For a temperature of 15° C - a density of 1.12 to 1.13 kg/dm3 indicates that the battery is flat; - a density of 1.25 to 1.26 kg/dm3 indicates that the battery is charged (battery capacity increased: 1.29 to 1.30 kg/dm3).

BATTERY CHARGING WARNINGS Before charging the battery, verify that the room is well aerated. Open the battery compartment door.

Make sure that all electrical connections (electrical cable terminals, battery terminals, plugssockets, etc.) are well attached and in good condition.

- Do not open either remove battery filling caps.

- Never top up before and while charging the battery.

- Do not smoke, do not stay close to naked flames and do not cause sparks next to batteries - Do not use the battery while it is being charged - Do not lean metal tools on the battery while under charge - Never repair the battery while under charge - Check that during the charging phase, the electrolyte temperature is kept below 50°C.

BATTERY WEIGHTS AND CAPACITY

2.5-3.5 ton AC page 47

2.5-3.5 ton AC page 48

SERVICE MANUAL

Electric 036-0409-02

OPERATIONAL FEATURES - Speed control.

- Optimum behaviour an a slope due to the speed feedback: - the motor speed follows the accelerator, starting a regenerative braking if the speed overtakes the speed set point.

- Stable speed in every position of the accelerator.

- Regenerative release braking based upon deceleration ramps.

- Regenerative braking when the accelerator pedal is partially released (deceleration).

- Direction inversion with regenerative braking based upon deceleration ramp.

- Regenerative braking and direction inversion without contactors: only the two main contactors are present.

- The release braking ramp can be modulated by an analog input, so that a proportional brake feature is obtained.

- Optimum sensitivity at low speeds.

- Voltage boost at the start and with overload to obtain more torque (with current control).

- High efficiency of motor and battery due to high frequency commutations.

- Self diagnosis with indication of the fault shown by a flashing led.

- Modification of parameters through the programming console.

- Internal hour-meter with values that can be displayed on the console.

- Memory of the last five alarms with relative hour-meter and temperature displayed on the console.

- Test function within console for checking main parameters.

- Hydraulic steering function: 1) traction inverter - the traction inverter sends a "hydraulic steering function" request to the pump inverter on the can-bus line 2) pump inverter - the pump inverter manage an "hydraulic steering function". That is, it drives the pump motor at the programmed speed for the programmed time.

DIAGNOSIS The microprocessor continually monitors the inverter and carries out a diagnostic procedure on the main functions. The diagnosis is made in 4 points 1) Diagnosis on key switch closing that checks: watchdog circuit, current sensor, capacitor charging, phase's voltages, contactor drives, can-bus interface, if the switch sequence for operation is correct and if the output of accelerator unit is correct.

2) Standby diagnosis at rest that checks: watchdog circuit, phase's voltages, contactor driver, current sensor, can-bus interface.

3) Diagnosis during operation that checks: watchdog circuits, contactor driver, current sensors, can-bus interface.

4) Continuos diagnosis that check: temperature of the inverter.

Diagnosis is provided in two ways.

-the diagnostic ERROR DISPLAY placed to the dashboard that will show code number for a given alarm (see the chapters ALARMS).

-the digital console, which gives a more detailed information about the failure.

Electric 036-0409-02

SERVICE MANUAL

2.5-3.5 ton AC page 49

GENERAL PRECAUTIONS - Never connect SCR low frequency chopper with ASYNCHRONOUS INVERTER because the ASYNCHRONOUS filter capacitors alter the SCR choppers' work. If it is necessary to use two or more control units (traction + lift. for ex.), they must belong to the ZAPIMOS family.

- Do not connect the inverter to a battery with a nominal value different from the value indicated on the chopper plate. If the battery value is greater, the MOS may fail; if it is lower, the control unit does not "power up".

- During battery charge, disconnect ASYNCHRONOUS from the battery.

- Supply the ASYNCHRONOUS only with battery for traction; do not use a power supply.

- When the chopper is installed, make tests with the wheels raised from the ground, in order to avoid dangerous situations due to connection errors.

- After the chopper is switched off (key off), the filter capacitor remains charged for some minutes; if you need to work on the inverter, discharge them using a 10W ÷ 100W resistance connected from the +Batt to the -Batt.

- Before carrying out any arc-welding on the trucks, disconnect the battery and short-circuit the unit between positive (+) and negative (-).

PROTECTIONS Battery polarity inversion: A MAIN CONTACTOR is fitted to protect the inverter against reverse battery polarity and for safety reasons.

Connection Errors: All inputs are protected against connection errors.

Thermal protection: If the chopper temperature exceeds 75°C, the maximum current is reduced in proportion to the thermal increase. The temperature can never exceeds 85°C. External agents: The inverter is protected against dust and the spray of liquid to a degree of protection meeting IP54.

Protection against uncontrolled movements: The main contactor will not close if: - the Power unit is not functioning.

- the Logic is not functioning perfectly.

- the output voltage of the accelerator does not fall below the minimum voltage value stored, with 1V added.

- running microswitch in closed position.

Protection against accidental Start up A precise sequence of operations are necessary before the machine will start.

Operation cannot begin if these operations are not carried out correctly.

Requests for drive, must be made after closing the key switch

2.5-3.5 ton AC

SERVICE MANUAL

page 50

Electric 036-0409-02

ELECTRONIC PANELS TECHNICAL FEATURES

Traction Unit

Lifting Unit

AC3T

AC3P

80V

80V

Inverter for AC asyncronous 3-phase motors Regenerative braking functions Can-bus interface Digital control based upon a microcontroller Voltage Maximum current

450A (RMS*)

450A (RMS*)

All the different versions have a booster of 50 Arms for some seconds Operating frequency: External temperature range: Maximum inverter temperature (at full power):

8kHz -30°C ÷ 40°C 75°C

8kHz -30°C ÷ 40°C 75°C

RMS* (Root Mean Squared)

On joysticks / fingertips version, fingertips or joysticks, forward control, backward control and horn control, are implemented by CAN-BUS tecnology

Electric 036-0409-02

SERVICE MANUAL

ELECTRIC BLOCK DIAGRAM

ELECTRIC MOTORS ENCODER TRACTION MOTOR

TRACTION ENCODER TRACTION MOTOR V 50 (nominal) Frequency = 40 Hz Rpm nominal max. = 1140 (rpm/min) Classe IS F

Kw 14 Service S2 = 60’ N° poles 4

2.5-3.5 ton AC page 51

2.5-3.5 ton AC page 52

SERVICE MANUAL

Electric 036-0409-02

REPLACING OF THE ENCODER

_ 34.5+0.25

- Screw in the nut [1] on the sensor threaded part.

- Inser the sensor in the support plate opening.

- Adjust the nut [1] until reaching the measure shown in the sketch.

- Turn the sensoe until the reference dot [2] position corrispond to that shown in the sketch.

- Screw in and tight the nut [3] to fix the sensor to the support plate - Verify that the measure and the reference dot [2] position are those shown in the sketch - When the sensor is assembled on the motor the reference dot [2] must face above (See page 95 to disable the encoder)

LIFTING MOTOR

PUMP SIDE TOP VIEW LIFTING MOTOR V 50 (nominal) Frequency = 80 Hz Rpm nominal max. = 2300 (rpm/min) Classe IS F

Kw 14

LIFTING BEARING ENCODER

Service S3=20% N° poles 4 (See page 108 to disable the encoder)

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SERVICE MANUAL

2.5-3.5 ton AC page 53

ELECTRICAL CIRCUIT CONNECTION AC3 TRACTION UNIT AND AC3 LIFTING UNIT CUTBACK SPEED 3

¤

TRUCK CAN-BUS SIGNAL

DISCONNECT WITH MECHANICAL VALVE CONTROL

SPEED 3 ( ENABLED BY FIXING A MICROSWITCH ¤ CUTBACK NORMALY CLOSED; WHEN THE MICROSWITCH IS OPEN THE

see legend at pag. 54

SPEED RIDUCTION IS OPERATING)

2.5-3.5 ton AC

SERVICE MANUAL

page 54

Electric 036-0409-02

LEGEND SR SEAT PMC NMC CAN LOW CAN HIGH LIFT RED. SPEED (FFL)

= = = = = =

Speed reduction input.

Seat microswich.

Positive of main contactor.

Negative of main contactor.

Low level CAN-BUS voltage I/O. Higt level CAN-BUS voltage I/O.

=

Speed lifting reduction input with Full Free Lift mast group only

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SERVICE MANUAL

2.5-3.5 ton AC page 55

CAN-BUS AND ONBOARD COMMANDS DIAGRAM

ARM COMMANDS

ARM CARD

DASHBOARD

MECCHANIC DISTRIBUTOR BACK LIGHTS BOARD

I /O CARD PEDALS TEMPERATURE SENSORE

MHYRIO BOARD

AC3 TRACTION

= CAN-BUS CONNECTION (4 WIRES) = ANALOGIC CONNECTION (SEVERAL WIRES)

see legend at page 56

ELECTRO CONTROL VALVE

AC3 LIFTING

2.5-3.5 ton AC

SERVICE MANUAL

page 56

Electric 036-0409-02

LEGEND ARM COMANDS =

- forward swicth - backward swicth - horn swicth - 5° way (opt) - joystick liftig-tilt - joystick sideshift / 4° way (opt) - lifting fingertip - tilt fingertip - sideshift fingertip - 4° way fingertip (opt) - 5° way fingertip (opt)

ARM CARD

=

see page 58

LIGHT CARD

=

see page 60

I / O CARD

=

see page 61

AC3P

=

lifting logic unit

AC3T

=

traction logic unit

LIFT ON BOARD COMMAND

=

lift reduction speed (FFL only)

TRACTION ON BOARD COMMAND=

park brake swicth accelerator swicth traction potentiometer seat swicth pedal brake swicth

MHYRIO

=

see page 62

ELECTRO CONTROL VALVES

=

see page 133

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SERVICE MANUAL

2.5-3.5 ton AC page 57

CAN - BUS DESCRIPTION Controller Area Network The CAN BUS technology is a way to assemble the electronic parts of the machines. It has been ideated to avoid the enormous quantity of cables that normally are used to connect two or more electric components. For example, in case you want to connect all potentiometers to control the distributor, it is necessary to fix a lot of wires with consequent reduction of space. Normally a cable in an electric installation is used for only one function: either positive, or negative, or signal.

In order to avoid the above problem the NEW THECNOLOGY is used for saving in space given that all the information go only through two cables and they are decoded by microchips collocated in different parts of the truck.

One of the greatest advantages is that all microchips can communicate with each other and control functions which work contemporaneously in a short time.

The CAN transfers all data giving priority to the most important signals.

The CAN is constituted by four cables: two for the feeding and two for the signals.

Yellow Green White Brown

+24Volt Negative High signal Low signal

It is necessary to have two cables for the feeding given that the microchips are not fed.

BUS: In electronics and computer science it indicates a set of wires connecting several microchips, thus allowing information exchange within the circuit.

BIT:

Figure of the binary numeration that can have only two values: 1(high) - 0 (low).

In computer science it defines the information unit. The bit/sec. defines the capacity of a channel, that is the quantity of information which can be transmitted through the channel in one second.

PULL UP RESISTANCES DASHBOARD = 120 ohn LIGHT CARD = 120 ohm

Electric

2.5-3.5 ton AC

SERVICE MANUAL

page 58

036-0409-02

ARM CARD

The arm card is positionated on the arm seat.

It is one and it is used both for the fingertips and for the joysticks.

On it there is a switch box ( n°9) which permits the using of it in both versions.

JOYSTICKS FINGERTIPS

all the dip switches are OFF the dip switch n°2 is On (In case this one is not abilitate the logic unit goes in alarm INCORRECT START)

FUNCTIONS The arm card controls the push buttons signals of the forward and backward directions, of the horn and of the fingertips/joysticks. All signals use the CAN-BUS to control the information.

By activating an arm seat function, an analogic signal is converted in a digital signal and tranfered to the light card through the CANBUS. After that it goes through both the logic units until it reaches the I / O card.

9 7 8

1

2

3

4

5

6

LAY-OUT 1. Connector for the lifting potentiometer (finger/joystick) 2. Connector for the tilt potentiometer (finger/joystick) 3. Connector for the sideshift potentiometer (finger/joystick) 4. Connector for the 4° way potentiometer (finger/joystick) 5. Connector for the 5° way potentiometer (finger/joystick) 6. Connector for the auxiliary funtions: push buttons for the horn and for the directions.

7. Connector for the CAN-BUS 8. Connector for the programming of the microchip.

9. Dip switches

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SERVICE MANUAL

PB1=Forward pushbutton PB2=Horn pushbutton PB3=Backward pushbutton

PB3

PB2 PB1

2.5-3.5 ton AC page 59

Electric

2.5-3.5 ton AC

SERVICE MANUAL

page 60

036-0409-02

LIGHT CARD The Light card is collocated on the back side of the truck and connected to the CAN-BUS of the arm.

This card receives the CAN on two different connectors connected in parallel. In the first one arrives the CAN from the logic units, in the second one arrives the CAN from the arm seat.

FUNCTIONS - Controlling the back lights.

1.

2.

3.

4.

4

3

2

1

CAN-BUS. CAN-BUS. Not used.

Connector for the lights.

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SERVICE MANUAL

036-0409-02

2.5-3.5 ton AC page 61

I/O CARD Input/output card.

This card is located on the front side of the truck below the footboard.

It controls and converts analogic signals in digital signal and vice versa.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Connector for temperature sensors of traction and lifting motors.

Connector for controlling of the the electric horn. The horn is electronic and this is the electric connection on the card: 2a) pin 1. command signal (104) from Arm Card via CAN-BUS 2b) pin 2. - negative (924) CAN-BUS CAN-BUS Connector for feeding of the Mhyrio card.

CAN-BUS for Mhyrio card.

Connector for the pedals: accelerator pedal, brake pedal, parking brake pedal. It is also an input for the horn in truck with mechanic distributor.

Connector for input of the brake oil tank LED, bottons for the programmated performance, botton for the reduction speed.

Connector for the mechanic distributor (in this case the voltage on the micro is 5volt).

Connector to program the card by means of the PC.

6

7

8

3

HORN ELECTRIC CONNECTION ( horn side) The horn is electronic and it need a signal in order to work. It is continually supplied by the following cables: 9 203 positive + 24 V ["+" on the horn] and 924 negative ["-" on the horn]. The command signal on cable 104 ["IN" on the horn] is a high signal, when the horn pushbutton is pushed the signal goes to the negative and 10 the horn begins to sound

2

1

5 4

2b 2a

2.5-3.5 ton AC page 62

SERVICE MANUAL

Electric 036-0409-02

MHYRIO CARD The Mhyrio card receives the digital inputs from the CAN and it converts them in analogic signals to control the solenoid valves with 24 Volts.

The feeding arrives to the card through three cables: 925 negative 254 positive 254 positive The cables for the CAN-BUS (it means for digital input) arrive to the same connector used for the feeding: WHITE cable BROWN cable

CAN H (high) CAN L (low)

It is collocated on the front side of the truck. On the left side it has two connectors: the smaller is used for the CAN the bigger is used to control the solenoid valves for the 4°- 5° way.

On the right side there is the biggest connector used to control the solenoid valves for the lifting, tilt and sideshift.

The connectors which arrive to the Myrio use a particular block sistem and it is necessary to remove it pushing downwards.

HYDRAULIC ELECTRIC CONTROL VALVES

Electric

SERVICE MANUAL

036-0409-02

2.5-3.5 ton AC page 63

ACCELERATOR POTENTIOMETER CONFIGURATION 111 :

aproximately

4,8 V

109 :

aproximately

0 ÷ 1.2 V (by multimeter) 0.6 ÷ 1.6V ( by console)

110 :

0V

é

with pedal pressed with pedal pressed

Yellow

)

110

Red

)

109

Green

)

111

4.5KOhm

ç

1.2KOhm

SINGLE PEDAL VERSION

DOUBLE PEDAL VERSION

2.5-3.5 ton AC

SERVICE MANUAL

page 64

Electric 036-0409-02

LIFTING POTENTIOMETER CONFIGURATION (CONTROL VALVE VERSION) 137

:

4,8 V

135

:

1.3 ÷ 5 V (by multimeter) with lifting lever pulled 0 ÷ 5V (by console) with lifting lever pulled

136

:

0V 137 1

2

5 KOhm 3

ç

135 136

Electric 036-0409-02

SERVICE MANUAL

2.5-3.5 ton AC page 65

POTENTIOMETER CONFIGURATION (JOYSTICKS / FINGERTIPS VERSION)

è

è è

è

è

HORN PUSHBUTTON (PB2)

è BACKWARD PUSHBUTTON (PB3) FORWARD PUSHBUTTON (PB1)

2.5-3.5 ton AC

Electric

SERVICE MANUAL

page 66

036-0409-02

FINGERTIPS RED

:

5V

GREEN

:

0 ÷ 5(AT REST 2,5 V)

BLACK

:

0V

JOYSTICK (FORWARD-BACKWARD MOV.)

JOYSTICK (LEFT-RIGHT MOV.)

ORANGE :

5V

GREEN

:

5V

YELLOW :

0 ÷ 5(AT REST 2,5 V)

BLACK

:

0 ÷ 5 (AT REST 2,5 V)

RED

0V

WHITE

:

0V

:

Electric 036-0409-02

SERVICE MANUAL

2.5-3.5 ton AC page 67

CONSOLE FUNCTION GENERAL DESCRIPTION

HOUR METER The hour meter appears in the second line of the display when the chopper is connected. It shows the real working hours.

PARAMETER CHANGE The chopper parameters can be displayed and programmed via the keyboard, in real time and with operating machine, thereby making it possible to set the chopper easily.

TESTER It makes it possible to display the state of the chopper analogue and digital values and thereby to have a useful tool for the analysis of chopper operation and external cables.

SAVE PARAMETER It makes it possible to store all values relating to the parameters and the chopper hardware configuration into the console with a program which can be selected from the keyboard.

RESTORE PARAMETER It makes it possible to program a chopper with the parameters contained in a program generated by a SAVE. ALARMS The console features the possibility to read the last five alarm messages stored in the chopper and displayed together with the time of occurrence, the number of times the alarm was sent and the temperature value at the time of the alarm.

PROGRAM VACC It allows to program the accelerator max. stroke.

CONSOLE DESCRIPTION KEYBOARD Description of key functions:

ROLL 1 = Allows selection of an option or the next menu item ROLL 2 = Allows select of an option or the previous menu item ENTER = Allow confirmation of selected options OUT

= Retains the current function

PARAM = Allows an increase in the parameters or selects the type of connected I/O SET

= Allows a reduction in the parameters or selects the type of connected I/O

2.5-3.5 ton AC page 68

SERVICE MANUAL CONSOLE CONNECTION

LOGIC UNIT

The connection has to be made with resting machine.

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SERVICE MANUAL

2.5-3.5 ton AC page 69

PARAMETER CHANGE FUNCTION AC3 TRACTION UNIT ACCELER/DELAY RELEASE BRAKING INVERSION BRAKING PEDAL BRAKING SPEED LIMIT BRAKING BRAKE CUTBACK MAX SPEED FORWARD MAX SPEED BACKWARD CUTBACK SPEED CUTBACK SPEED 2 CUTBACK SPEED 3 FREQUENCY CREEP MAXIMUM CURRENT ACC. SMOOTH INV. SMOOTH STOP SMOOTH AUXILIARY TIME

determines the acceleration ramp. controls the deceleration ramp when the travel request is released. controls the deceleration ramp when the direction switch is inverted during travel. determines the deceleration ramp when the travel request is released and the brake pedal switch is closed. deceleration ramp when the pedal position is changed but not completely released. determines the deceleration ramp when the speed reduction input becomes active and the motor slow down. determines the maximum speed in forward direction. determines the maximum speed in backward direction. speed reduction when the cutback switch is active. See on page 9, paragraph 2: “Low speed selector”. speed reduction when the brake switch is active.

Speed reduction when the cutback swicth is active (Pin B7 to pin B10) Signal active low (switch open) minimum speed when the forward or reverse switch is closed, but the accelerator is on a minimum position. this changes the maximum current of the inverter. this delays the acceleration ramp from 0 hz to “stop smooth” value. this delays the deceleration ramp of the inversion from “stopsmooth” value to 0 hz. reference speed determines the time that the truck is hold on the ramp if the “stop on ramp” option is ON. Enabled, not settable

AC3 LIFTING UNIT PU. ACCELER/DELAY PU. DECELER/DELAY MAX SPEED UP MIN SPEED UP CUTBACK SPEED CUTBACK SPEED2 1ST SPEED FINE 2ND SPEED FINE 3RD SPEED FINE 4TH SPEED FINE HYD SPEED FINE MAXIMUM CURRENT AUXILIARY TIME

acceleration ramp. deceleration ramp. determines the maximum lifting speed with a potentiometer control. determines the minimum lifting speed with a potentiometer control when the lifting enable switch is closed.

Speed reduction when the cutback swicth is active(Pin A9) Signal active low (switch open) Not used.

Used only for FFL mast tilting speed, fine regulation. side-shift speed, fine regulation. th 4th lever speed, fine regulation.

5 lever speed, fine regulation. hydro speed, fine regulation. the maximum current of the inverter. time delay when an hydraulic steering function request is switched off.

2.5-3.5 ton AC

SERVICE MANUAL

page 70

Electric 036-0409-02

MHYRIO MODULE MIN LIFT MIN LOWER MIN DRAIN MIN REACH BWD MIN TILT UP MIN TILT DW MIN SHIFTH RGT MIN SHIFTH LFT MAX LIFT MAX LOWER MAX DRAIN MAX REACH BWD MAX TILT UP MAX TILT DW MAX SHIFTH RGT MAX SHIFTH LFT LIFT/LOW ACC. DELAY DRAIN ACC. DELAY TI/SH ACC. DELAY LIFT/LOW DEC. DELAY DRAIN DEC. DELAY TI/SH DEC. DELAY

Min. voltage on the lifting solenoid valve Min. voltage on the lowering solenoid valve Min voltage on the draining solenoid valve Not used Min voltage on the backward tilt solenoid valve Min voltage on the forward tilt solenoid valve Min voltage on the sideshift right solenoid valve Min voltage on the sideshift left solenoid valve Max voltage on the lifting solenoid valve Max. voltage on the lowering solenoid valve Max voltage on the draining solenoid valve Not used Max voltage on the tilt backward solenoid valve Max voltage on the tilt forward solenoid valve Max voltage on the sideshift right solenoid valve Max voltage on the sideshift left solenoid valve Delay in reaching the selected voltage on the lifting/lowering solenoid valve ( in opening ) Delay in reaching the selected voltage on the draining solenoid valve ( in closing ) Delay in reaching the selected voltage on the tilt/sideshift solenoid valve ( in opening ) Delay in reaching the selected voltage on the lifting/lowering solenoid valve ( in closing ) Delay in reaching the selected voltage on the draining solenoid valve ( in opening ) Delay in reaching the selected voltage on the tilt/sideshift solenoid valve ( in closing )

NOTE Only two parameters can be adjusted: MIN DRAIN:

for changing the delay of the solenoid valve EV11 (see hydraulick diagram). Setting this parameter change the sensibility of the lifting potentiometer.

MAX LOWER: for changing the delay of the solenoid valve EV2 (see hydraulick diagram). Setting this parameter change the lowering speed of the mast.

Electric 036-0409-02

SERVICE MANUAL

2.5-3.5 ton AC page 71

TESTER FUNCTIONS AC3 TRACTION UNIT MOTOR VOLTAGE: a FREQUENCY: ENCODER: quency; SLIP VALUE: the CURRENT RMS: TEMPERATURE: MOSFET MOTOR TEMPERATURE: ACCELERATOR: voltage FORWARD SWITCH: entry BACKWARD SWITCH: entry BACKING FORW: BACKING BACK: CUTBACK SWITCH: A3) BRAKE SWITCH: SEAT SWITCH: EXCLUSIVE HYDRO: HAND BRAKE: VOLTAGE BOOSTER: it BATTERY VOLTAGE: COS FI: BATTERY CURRENT: BATTERY CHARGE:

this is the voltage supplied to the motor by the inverter; it is expressed as percentage of the full voltage (which depends of the battery voltage). this is the frequency of the voltage and current supplied to the motor. this is the speed of the motor, expressed in the same unit of the frethis information comes from the speed sensor. this is the difference of speed between the rotating field and the shaft of motor, expressed in the same unit of the frequency.

Root Mean Square value of the motor current. the temperature measured on the aluminum heat sink holding the devices.

Not used (0°). the voltage of the accelerator potentiometer's wiper (CPOT). The level and percentage value are shown. the level of the Forward direction digital entry FW. ON / +VB = active entry of closed switch OFF / GND = non active of open switch. the level of the Reverse direction digital entry BW. ON / +VB = active entry of closed switch OFF / GND = non active of open switch.

Not used Not used the level of the Speed Reduction Microswitch (Not used Optional Pin ON / GND = active entry of speed reduction microswitch.

OFF / +VB = non active entry of microswitch. the level of the Pedal Brake Microswitch.

ON / +VB = active entry of Brake pedal Microswitch.

OFF / GND = non active entry of microswitch. the level of the Seat Microswitch digital entry.

ON / +VB = active entry of closed seat switch.

OFF / GND = non active entry of open seat switch.

Not used the level of the Handbrake Microswitch.

ON / GND = active entry of Handbrake Switch.

OFF/ +VB = non active entry of microswitch. this is the booster of the voltage supplied to the motor in load condition; is expressed in a percentage of the full voltage. level of battery voltage measured at the input to the key switch. this is the cos f (real time calculated) of the motor. this is the battery current (not measured but calculated). the percentage Charge level of the battery.

2.5-3.5 ton AC page 72

SERVICE MANUAL

Electric 036-0409-02

AC3 LIFTING UNIT MOTOR VOLTAGE: FREQUENCY: ENCODER: SLIP VALUE: CURRENT RMS: TEMPERATURE: MOTOR TEMPERATURE: ACCELERATOR: LIFTING SWITCH: 1 ST SPEED SWITCH: 2 ND SPEED SWITCH: 3 RD SPEED SWITCH: 4 TH SPEED SWITCH: HYDRO SPEED REQ.: VOLTAGE BOOSTER: BATTERY VOLTAGE: COS FI: BATTERY CURRENT: BATTERY CHARGE:

this is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full voltage (which depends of the battery voltage). this is the frequency of the voltage and current supplied to the motor. this is the speed of the motor, expressed in the same unit of the frequency; this information comes from the speed sensor. this is the difference of speed between the rotating field and the shaft of the motor, expressed inthe same unit of the frequency.

Root Mean Square value of the motor current. the temperature measured on the aluminum heat sink holding the MOSFET devices. this is the temperature of the motor; if the option is programmed "None" (see chapter 4.4.b) it shows 0°. the voltage of the accelerator potentiometer's wiper (CPOT). The voltage level is shown on the Left Hand Side of the Console Display and the value in percentage is shown on the Right Hand Side. status of the lifting switch. status of the tilting switch of the pump. status of the side-shift switch of the pump. th status of the 4th lever switch of the pump. status of the 5 speed switch of the pump. status of the hydro speed request of the pump. this is the booster of the voltage supplied to the motor in load condition; it is expressed in a percentage of the full voltage. level of battery voltage measured at the input to the key switch. this is the cos f (real time calculated) of the motor. this is the battery current (not measured but calculated). the percentage Charge level of the battery.

Electric

SERVICE MANUAL

036-0409-02

MHYRIO MODULE DIGITAL INPUT 1 DIGITAL INPUT 2 DIGITAL INPUT 3 DIGITAL INPUT 4 DIGITAL INPUT 5 DIGITAL INPUT 6 DIGITAL INPUT 7 DIGITAL INPUT 8 LOWER EV LIFT EV DRAIN EV TILT UP TILT DW SHIFT LFT EV SHIFT RGT EV STATUS 1 STATUS 2 STATUS 3 ENCODER ANALOG INPUT 1 ANALOG INPUT 2 *:

not used not used not used not used not used not used not used not used it shows the state of the lower solenoid valve: ON or OFF* it shows the state of the lift solenoid valve: ON or OFF* it shows the state of the drain solenoid valve: ON or OFF* it shows the state of the tilt up solenoid valve: ON or OFF* it shows the state of the tilt down solenoid valve: ON or OFF* it shows the state of the shift left solenoid valve: ON or OFF* it shows the state of the shift right solenoid valve: ON or OFF* it shows the state of the 4th way /extra solenoid valve: ON or OFF* it shows the state of the 4th way /extra solenoid valve: ON or OFF* it shows the state of the 4th way /extra solenoid valve: ON or OFF* not used not used not used

ON= active when the switch is closed (+ BATT) OFF= not active when the switch is opened (GND)

2.5-3.5 ton AC page 73

2.5-3.5 ton AC

SERVICE MANUAL

page 74

Electric 036-0409-02

ALARMS FUNCTIONS AC3 TRACTION UNIT DISPLAY DIAGNOSTIC CODE (DASHBOARD)

CONSOLE / LOGIC UNIT ALARM DESCRIPTION

REPAIR DESCRIPTION

1 2

WATCH - DOG EEPROM KO

3 4

LOGIC FAILURE #3 LOGIC FAILURE #2

5

LOGIC FAILURE #1

6

VMN LOW

7

VMN HIGH

8

CONTACTOR OPEN

9

STBY I HIGH

10

CAPACITOR CHARGE

11

HIGH TEMPERATURE

Logic defect. Replace the AC3 traction unit.

Fault in the area of memory in which the adjustment parameters are stored; this alarm inhibits the truck operation, but the controller will use default parameters. If the defect persists when the key is switched OFF and ON again, replace the logic. If the alarm disappears, remember that the parameters previously stored have been deleted and replaced by the default values.

Logic defect. Replace the AC3 traction unit.

Fault in the hardware section of the logic board which manages the phase voltage feedback. Check the power cables connected to the motor. Replace the AC3 traction unit.

This alarm signals that the interruption of protection against undervoltage / overvoltage has been triggered. Two possible reasons: a. Actual undervoltage / overvoltage. b. Fault in the hardware section of the logic board which controls the overvoltage protection. Logic defect. Replace the AC3 traction unit.

Failure in the VMN test. Check: - Motor isolation and relevant cables -AC3 traction unit.

The test is carried out during initial diagnosis and in standby. Possible causes: a. problem with the motor connections or the motor power circuit; check if the 3 phases are correctly connected; b. inverter failure, replace it.

The main contactor coil has been driven by the logic board, but the contactor does not close. Two possible reasons: a) the wires to the coil are interrupted or not well connected. b) the contact of the contactor is not properly working.

Failure on the current sensor.

Replace the AC3 traction unit.

Failure on the VMN test. Check: - Motor isolation and relevant cables - AC3 traction unit.

The temperature of the AC3 traction unit exceeds 75°C. The maximum current is reduced proportionally to the temperature increase. The chopper stops at 85° C. If the alarm appears in cold conditions, replace the AC3 traction unit.

Electric 036-0409-02

SERVICE MANUAL

2.5-3.5 ton AC page 75

DISPLAY DIAGNOSTIC CODE (DASHBOARD)

CONSOLE / LOGIC UNIT ALARM DESCRIPTION

REPAIR DESCRIPTION

12

MOTOR TEMPERAT.

13

ENCODER ERROR

14

THERMIC SENS KO

15 16

SAFETY CAN BUS KO

This warning signals that the temperature switches of the right motor are open (digital sensor). If it occurs when the motor is cold, check the wiring, the I/O card (5V must be present on the relevant positive and negative in the connector J1).

Encoder failure. Check: - Encoder and relevant cables The range of inverter temperature sensor is always checked and a warning is signalled if it is out of range.

When this alarm is signalled, replace the logic unit.

17

WAITING FOR NODES

18

AUX OUTPUT KO

19

DRIVER SHORTED

20

CONTACTOR DRIVER

21

COIL SHORTED

22

VACC NOT OK

23

INCORRECT START

24

PEDAL WIRE KO

25

WRONG BATTERY

Failure detection from can-bus. Check: - the wires connected between the logic units, traction, lifting, Mhyrio (if it is present) and all the cards.

Failure detection from can-bus. Check: - the wires connected between the two logic units: traction and lifting.

- Replace theAC3 traction unit.

Failure on the contactor driver. Replace the AC3 traction unit.

Failure on the contactor driver. Check: - Main contactors coils and relevant wirings.

Failure on the contactor driver. Check: - Main contactors coils and relevant wirings.

Failure on the contactor driver. Check: - Main contactors coils and relevant wirings.

Failure on the acceleartion potentiometer signal at rest.

Check: - Traction potentiometer (could be damaged or not correctly= calibrated) - Traction potentiometer wiring.

Incorrect sequence by starting. Check: - Microswitch for forward/Backward directions and relevant wires.

- Microswitch for parking brake and relevant wires.

Failure on the acceleartion potentiometer signal at rest, Check: - Traction potentiometer (could be damaged or not correctly calibrated) - Traction potentiometer wiring.

When the key is turned ON, the controller check the battery voltage and compares it with the “SET BATTERY” parameter setting. If the actual value is 20% higher or lower than nominal value, the fault condition is entered.

Replace the battery with a correct one.

2.5-3.5 ton AC

SERVICE MANUAL

page 76

Electric 036-0409-02

DISPLAY DIAGNOSTIC CODE (DASHBOARD)

CONSOLE / LOGIC UNIT ALARM DESCRIPTION

REPAIR DESCRIPTION

26 27 28 29

REMOTE INPUT BAD STEER 0-SET STEER SENSOR KO FORW + BACK

1A

I=0 EVER

1C

BATTERY_LOW

2A

CHOPPER NOT CONF

1E

CONTACTOR CLOSED

2C

GAIN ACQUISITION

2E

HANDBRAKE

Incorrect start Not used Not used Incorrect sequence by starting. Check: - Microswitch for forward/Backward directions and relevant wires - Microswitch for parking brake and relevant wires.

Failure on the current sensor. Replace the AC3 traction unit.

Discharged battery. If the “battery check” option is ON, a battery discharge algorithm is carried out. When the charge level is 10% , this alarm is signalled and the current is reduced to the half of the programmed level.

The AC3 traction unit has an erroneous configuration.

Using the programming console it is possibleto to put the unit in the correct way that depends on the truck configuration: (0) double pedal version; (1) manual inversor version; (2) with inversor on the armrest.

Failure on the contactor driver. Check: - Main contactors coils and relevant wirings.

This warning communicate that the logic is in the acquisition phase of current gain. In this phase the logic doesn't start.

Failure on parking brake. Check: parking brake microswitch and relevant cables.

Electric

SERVICE MANUAL

036-0409-02

2.5-3.5 ton AC page 77

AC3 LIFTING UNIT DISPLAY DIAGNOSTIC CODE (DASHBOARD)

CONSOLE / LOGIC UNIT ALARM DESCRIPTION

REPAIR DESCRIPTION

31 32

WATCH - DOG EEPROM KO

33 34

LOGIC FAILURE #3 LOGIC FAILURE #2

35

LOGIC FAILURE #1

36

VMN LOW

37

VMN HIGH

38

CONTACTOR OPEN

39 40

STBY I HIGH CAPACITOR CHARGE

41

HIGH TEMPERATURE

42

MOTOR TEMPERAT.

Logic defect. Replace the AC3 lifting unit.

Fault in the area of memory in which the adjustment parameters are stored; this alarm inhibits machine operation. If the defect persists when the key is switched OFF and ON again, replace the logic. If the alarm disappears, remember that the parameters stored previously have been cancelled and replaced by the default values.

Logic defect. Replace the AC3 lifting unit.

Fault in the hardware section of the logic board which manages the phase’ s voltage feedback. Replace the AC3 lifting unit.

This alarm signals that the interruption of protection against undervoltage / overvoltage has been triggered. Two possible reasons: a. Actual undervoltage / overvoltage. b. Fault in the hardware section of the logic board which controls the overvoltage protection. Logic defect. Replace the AC3 lifting unit.

The test is carried out during initial diagnosis and in standby. Possible causes: a. problem with the motor connections or the motor power circuit; check if there’s a dispersion of the motor towards ground; b. inverter failure, replace it.

The test is carried out during the initial diagnosis and in standby. Possible causes: a. problem with the motor connections or the motor power circuit; check if the 3 phases are correctly connected; b. chopper failure, replace it Failure on the contactor driver. Check: - Main contactors coils and relevant wirings.

Failure on the current sensor. Replace the AC3 lifting unit.

Failure on the VMN test. Check: - Motor isolation and relevant cables - AC3 lifting unit.

The temperature of the AC3 lifting unit exceeds 75° C. The maximum current is reduced proportionally to the temperature increase. The chopper stops at 85° C. If the alarm appears in cold conditions, replace AC3 lifting unit.

Motor temperature. Check: - Motor and relevant cables

2.5-3.5 ton AC

SERVICE MANUAL

page 78

Electric 036-0409-02

DISPLAY DIAGNOSTIC CODE (DASHBOARD)

CONSOLE / LOGIC UNIT ALARM DESCRIPTION

REPAIR DESCRIPTION

43

ENCODER ERROR

44

THERMIC SENS KO

45 46

SAFETY CAN BUS KO

Encoder failure. Check: - Encoder and relevant cables The range of inverter temperature sensor is always checked and a warning is signalled if it is out of range.

When this alarm is signalled, replace the logic unit.

47

WAITING FOR NODES

48

AUX OUTPUT KO

49

DRIVER SHORTED

50

CONTACTOR DRIVER

51

COIL SHORTED

52

VACC NOT OK

53

INCORRECT START

54 55

PEDAL WIRE KO WRONG BATTERY

56 57

REMOTE INPUT XX WAITING MHYRIO

58

I= 0 EVER

59 4A 4C

BATTERY_LOW

5E

Failure detection from can-bus. Check: - the wires connected between the logic units, traction, lifting, Mhyrio (if it is present) and all the cards.

Failure detection from can-bus. Check: - the wires connected between the two logic units: traction and lifting.

- Replace theAC3 lifting unit.

Failure on the contactor driver.

Replace theAC3 lifting unit.

Failure on the contactor driver. Check: - Main contactors coils and relevant wirings.

Failure on the contactor driver. Check: - Main contactors coils and relevant wirings.

Failure on the contactor driver. Check: - Main contactors coils and relevant wirings.

Failure on the acceleartion potentiometer signal at rest.

Check: - Lifting potentiometer (could be damaged or not correctly calibrated) - Lifting potentiometer wiring.

Incorrect sequence by starting. Check: - Microswitches of the control valve and relevant wires.

Not used.

When the key is turned ON, the controller check the battery voltage and compares it with the “SET BATTERY” parameter setting. If the actual value is 20% higher or lower than nominal value, the fault condition is entered.

Replace the battery with a correct battery.

Incorrect start Failure detection from can-bus. Check: - the wires connected between the logic units: traction, lifting and mhyrio.

Failure on the current sensor.

Replace theAC3 lifting unit.

Not used Not used Discharged battery. If the “battery check” option is ON, a battery discharge algorithm is carried out. When the charge level is 10% , this alarm is signalled and the current is reduced to the half of the programmed level.

Not used

Electric

SERVICE MANUAL

036-0409-02

2.5-3.5 ton AC page 79

DISPLAY DIAGNOSTIC CODE (DASHBOARD)

CONSOLE / LOGIC UNIT ALARM DESCRIPTION

REPAIR DESCRIPTION

5A

CHOPPER NOT CONF

4E 5C

GAIN ACQUISITION

The AC3 lifting unit has an erroneous configuration.

Using the programming console it is possibleto to put the unit in the correct way that depends on the truck configuration: (joystick ON) control valve version / (joystick OFF) fingertips - joysticks version. (see page 127).

Not used This warning communicate that the logic is in the acquisition phase of current gain. In this phase the logic doesn't start.

MHYRIO MODULE DISPLAY DIAGNOSTIC CODE (DASHBOARD)

CONSOLE / LOGIC UNIT ALARM DESCRIPTION

REPAIR DESCRIPTION

A1

EEPROM KO

A2

DRIVER SHORTED

A3 A4 A5

CAN BUS KO FF VALVES DRIVER OPEN

A6

DRIVER EPV GR1

A7

DRIVER EPV GR2

A8

DRIVER EPV GR3

Fault in the area of memory in which the adjustment parameters are stored; this alarm inhibits the truck operation, but the controller will use default parameters. If the defect persists when the key is switched OFF and ON again, replace the logic. If the alarm disappears, remember that the parameters previously stored have been deleted and replaced by the default values.

The transistor that controls the lift and lower valves positive supply is closed when it should be open.

Not used.

Not used The transistor that controls the lift and lower valves positive supply is open when it should be closed.

One or more MOS controlling the valves are in short circuit.

One or more MOS controlling the valves are in short circuit.

One or more MOS controlling the valves are in short circuit.

DASHBOARD DISPLAY DIAGNOSTIC CODE (DASHBOARD)

D1

CONSOLE / LOGIC UNIT ALARM DESCRIPTION

NO CANBUS MSG N._ _

REPAIR DESCRIPTION

Can-bus detection failure. The dashboard does not receive information from the CAN-BUS.

2.5-3.5 ton AC

SERVICE MANUAL

page 80

Electric 036-0409-02

FINGERTIPS/JOYSTICKS (NOT SHOWN BY THE CONSOLE) ISPLAY DIAGNOSTIC CODE (DASHBOARD)

ALARM DESCRIPTION

E1 E2

BAD LIFT POT

E3

BAD TILT POT

E4

BAD SIDESH. POT

E5

BAD IV POT

E6

BAD V POT

E7 E8 BF

INCORRECT START BAD POTENTIOMETER FW+BW

REPAIR DESCRIPTION

Not used.

Failure on the lifting potentiometer in fingertips/joysticks group. Check and if it is necessary replace the concerned fingertip/joystick .

Failure on the tilting potentiometer in fingertips/joysticks group. Check and if it is necessary replace the concerned fingertip/joystick .

Failure on the sideshift potentiometer in fingertips/joysticks group. Check and if it is necessary replace the concerned fingertip/joystick .

Failure on the 4th way potentiometer in fingertips/joysticks group. Check and if it is necessary replace the concerned fingertip/joystick .

Failure on the 4th way potentiometer in fingertips/joysticks group. Check and if it is necessary replace the concerned fingertip/joystick .

Incorrect starting sequence.

Incorrect starting sequence. Check and if it is necessary replace the forward pushbutton (PB1), backward pushbutton (PB3) and the relevant cables placed on the arm.

LIGHT CARD (NOT SHOWN BY THE CONSOLE) SPLAY DIAGNOSTIC CODE (DASHBOARD)

ALARM DESCRIPTION

REPAIR DESCRIPTION

C1

STOP-OPEN

C2

STOP-SHORT

C3 C4

RETRO-OPEN

C5 C6 C7 C8

RETRO-SHORT

Failure on the stop lights. Check the bulbs of the stop streetlights and the relevant cables.

Failure on the stop lights. Check the bulbs of the stop streetlights and the relevant cables.

Not used.

Failure on the reversing lights. Check the bulbs of the reversing streetlights and the relevant cables.

Not used.

Not used.

Not used.

Failure on the reversing lights. Check the bulbs of the reversing streetlights and the relevant cables.

Electric

SERVICE MANUAL

036-0409-02

2.5-3.5 ton AC page 81

I / O CARD (NOT SHOWN BY THE CONSOLE) SPLAY DIAGNOSTIC CODE (DASHBOARD)

ALARM DESCRIPTION

REPAIR DESCRIPTION

81

INCORRECT START

82 83

LOGIC FAILURE PEDAL WIRE KO

84 85 86 87 88

BAD MICROSWITCH

Incorrect starting sequence.(control valve version).

Check: - forward, backward micros and the relevant cables - parking brake micro and the relevant cables Logic defect.(control valve version).

Failure on the acceleartion potentiometer signal at rest, Check: - Traction potentiometer (could be damaged or not correctly calibrated) - Traction potentiometer wiring.

INCORRECT START PUMP INCORRECT START

Not used.

Not used.

2.5-3.5 ton AC page 82

Electric

SERVICE MANUAL

036-0409-02

PARAMETER SETTING TABLE TRACTION UNIT

PROGRAMMED LEVEL PARAMETER UNIT

0

1

2

3

4

5

6

7

8

9

ACCELERATION DELAY (*)

SEC

2.5

3.0

3.5

4.0

4.5

5.0

5.5

6.0

6.5

7.0

RELEASE BRAKING (**)

SEC

5.5

5.0

4.5

4.0

3.5

3.0

2.5

2.0

1.5

1.0

INVERS 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

BRAKE CUTBACK (**)

SEC

5.5

5.0

4.5

4.0

3.5

3.0

2.5

2.0

1.5

1.0

MAX SPEED FW

HZ

65

80

95

110

125

140

155

170

185

200

MAX SPEED BW

HZ

65

80

95

110

125

140

155

170

185

200

CUTBACK SPEED

% MAX SPEED

10

20

30

40

50

60

70

80

90

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

ACC. SMOOTH INV. SMOOTH STOP SMOOTH

HZ

AUXILIARY TIME

SEC

(*)

The acceleration time shown is the time from 0 Hz to 100 Hz. This is the ideal ramp calculated by the software; the real ramp could change as a function of motor control parameter setting and, obviously, as a function of the load.

(**) The braking feature is based upon deceleration ramps. The value shown in the table is the time to decrease the speed from 100 Hz to 0 Hz. This is the ideal ramps calculated by the software; the real ramp could change as a function of motor control parameter setting and, obviously, as a function of the load.

Electric 036-0409-02

2.5-3.5 ton AC

SERVICE MANUAL

page 83

LIFTING UNIT

PROGRAMMED LEVEL PARAMETER UNIT

0

1

2

3

4

5

6

7

8

9

ACCELERATION DELAY (*)

SEC

0.5

0.7

1.0

1.4

1.9

2.5

3.2

4.0

4.8

5.5

DELERATION DELAY (**)

SEC

0.5

0.7

1.0

1.4

1.9

2.5

3.2

4.0

4.8

5.5

MAX SPEED UP

HZ

65

80

95

110

125

140

155

170

185

200

MIN SPEED UP

HZ

12.0

13.5

15.0

16.5

18.0

19.5

21.0

22.5

24.0

25.5

SPEED FINE (ALL) (***)

HZ

-

-

-

-

-

-

-

-

-

-

MAXIMUM CURRENT

% IMAX

47

53

58

64

70

76

82

88

94

100

AUXILIARY TIME

SEC

0

0.2

0.4

0.8

1.0

1.5

2.0

3.0

4.0

5.0

(*)

The acceleration time shown is the time from 0 Hz to 100 Hz (maximum selectable speed). This is the ideal ramp calculated by the software; the real ramp could change as a function of motor control parameter setting and, obviously, as a function of the load.

(**) The deceleration time shown in the table is the time from 100 Hz to 0 Hz. This is the ideal ramp calculated by the software; the real ramp could change as a function of motor control parameter setting and, obviously, as a function of the load. (***) Adjustable with a 1Hz resolution in the 0 to 200 Hz range.

SERVICE MANUAL MAPS FOR USING THE CONSOLE

TRACTION

2.5-3.5 ton AC

SERVICE MANUAL

page 86

Electric 036-0409-02

DESCRIPTION OF STANDARD CONSOLE MENU AC3 TRACTION UNIT The console can be connected to the traction logic unit in two different ways: 1.

2.

Directly by means of the interface cable on the logic unit.

Connecting the console in the lifting logic unit and select the relevant connecting number as showen in the map here below.

AC3P2BIB 80V 450A

CE 1.02 00000

In case the console is connected to the lifting logic unit Press ROLL and PARAM together

CONFIG. MENU SET MODEL

Press ENTER CONNECTED TO 5

It is the connecting number of the lifting logic unit.

Press SET and select the connecting number of the traction logic unit

CONNECTED TO 2

Traction logic unit

Press OUT

CONNECTION NUMBER

ARE YOU SURE? YES=ENTER NO=OUT

Press ENTER to confirm

2 5 9

TRACTION PUMP MHYRIO

CONFIG. MENU SET MODEL

Press ROLL, OUT and SET together AC3T2JIB 80V 450A

CE 1.02 00000

Connected to the traction logic unit

Electric 036-0409-02

SERVICE MANUAL

2.5-3.5 ton AC page 87

DESCRIPTION OF STANDARD CONSOLE MENU AC3 TRACTION LOGIC UNIT HEADING MAIN MENU

PARAMETER CHANGE

TESTER

ACCELERATION DELAY 0-9 RELEASE BRAKING 0-9 INVERS. BRAKING 0-9 PEDAL BRAKING 0-9 SPEED LIMIT BRAK. 0-9 BRAKE CUTBACK 0-9 MAX SPEED FORW Hz MAX SPEED BACK Hz CUTBACK SPEED Hz CUTBACK SPEED 2 Hz CUTBACK SPEED 3 Hz FREQUENCY CREEP Hz MAXIMUM CURRENT 0-9 ACC. SMOOTH 1-1.5 Hz INV. SMOOTH 0.4-1.5 Hz STOP SMOOTH 5-20 Hz AUXILIARY TIME Sec MOTOR VOLTAGE FREQUENCY ENCODER SLIP VALUE CURRENT RMS TEMPERATURE MOTOR TEMPERATURE ACCELERATOR FORWARD SWITCH BACKWARD SWITCH ENABLE SWITCH SEAT SWITCH CUTBACK SWITCH CUTBACK SWITCH 3 BRAKE SWITCH EXCLUSIVE HYDRO BRAKE PEDAL POT. HAND BRAKE VOLTAGE BOOSTER BATTERY VOLTAGE COS FI BATTERY CURRENT BATTERY CHARGE

% Hz Hz Hz A °C °C V ON-OFF ON-OFF ON-OFF ON-OFF ON-OFF ON-OFF ON-OFF ON-OFF not used ON-OFF V V A %

SAVE PARAMETER

RESTORE PARAMETER

ALARMS

PROGRAM VACC

STEER TABLE

h,

CODE N°, C°

VACC SETTING MIN/MAX

NOT AVAIBLE!

SET MODEL

CONNECTED TO 3

SET OPTIONS

HOUR COUNTER BATTERY CHECK CUT BACK MODE HYDRO KEY ON STOP ON RAMP AUX INPUT #1

ADJUSTMENTS

RUNNING/ KEY ON ON/OFF PRESENT/ABSENT ON/OFF ON/OFF EXCLUSIVE HYDRO OPTION #1 CUT BACK SPEED PEDAL BRAKING ANALOG/DIGITAL SET TEMPERATURE ANALOG/DIGITAL/ NONE

SET POT BRK MIN SET POT BRK MAX SET BATTERY TYPE ADJUST BATTERY ADJUSTMENT #4 ADJUSTMENT #3 THROTTLE 0 ZONE THROTTLE X ZONE THROTTLE Y ZONE ADJUSTMENT #02 ADJUSTMENT #01 LOAD HM FROM MDI CHECK UP DONE CHECK UP TYPE

....V ....V 48/72/80/96 ....V °C °C ....% ....% ....% 1-9 1-9 ON/OFF ON/OFF ON/OFF

2.5-3.5 ton AC

SERVICE MANUAL

page 88

MAIN MANU:

Electric 036-0409-02

PARAMETER CHANGE (TRACTION connecting number 2)

Select the program P on the dashboard before working in the main manu PARAMETER CHANGE. AC3T2JIB 80V 450A

CE 1.02 00000

Press ENTER MAIN MENU PARAM. CHANGE

Press ENTER

ACCELER/DELAY RELEASE BRAKING INVERSION BRAKING PEDAL BRAKING SPEED LIMIT BRAKING BRAKE CUTBACK MAX SPEED FORWARD MAX SPEED BACKWARD CUTBACK SPEED 1 CUTBACK SPEED 2 CUTBACK SPEED 3 FREQUENCY CREEP MAXIMUM CURRENT ACC. SMOOTH INV. SMOOTH STOP SMOOTH AUXILIARY TIME

determines the acceleration ramp. controls the deceleration ramp when the travel request is released. controls the deceleration ramp when the direction switch is inverted during travel. determines the deceleration ramp when the travel request is released and thebrake pedal switch is closed. deceleration ramp when the pedal position is changed but not completely released. determines the deceleration ramp when the speed reduction input becomes active and the motor slow down. determines the maximum speed in forward direction. determines the maximum speed in backward direction. speed reduction when the cutback switch is active. Turtle function. speed reduction when the microswitch of the brake pedal is pressed speed reduction actived when the signal b10 is low minimum speed when the forward or reverse switch is closed, but the accelerator is on a minimum position. this changes the maximum current of the inverter. this delays the acceleration ramp from 0 hz to “stop smooth” value. this delays the deceleration ramp of the inversion from 0 hz to “stop mooth” value. reference speed stop on ramp. No adjustable.

Scroll the paramters using ROLL and save the new values pressing OUT and after ENTER

Electric

SERVICE MANUAL

036-0409-02

MAIN MANU: AC3T2JIB 80V 450A

TESTER (TRACTION connecting number 2) CE 1.02 00000

Press ENTER MAIN MENU PARAM. CHANGE

Press ROLL MAIN MENU TESTER

Press ENTER

MOTOR VOLTAGE FREQUENCY ENCODER SLIP VALUE CURRENT RMS TEMPERATURE MOTOR TEMPERATURE ACCELERATOR FORWARD SWITCH BACKWARD SWITCH ENABLE SWITCH SEAT SWITCH CUTBACK SWITCH CUTBACK SWITCH 3 BRAKE SWITCH EXCLUSIVE HYDRO BRAKE PEDAL POT. HAND BRAKE VOLTAGE BOOSTER COS FI BATTERY CURRENT BATTERY CHARGE

Scroll the paramters using ROLL. Press OUT to escape.

2.5-3.5 ton AC page 89

2.5-3.5 ton AC

Electric

SERVICE MANUAL

page 90

MAIN MANU :

SAVE PARAMETER AC3T2JIB 80V 450A

036-0409-02

(TRACTION connecting number 2) CE 1.02 00000

Press ENTER MAIN MENU PARAM. CHANGE

Press ROLL MAIN MENU TESTER

Press ROLL MAIN MENU SAVE PARAM

Press ENTER Select a box (0-31) where you want to save the program: SELECT Mod 00 = Program number FREE/AC3T2JIB = Program version stored

SELECT Mod 00 FREE

SELECT Mod 00 AC3T2JIB

Press ENTER

Press ENTER OVERWRITE DATA? YES=ENTER NO=OUT

READING........

RUN ALL PARAMETERS

MAIN MENU SAVE PARAM

Press ENTER to confirm READING........

RUN ALL PARAMETERS

MAIN MENU SAVE PARAM

Press OUT to escape MAIN MENU SAVE PARAM

Electric

SERVICE MANUAL

036-0409-02

2.5-3.5 ton AC page 91

MAIN MANU : RESTORE PARAMETER (TRACTION connecting number 2) AC3T2JIB 80V 450A

CE 1.02 00000

Press ENTER MAIN MENU PARAM. CHANGE

Press ROLL MAIN MENU TESTER

Press ROLL MAIN MENU SAVE PARAM

Press ROLL MAIN MENU RESTORE PARAM

Press ENTER SELECT Mod 00 = Program number FREE/AC3T2JIB = Program version stored

SELECT Mod 00 AC3T2JIB

Press ROLL to Select a box (0-31) where you want to save the program OVERWRITE DATA? YES=ENTER NO=OUT

Press ENTER to confirm STORING........

RUN ALL PARAMETERS

MAIN MENU RESTORE PARAM

Press OUT to escape MAIN MENU RESTORE PARAM

2.5-3.5 ton AC

SERVICE MANUAL

page 92

MAIN MANU :

Electric

ALARM

036-0409-02

(TRACTION connecting number 2)

AC3T2JIB 80V 450A

CE 1.02 00000

Press ENTER MAIN. MENU PARAM. CHANGE

Press ROLL until reaching MAIN MENU ALARM MAIN. MENU ALARM

Press ENTER max 5 alarms stored

no alarms stored

00000h

NONE #00

0°C

23h

hour meter

ALARM CODE 2 25°C

n°alarms

temperature

Press OUT

Press ENTER CLEAR LOGBOOK YES=ENTER NO=OUT

Press OUT to escape

Press ENTER to confirm ARE YOU SURE? YES=ENTER NO=OUT

Press ENTER to confirm LOGBOOK CLEARED (PRESS OUT)

Press OUT to escape

Electric

SERVICE MANUAL

036-0409-02

MAIN MANU:

page 93

PROGRAM VACC. (TRACTION connecting number 2)

This setting must be made with the parking brake released AC3T2JIB 80V 450A

2.5-3.5 ton AC

CE 1.02 00000

Press ENTER MAIN MENU PARAM. CHANGE

Press ROLL until reaching the program VACC MAIN MENU PROGRAM VACC

Press ENTER VACC SETTING 0.6 1.6

These are the old parameters stored Press ENTER

VACC SETTING 0.0 0.0

Reset of the parameters Select the forward direction Press the accelerator pedal slowly until the maximun stroke

VACC SETTING 0.6 1.6

Press OUT keeping the acc. pedal pressed ARE YOU SURE? YES=ENTER NO=OUT

Press ENTER to confirm and release the pedal

Repeat the same operation selecting the backward direction.

2.5-3.5 ton AC

SERVICE MANUAL

page 94

Electric 036-0409-02

STOP ON RAMP (TRACTION connecting number 2)

AC3T2JIB 80V 450A

CE 1.02 00000

Press ROLL and PARAM together CONFIG. MANU SET MODEL

Press ROLL CONFIG. MANU SET OPTIONS

Press ENTER HOUR COUNTER BATTERY CHECK CUT BACK MODE HYDRO KEY ON

RUNNING/ KEY ON ON/OFF PRESENT/ABSENT ON/OFF

STOP ON RAMP

ON/OFF

AUX INPUT #1

EXCLUSIVE HYDRO OPTION #1 CUT BACK SPEED ANALOG/DIGITAL ANALOG/DIGITAL/NONE

PEDAL BRAKING SET TEMPERATURE

Scroll the paramters using ROLL

Select STOP ON RAMP and change the status using PARAM or SET ON ACTIVATED OFF DEACTIVETED and store the parameter pressing OUT and later ENTER to confirm.

After releasing the pedals the truck can stay still on a ramp for about 1 second.

This parameter active/deactive this function.

Electric

SERVICE MANUAL

036-0409-02

2.5-3.5 ton AC page 95

SLIP CONTROL (TRACTION connecting number 2) This functions is useful to understand if a traction problem is a due to the encoder or not.

In case of stopping or low speed of the machine with consequently high consume of current (and relevant alarm code shown on the dashboard) it is possible to disable the encoder for some seconds, no longer, given that the logic unit cannot control the motor anymore.

Do not work in this configuration.

AC3T2JIB 80V 450A

CE 1.02 00000

Press ENTER MAIN MENU PARAM. CHANGE

Press ROLL until reaching ALARM menu MAIN MENU ALARM

With the SLIP CONTROL OFF push the accelerator pedal slowly otherwise the motor stands still.

Press ENTER

DESCRIPTION OF THE ALARM CODE

Press PARAM and SET together MENU SPECIAL ADJUST

Press ROLL MENU ARDWARE SETTING

Press ENTER COMPENSATION SLIP CONTROL

ON/OFF

Select SLIP CONTROL ON or OFF and store the parameter pressing OUT and later ENTER to confirm.

After that switch the truck OFF and ON.

2.5-3.5 ton AC

Electric

SERVICE MANUAL

page 96

036-0409-02

BATTERY (TRACTION connecting number 2) The control of the battery LED indication on the dashboard and the relevant reduction of the speed are managed by the traction logic unit.

AC3T2JIB 80V 450A

CE 1.02 00000

Press ROLL and PARAM together CONFIG.. MANU SET MODEL

Press ROLL CONFIG. MANU SET OPTIONS

Scroll the paramters using ROLL and save the new values pressing OUT and after ENTER HOUR COUNTER

RUNNING/ KEY ON

BATTERY CHECK

ON

CUT BACK MODE HYDRO KEY ON STOP ON RAMP AUX INPUT #1

PRESENT/ABSENT ON/OFF ON/OFF EXCLUSIVE HYDRO OPTION #1 CUT BACK SPEED ANALOGIC DIGITAL ANALOG/DIGITAL/NONE

Press ENTER PEDAL BRAKING SET TEMPERATURE ARE YOU SURE? YES=ENTER NO=OUT

Press OUT Press ENTER

CONFIG. MANU SET OPTIONS

Press ROLL CONFIG. MANU ADJUSTMENTS

Press ENTER

SET POT BRK MIN SET POT BRK MAX SET BATTERY TYPE ADJUST BATTERY ADJUSTMENT #04 ADJUSTMENT #03 THROTTLE 0 ZONE THROTTLE X ZONE THROTTLE Y ZONE ADJUSTMENT #02 ADJUSTMENT #01 LOAD HM FROM MDI CHECK UP DONE CHECK UP TYPE

V V 48 V °C °C % % % 1-9 1-9 ON/OFF ON/OFF ON/OFF

ARE YOU SURE? YES=ENTER NO=OUT

Press ENTER

Press OUT

Electric 036-0409-02 SET BATTERY TYPE: ADJUST BATTERY: ADJUSTMENT #02 ADJUSTMENT #01

SERVICE MANUAL

2.5-3.5 ton AC page 97

selects the nominal battery voltage Adjust the value written in the Console with the real value of the Battery (measured by a multimeter Adjustment for the lower value of charge of the battery Adjustment for the reset value of the Battery Indicator

ADJUSTMENT #01

CONSOLE VALUE 0 1 2 3 4 5 6 7 8 9

VOLT 81.8 82.2 82.6 83.1 83.6 84.0 84.5 84.9 85.4 86.3

ADJUSTMENT #02

CONSOLE VALUE 0 1 2 3 4 5 6 7 8 9

VOLT 76.4 76.8 77.3 77.7 78.2 78.7 79.1 79.5 80.0 80.9

2.5-3.5 ton AC

SERVICE MANUAL

page 98

TRACTION ACQUISITION

Electric 036-0409-02

(TRACTION connecting number 2)

Connect the console to the TRACTION logic unit AC3T2JIB 80V 450A

CE 1.02 00000

Press ROLL and PARAM together CONFIG. MANU SET MODEL

Press ENTER CONNECTED TO 2

Press ROLL LEVEL 0

0 with double pedal version

LEVEL 1

1 with manual inversor version

LEVEL 2

2 with inversor on the arm

Press OUT ARE YOU SURE? YES=ENTER NO=OUT

Press ENTER to confirm

Select the parameter using PARAM

LIFTING

2.5-3.5 ton AC

SERVICE MANUAL

page 100

Electric 036-0409-02

DESCRIPTION OF STANDARD CONSOLE MENU AC3 LIFTING UNIT The console can be connected to the lifting logic unit in two different ways: 1.

2.

Directly by means of the interface cable on the logic unit.

Connecting the console in the traction logic unit and select the relevant connecting number as shown in the map here below.

AC3T2JIB 80V 450A

CE 1.02 00000

In case the console is connected to the traction logic unit

Press ROLL and PARAM together CONFIG. MENU SET MODEL

Press ENTER CONNECTED TO 2

It is the connecting number of the traction logic unit.

Press PARAM and select the connecting number of the traction logic unit

CONNECTED TO 5

lifting logic unit Press OUT

CONNECTION NUMBER

ARE YOU SURE? YES=ENTER NO=OUT

Press ENTER to confirm MAIN MENU SET MODEL

2 5 9

TRACTION PUMP MHYRIO

Press ROLL, OUT and SET together AC3P2BIB 80V 450A

CE 1.02 00000

Connected to the traction logic unit

Electric 036-0409-02

SERVICE MANUAL

2.5-3.5 ton AC page 101

DESCRIPTION OF STANDARD CONSOLE MENU AC3 LIFTING LOGIC UNIT HEADING MAIN MENU

PARAMETER CHANGE

ACCELER DELAY DECELER DELAY MAX SPEED UP MIN SPEED UP CUTBACK SPEED CUTBACK SPEED 2 1ST SPEED FINE 2ND SPEED FINE 3RD SPEED FINE 4TH SPEED FINE AUX FUNCTION 1 HYD SPEED FINE MAXIMUM CURRENT AUXILIARY TIME

SET MODEL

SET OPTIONS

TESTER

MOTOR VOLTAGE FREQUENCY ENCODER SLIP VALUE CURRENT RMS TEMPERATURE MOTOR TEMPERATURE ACCELERATOR LIFTING SWITCH 1ST SPEED SWITCH 2ND SPEED SWITCH 3RD SPEED SWITCH 4TH SPEED SWITCH HYDRO SPEED REQ. CUT BACK SWITCH CUT BACK SWITCH 2 VOLTAGE BOOSTER BATTERY VOLTAGE COS FI BATTERY CURRENT BATTERY CHARGE

% Hz Hz Hz A °C °C V ON-OFF ON-OFF ON-OFF ON-OFF ON-OFF ON-OFF ON-OFF ON-OFF % V

ADJUSTMENTS

A %

SAVE PARAMETER

RESTORE PARAMETER

ALARMS

PROGRAM VACC

STEER TABLE

h,

CODE N°, C°

VACC SETTING MIN/MAX

NOT AVAIBLE

CONNECTED TO 5

HOUR COUNTER RUNNING/KEY ON BATTERY CHECK ON/OFF SET TEMPERATURE DIGITAL/ANALOG/ NONE

SET BATTERY TYPE ADJUST BATTERY ADJUSTMENT #04 ADJUSTMENT #03 THROTTLE 0 ZONE THROTTLE X ZONE THROTTLE Y ZONE ADJUSTMENT #02 ADJUSTMENT #01

48/72/80/96 ....V ....°C ....°C ....% ....% ....% 1-9 1-9

2.5-3.5 ton AC

SERVICE MANUAL

page 102

MAIN MANU: AC3P2BIB 80V 450A

Electric 036-0409-02

PARAMETER CHANGE (PUMP connecting number 5) CE 1.02 00000

Press ENTER MAIN MENU PARAM. CHANGE

Press ENTER

ACCELER/DELAY DECELER/DELAY MAX SPEED UP MIN SPEED UP CUTBACK SPEED CUTBACK SPEED 2 1ST SPEED FINE 2ND SPEED FINE 3RD SPEED FINE 4TH SPEED FINE AUX FUNCTION 1 HYD SPEED FINE MAXIMUM CURRENT AUXILIARY TIME

acceleration ramp. deceleration ramp. determines the maximum lifting speed with a potentiometer control. determines the minimum lifting speed with a potentiometer control when the lifting enable switch is closed. speed reduction when the cutback switch is active.(+V =A4; input A13; A13 open Cutbackspeed on, A13 closed Cutbackspeed off. not used tilting speed, fine regulation. side-shift speed, fine regulation. th 4 lever speed, fine regulation. th 5 lever speed, fine regulation. pot. value that increase motor RPM hydro speed, fine regulation. the maximum current of the inverter. time delay when an hydraulic steering function request is switched off.

Scroll the paramters using ROLL and save the new values pressing OUT and after ENTER

Electric

SERVICE MANUAL

036-0409-02

MAIN MANU:

AC3P2BIB 80V 450A

2.5-3.5 ton AC page 103

TESTER (PUMPconnecting number 5)

CE 1.02 00000

Press ENTER MAIN MENU PARAM. CHANGE

Press ROLL MAIN MENU TESTER

Press ENTER

MOTOR VOLTAGE FREQUENCY ENCODER SLIP VALUE CURRENT RMS TEMPERATURE MOTOR TEMPERATURE ACCELERATOR LIFTING SWITCH 1ST SPEED SWITCH 2ND SPEED SWITCH 3RD SPEED SWITCH 4TH SPEED SWITCH HYDRO SPEED REQ. CUT BACK SWITCH CUT BACK SWITCH 2 VOLTAGE BOOSTER BATTERY VOLTAGE COS FI BATTERY CURRENT BATTERY CHARGE

Scroll the paramters using ROLL. Press OUT to escape.

2.5-3.5 ton AC

Electric

SERVICE MANUAL

page 104

MAIN MANU :

036-0409-02

SAVE PARAMETER (PUMP connecting number 5) AC3P2BIB 80V 450A

CE 1.02 00000

Press ENTER MAIN MENU PARAM. CHANGE

Press ROLL MAIN MENU TESTER

Press ROLL MAIN MENU SAVE PARAM

Press ENTER Select a box (0-31) where you want to save the program: SELECT Mod 00 = Program number FREE/AC3P2BIB = Program version stored

SELECT Mod 00 FREE

SELECT Mod 00 AC3P2BIB

Press ENTER

Press ENTER OVERWRITE DATA? YES=ENTER NO=OUT

READING........

RUN ALL PARAMETERS

MAIN MENU SAVE PARAM

Press ENTER to confirm READING........

RUN ALL PARAMETERS

MAIN MENU SAVE PARAM

Press OUT to escape MAIN MENU SAVE PARAM

Electric

SERVICE MANUAL

036-0409-02

MAIN MANU :

2.5-3.5 ton AC page 105

RESTORE PARAMETER (PUMPconnecting number 5) AC3P2BIB 80V 450A

CE 1.02 00000

Press ENTER MAIN MENU PARAM. CHANGE

Press ROLL MAIN MENU TESTER

Press ROLL MAIN MENU SAVE PARAM

Press ROLL MAIN MENU RESTORE PARAM

Press ENTER SELECT Mod 00 = Program number FREE/AC3P2BIB = Program version stored

SELECT Mod 00 AC3P2BIB

Press ROLL to Select a box (0-31) where you want to save the program OVERWRITE DATA? YES=ENTER NO=OUT

Press ENTER to confirm STORING........

RUN ALL PARAMETERS

MAIN MENU RESTORE PARAM

Press OUT to escape MAIN MENU RESTORE PARAM

Electric

2.5-3.5 ton AC

SERVICE MANUAL

page 106

MAIN MANU :

036-0409-02

ALARM (PUMP connecting number 5) AC3P2BIB 80V 450A

CE 1.02 00000

Press ENTER

MAIN. MENU PARAM. CHANGE

Press ROLL until reaching MAIN MENU ALARM MAIN. MENU ALARM

Press ENTER max 5 alarms stored

no alarms stored

00000h

NONE #00

0°C

23h

hour meter

ALARM CODE 2 25°C

n°alarms

temperature

Press OUT

Press ENTER CLEARLOGBOOK YES=ENTER NO=OUT

Press OUT to escape

Press ENTER to confirm ARE YOU SURE? YES=ENTER NO=OUT

Press ENTER to confirm LOGBOOK CLEARED (PRESS OUT)

Press OUT to escape

Electric

SERVICE MANUAL

036-0409-02

MAIN MANU:

PROGRAM VACC.

CE 1.02 00000

Press ENTER MAIN MENU PARAM. CHANGE

Press ROLL until reaching the program VACC

MAIN MENU PROGRAM VACC

Press ENTER VACC SETTING 0.2 4.8

These are old the parameters stored Press ENTER

VACC SETTING 0.0 0.0

page 107

(PUMP connecting number 5)

This setting must be made with the parking brake released AC3P2BIB 80V 450A

2.5-3.5 ton AC

Reset of the parameters

Pull the lifting lever slowly until the maximun stroke VACC SETTING 0.2 4.8

Press OUT keeping the lever pulled ARE YOU SURE? YES=ENTER NO=OUT

Press ENTER to confirm and release the lever

2.5-3.5 ton AC

SERVICE MANUAL

page 108

Electric 036-0409-02

SLIP CONTROL (PUMP connecting number 5) This functions is useful to understand if a lifting problem is a due to the encoder or not.

In case of stopping or low speed of the machine with consequently high consume of current (and relevant alarm code shown on the dashboard) it is possible to disable the encoder for some seconds, no longer, given that the logic unit cannot control the motor anymore.

Do not work in this configuration.

AC3P2BIB 80V 450A

CE 1.02 00000

Press ENTER MAIN MENU PARAM. CHANGE

Press ROLL until reaching ALARM manu MAIN MENU ALARM

Press ENTER

With the SLIP CONTROL OFF pull the lever of the potentiometer slowly otherwise the motor stands still.

DESCRIPTION OF THE ALARM CODE

Press PARAM and SET together

MENU SPECIAL ADJUST

Press ROLL MENU ARDWARE SETTING

Press ENTER COMPENSATION SLIP CONTROL

ON/OFF

Select SLIP CONTROL ON or OFF and store the parameter pressing OUT and later ENTER to confirm.

After that switch the truck OFF and ON.

Electric

2.5-3.5 ton AC

SERVICE MANUAL

036-0409-02

page 109

BATTERY (PUMP connecting number 5) The control of the battery LED indication on the dashboard and the relevant reduction of the speed are managed by the the traction logic unit.

AC3P2BIB 80V 450A

Scroll the paramters using ROLL and save the new values pressing OUT and after ENTER

CE 1.02 00000

Press ROLL and PARAM together

CONFIG. MENU SET MODEL

Press ROLL CONFIG. MENU SET OPTIONS

Press ENTER

HOUR COUNTER

RUNNING/ KEY ON

BATTERY CHECK

OFF

HYDRO KEY ON STOP ON RAMP AUX INPUT #1

ON/OFF ON/OFF EXCLUSIVE HYDRO OPTION #1 CUT BACK SPEED ANALOG/DIGITAL ANALOG/DIGITAL/NONE OPTION #1 OPTION #2

PEDAL BRAKING SET TEMPERATURE STEER TABLE

ARE YOU SURE? YES=ENTER NO=OUT

Press OUT Press ENTER

CONFIG. MENU SET OPTIONS

Press ROLL

SET BATTERY TYPE ADJUST BATTERY

80 ....V

Press ENTER

ADJUSTMENT #03 ADJUSTMENT #04 THROTTLE 0 ZONE THROTTLE X ZONE THROTTLE Y ZONE ADJUSTMENT #02 ADJUSTMENT #01

....°C ....°C ....% ....% ....% 1-9 1-9

CONFIG. MENU ADJUSTMENTS

ARE YOU SURE? YES=ENTER NO=OUT

Press OUT Press ENTER

2.5-3.5 ton AC

SERVICE MANUAL

page 110

Electric 036-0409-02

LIFTING ACQUISITION (PUMP connecting number 5) Connect the console to the LIFTING logic unit

AC3P2BIB 80V 450A

CE 1.02 00000

Press ROLL and PARAM together CONFIG. MENU SET MODEL

Press ENTER CONNECTED TO 5

Press ROLL JOYSTICK

with electric distributor

ON

Select the parameter using PARAM JOYSTICK

with mechanic distributor

OFF

Press OUT ARE YOU SURE? YES=ENTER NO=OUT

Press ENTER to confirm

MHYRIO

2.5-3.5 ton AC

SERVICE MANUAL

page 112

Electric 036-0409-02

DESCRIPTION OF STANDARD CONSOLE MENU MHYRIO UNIT

The console can be connected to the MHYRIO logic unit following the below instruction Connect the console in another logic unit (pump or traction) and select the relevant connecting number as showen in the map here below.

AC3T2JIB 80V 450A

CE 1.02 00000

In case the console is connected to the traction logic unit

Press ROLL and PARAM together CONFIG. MENU SET MODEL

Press ENTER CONNECTED TO 2

Press PARAM and select the connecting number of the Mhyrio logic unit CONNECTED TO 9

Press OUT

CONNECTION NUMBER

ARE YOU SURE? YES=ENTER NO=OUT

Press ENTER to confirm

2 5 9

TRACTION PUMP MHYRIO

MAIN MENU SET MODEL

Press ROLL, OUT and SET together MHYRIO 24V 0A

CE V1.05 00000

Connected to the MHYRIO logic unit

Electric 036-0409-02

SERVICE MANUAL

2.5-3.5 ton AC page 113

DESCRIPTION OF STANDARD CONSOLE MENU MHYRIO UNIT HEADING MAIN MENU

MIN LIFT PARAMETER CHANGE

TI/SH ACC. DELAY

MIN LOWER

LIFT/LOW DEC. DELAY

MIN DRAIN

DRAIN DEC. DELAY

MIN REACH BWD MIN TILT UP

SET MODEL

CONNECTED TO 9

SET OPTIONS

SET BATTERY TYPE V VALVES COIL VALVES SUPPLAY EVP TYPE EVP1 TYPE EVP2 TYPE EVP3 TYPE EVP4 TYPE EVP5 TYPE EVP6 TYPE EVP7 TYPE EVP8 TYPE

ADJUSTMENTS

ADJUST BATTERY

TI/SH DEC. DELAY

MIN TILT DW MIN SHIFTH RGT MIN SHIFTH LFT MAX LIFT MAX LOWER MAX DRAIN MAX REACH BWD MAX TILT UP MAX TILT DW MAX SHIFTH RGT MAX SHIFTH LFT LIFT/LOW ACC. DELAY DRAIN ACC. DELAY

12/24/36/48/72/80V 12/24/36/48/72/80V 12/24/36/48/72/80V Analogic/digital Analogic/digital Analogic/digital Analogic/digital Analogic/digital Analogic/digital Analogic/digital Analogic/digital Analogic/digital

TESTER BATTERY VOLTAGE VALVES SUPPLY CAN POT EVP CAN POT GROUP 1 CAN POT GROUP CAN POT GROUP CAN POT GROUP INPUT 0 INPUT 1 INPUT 2 ANALOG INPUT 1

V V % % % % % ON/OFF ON/OFF ON/OFF 0/256

SAVE PARAMETER

RESTORE PARAMETER

ALARMS

PROGRAM VACC

STEER TABLE

h,

CODE N°, C°

VACC SETTING MIN/MAX

NOT AVAIBLE

....V

2.5-3.5 ton AC

SERVICE MANUAL

page 114

MAIN MENU: MHYRIO 24V 0A

Electric 036-0409-02

PARAMETER CHANGE (Mhyrio connecting number 9)

CE V1.05 00000

Press ENTER MAIN MENU PARAM. CHANGE

Press ENTER

MIN LIFT MIN LOWER MIN DRAIN MIN REACH BWD MIN TILT UP MIN TILT DW MIN SHIFTH RGT MIN SHIFTH LFT MAX LIFT MAX LOWER MAX DRAIN MAX REACH BWD MAX TILT UP MAX TILT DW MAX SHIFTH RGT MAX SHIFTH LFT LIFT/LOW ACC. DELAY DRAIN ACC. DELAY TI/SH ACC. DELAY

Min. voltage on the lifting solenoid valve Min. voltage on the lowering solenoid valve Min voltage on the draining solenoid valve Not used Min voltage on the backward tilt solenoid valve Min voltage on the forward tilt solenoid valve Min voltage on the sideshift right solenoid valve Min voltage on the sideshift left solenoid valve Max voltage on the lifting solenoid valve Min. voltage on the lowering solenoid valve Min voltage on the draining solenoid valve Not used Max voltage on the tilt backward solenoid valve Max voltage on the tilt forward solenoid valve Max voltage on the sideshift right solenoid valve Max voltage on the sideshift left solenoid valve Delay in reaching the selected voltage on the draining solenoid valve (in closing) Delay in reaching the selected voltage on the draining solenoid valve (in closing ) Delay in reaching the selected voltage on the tilt/sideshift solenoid valve (in opening ) LIFT/LOW DEC. DELAY Delay in reaching the selected voltage on the lifting/lowering solenoid valve (in closing) DRAIN DEC. DELAY Delay in reaching the selected voltage on the draining solenoid valve (in opening) TI/SH DEC. DELAY Delay in reaching the selected voltage on the tilt/sideshift solenoid valve (in closing) Scroll the paramters using ROLL and save the new values pressing OUT and after ENTER

Electric

SERVICE MANUAL

036-0409-02

MAIN MENU: MHYRIO 24V 0A

TESTER

(Mhyrio connecting number 9)

CE V1.05 00000

Press ENTER MAIN MENU PARAM. CHANGE

Press ROLL MAIN MENU TESTER

Press ENTER

BATTERY VOLTAGE V VALVES SUPPLY V CAN POT EVP % CAN POT GROUP 1 % CAN POT GROUP % CAN POT GROUP % CAN POT GROUP % INPUT 0 ON/OFF INPUT 1 ON/OFF INPUT 2 ON/OFF ANALOG INPUT 1 0/256

Scroll the paramters using ROLL. Press OUT to escape.

2.5-3.5 ton AC page 115

2.5-3.5 ton AC

Electric

SERVICE MANUAL

page 116

MAIN MENU :

036-0409-02

SAVE PARAMETER (Mhyrio connecting number 9) MHYRIO 24V 0A

CE V1.05 00000

Press ENTER MAIN MENU PARAM. CHANGE

Press ROLL MAIN MENU TESTER

Press ROLL MAIN MENU SAVE PARAM

Press ENTER Select a box (0-31) where you want to save the program: SELECT Mod 00 = Program number FREE/MHYRIO CE V1 = Program version stored

SELECT Mod 00 FREE

SELECT Mod 00 MHYRIO CE V1

Press ENTER

Press ENTER OVERWRITE DATA? YES=ENTER NO=OUT

READING........

RUN ALL PARAMETERS

MAIN MENU SAVE PARAM

Press ENTER to confirm READING........

RUN ALL PARAMETERS

MAIN MENU SAVE PARAM

Press OUT to escape MAIN MENU SAVE PARAM

Electric 036-0409-02

MAIN MENU :

SERVICE MANUAL

2.5-3.5 ton AC page 117

RESTORE PARAMETER (Mhyrio connecting number 9) MHYRIO 24V 0A

CE V1.05 00000

Press ENTER MAIN MENU PARAM. CHANGE

Press ROLL MAIN MENU TESTER

Press ROLL MAIN MENU SAVE PARAM

Press ROLL MAIN MENU RESTORE PARAM

Press ENTER SELECT Mod 00 MHYRIO CE V1

SELECT Mod 00 = Program number FREE/MHYRIO CE V1 = Program version stored Press ROLL to Select a box (0-31) where you want to save the program

OVERWRITE DATA? YES=ENTER NO=OUT

Press ENTER to confirm STORING........

RUN ALL PARAMETERS

MAIN MENU RESTORE PARAM

Press OUT to escape MAIN MENU RESTORE PARAM

2.5-3.5 ton AC

SERVICE MANUAL

page 118

MAIN MENU :

Electric

ALARM

036-0409-02

(Mhyrio connecting number 9)

MHYRIO 24V 0A

CE V1.05 00000

Press ENTER MAIN. MENU PARAM. CHANGE

Press ROLL until reaching MAIN MENU ALARM MAIN. MENU ALARM

Press ENTER max 5 alarms stored

no alarms stored

00000h

NONE #00

0°C

23h

hour meter

ALARM CODE 2 25°C

n°alarms

temperature

Press OUT

Press ENTER CLEAR LOGBOOK YES=ENTER NO=OUT

Press OUT to escape

Press ENTER to confirm ARE YOU SURE? YES=ENTER NO=OUT

Press ENTER to confirm LOGBOOK CLEARED (PRESS OUT)

Press OUT to escape

Electric 036-0409-02

MAIN MENU :

SERVICE MANUAL

2.5-3.5 ton AC

PROGRAM VACC. (Mhyrio connecting number 9)

Not available MAIN MENU : Not available

page 119

STEER TABLE (Mhyrio connecting number 9)

2.5-3.5 ton AC page 120

SERVICE MANUAL

NECESSARY SETTING AFTER REPLACING THE TRACTION LOGIC UNIT 1.

2.

3.

TRACTION ACQUSITION ADJUST BATTERY Vacc PROGRAM

see page 98 see page 97 see page 93

NECESSARY SETTING AFTER REPLACING THE LIFTING LOGIC UNIT 1.

2.

LIFTING ACQUSITION Vacc PROGRAM (with mecchanic distributor only)

SPEED CALCULATION ENCODER FREQUENCY x 0.138 = Km\h RPM CALCULATION ENCODER FREQUENCY x 30

see page 110 see page 107

Electric 036-0409-02

SERVICE MANUAL WIRING DIAGRAMS

2.5-3.5 ton AC page 122

SERVICE MANUAL

Electric 036-0409-02

Electric 036-0409-02

SERVICE MANUAL

2.5-3.5 ton AC page 123

2.5-3.5 ton AC page 124

SERVICE MANUAL

Electric 036-0409-02

Electric 036-0409-02

SERVICE MANUAL

2.5-3.5 ton AC page 125

PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE WEIß SEITE PÁGINA INTENCIONALMENTE BLANCA

SERVICE MANUAL HYDRAULIC SYSTEM

HYDRAULIC SYSTEM INDEX CONTROL VALVE SYSTEM (CONTROL VALVE VERSION)

page 129

CONTROL VALVE SYSTEM (JOYSTICKS/FINGERTIPS VERSION)

page 130

LIFTING EQUIPMENT OIL AND OIL FILTER

page 131

REPLACEMENT OF THE PUMP

page 132

HYDRAULIC CONTROL VALVES (CONTROL VALVE VERSION)

page 133

HYDRAULIC CONTROL VALVES (JOYSTICKS / FINGERTIPS VERSION)

page 135

Electric

2.5-3.5 ton AC

SERVICE MANUAL

036-0409-02

page 129

CONTROL VALVE HYDRAULIC SYSTEM Control valve version Drain hose

Control valve

Manometer connection

Priority valve Hydraulic oil filter Lowering valve

Hydraulic oil tank AGIP ARNICA 46 ~47 litres

The correct position of the valve is shown in the picture

tank

control valve 0,5 Bar

2.5-3.5 ton AC page 130

SERVICE MANUAL

Electric 036-0409-02

ELECTRIC CONTROL VALVE HYDRAULIC SYSTEM Joysticks / fingertips version Electric Control valve

Priority valve

Lowering valve

Drain hose Hydraulic oil tank Hydraulic oil filter

AGIP ARNICA 46 ~47 litres

Manometer connection

Electric

SERVICE MANUAL

036-0409-02

2.5-3.5 ton AC page 131

LIFTING EQUIPMENT OIL AND FILTER B

The hydraulic lift oil tank is located under the platform.

The filter cartridge (D) (15 µ) is beneath the screw cap (B).

D

A

After the first 50 hours of work - first filter change After the first 500 hours of work - second filter change.

Every 250 hours - check the level of oil in the tank using the dipstick (A); - check and clean the tank breather valve filter (C).

Every 2 000 hours - replace the oil and the filter.

C

To change the oil and the filter: - remove the filling cap (B), extract the filter; - remove the drain cap (E); drain out all the oil into an appropriate container then replace the drain cap and tighten firmly; - fit a new filter (D) after checking the state of the seals; - Fill the tank with approx. 47 liters oil through the filter until the dipstick notch (max level).

E B

A D

C

Hydraulic oil tank AGIP ARNICA 46 E

~47 litres

Electric

2.5-3.5 ton AC page 132

SERVICE MANUAL

036-0409-02

REPLACEMENT OF THE PUMP 1)

After replacing the pump we advise to help it suck oil during the first working period by blowing compressed air into the hole for the oil dip stick (point A). Maximum pressure to use 0.5 Bar.

2)

It is also possible to use the connection B for the manometer to fill the main hose C with oil in order to avoid that the pump turns without oil during the first working period.

B

C A

Tightening torque 45 +/- 5 Nm

Electric 036-0409-02

SERVICE MANUAL

2.5-3.5 ton AC page 133

HYDRAULIC CONTROL VALVES Control valve version Sideshift 4th way

Tilting Lifting

Max pressure valve 130 BAR Max pressure valve 200 BAR

Max pressure valve 130 BAR

MANOMETER CONNECTION POINT FOR HYDRAULIC PRESSURE CONTROL

2.5-3.5 ton AC page 134

SERVICE MANUAL HYDRAULIC DIAGRAM Control valve version

Electric 036-0409-02

Electric

2.5-3.5 ton AC

SERVICE MANUAL

036-0409-02

page 135

HYDRAULIC ELECTRIC CONTROL VALVES Joysticks / fingertips version Drain line Priority valve Cap Proportional valve 4th way Sideshift Tilting

Lifting Pressure relief valve

CONNECTION FOR THE MANOMETER On the control valve there is a manometer connection in order to read the pressure of the tilt, sideshift, 4°way,5°way.

To check the pressure of the power steering and of the lifting insted there is the manometer connection on the pump.

To reduce the pressure on the circuit in case you want to replace a hole the are two spools for each solenoid valve.

With the mast closed and the truck swich off it is enough to press in the spool with a allen key.

NOTES

B

A

1) Before connecting/disconnecting a hydraulic system equipped with rapid action couplings, reduce the pressure of the circuit by pressing a metal bit on the spool of the corresponding solenoid valve (point A).

2) In case of failure of the load lowering proportional electrovalve, the emergency downstroke of the load can be activated by slightly tightening the socket head screw B that is normally at the limit stop and completely loose. Once the failure has been rectified, the lift truck can be restored to its standard operation and socket screw B must be completely loosened

Electric

2.5-3.5 ton AC page 136

SERVICE MANUAL

036-0409-02

ELECTRIC CONTROL VALVES

5

1. Safety valve for load lowering in case of failure of the lifting solonoid valve.

10 2. Valve for the maximum pression (220-240 bar).

3. Lifting box.

9 4. Oil fluw valve: DON NOT TOUCH. 8 5. Connection for the manometer.

6. Tilt, sideshift, 4° way, 5° way max pressure valve.

7 7. Tilt box.

8. Sideshift box.

6 9. 4° Way box.

10. Proportional valve (EV11).

11 11. Drain pipe connection.

13 12. Main lifting pipe connection.

13. Priority valve pipe connection.

12

1 2 3 4 Version with fingertips control and joysticks It is consist of: 1.

Double 24V lifting ON/OFF solenoid valve.

Proportional solenoid valve for the lowering 2.

Two 24V ON/OFF tilt control solenoid valve 3.

Two 24V ON/OFF sideshift control solenoid valve The movement speed is according to the lifting motor rpm number. The solenoide valve EV11has been integrated in the circuit given that there is only one motor for both funtions, lifting and power steering. It allows the oil in excess to return into the tank reducing the pressure in the hydrulic control valve circuit. By means of this valve it is possible to increase or decrease the sensibility of the lifting, acting on the delay in opening and closing it (MHYRIO setting funtion).

DESCRIPTION OF THE CONTROL VALVE BOX Lifting box

uses one solenoide valve EV1 ON/OFF for the lifting, one proprtional solenoid valve for the drain EV2 and a valve for the maximum pressure (220-240 Bar).

Between the lifting box and the other ones there is a valve to limit the pressure to 150-160 bar. It is set by the supplier. It is not neccessary to increase the Bar value.

Tilting box

has a governor of oil capacity (20L). In this way the oil quantity is reduced in case of using of double functions: lifting-tilt. This one is necessary given that the logic is set for the high speed. It means that without the governor the speed of the first functions activated can increase too much. In this box there is also an OVER CENTER valve to avoid in case of min. rpm of the motor, any forward movement of the mast with load on the forks and the emptying of the tilt cylinders.

Sideshift box

has a governor of oil capacity (20L). In this way the oil is reduce in case of using of double functions: lifting-sideshift.

This one is necessary given that the logic is setted for the high speed.

Electric 036-0409-02

SERVICE MANUAL HYDRAULIC DIAGRAM Joysticks / fingertips version

2.5-3.5 ton AC page 137

PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE WEIß SEITE PÁGINA INTENCIONALMENTE BLANCA

SERVICE MANUAL LIFTING MASTS

MAST GROUPS INDEX MAST

page 141

TRIPLE MAST SECTION

page 142

CENTRAL DISPLACEMENT CYLINDER WITH BRAKING EFFECT

page 143

SIDE DISPLACEMENT CYLINDER WITH BRAKING EFFECT

page 144

SIDE TELESCOPIC CYLINDER WITH BRAKING EFFECT(WITH SPHERE)

page 145

TELESCOPIC CYLINDER WITHOUT BRAKING EFFECT

page 146

CYLINDER CHECKING METHODS

page 147

LIFTING EQUIPMENT LUBRICATION

page 148

GUIDE ROLLERS AND GUIDE SHOES REPLACING

page 150

FORK CARRIAGE GUIDE SHOES REPLACING

page 151

MAST CHAINS INSPECTION

page 152

FORK INSPECTIONS

page 153

Electric 036-0409-02

2.5-3.5 ton AC

SERVICE MANUAL

page 141

MAST The mast profile with double stiffening flange is characterised by a high flexural and torsional strength.

It allows wide visibility thanks to the reduced dimensions of the profile itself.

Cylinders are single-acting type.

The sideshift system has been housed inside the profiles.

The mast group is a roller type with a variable centre distance (i.e. a fixed roller is fitted on the outer mast and a mobile one on the inner mast, instead of a number of mobile rollers only on the inner mast). This solution ensures better grip and stability on operation.

Other features: side plays adjustable from outside. Plastic guide shoes. Roller bearings with grease nipples, ball joints on axle couplings and tilt cylinders.

Lifting cylinders: Duplex mast: VT 2 side cylinders FFL 2 side cylinders 1 short central cylinder Triplex mast VT 2 side cylinders FFL 2 side cylinders 1 short central cylinder

2M TV 3M TV 2M FFL 3M FFL

CENTRAL CYLINDERS / / TELESCOPIC CYLINDERS TELESCOPIC CYLINDERS

Grease nipple

Adjusting screw

SIDE CYLINDERS TELESCOPIC CYLINDERS TELESCOPIC CYLINDERS DISPLACEMENT CYLINDERS TELESCOPIC CYLINDERS (WITH SPHERE)

Shoe

Roller

2.5-3.5 ton AC page 142

SERVICE MANUAL

TRIPLE MAST SECTION Fork carriage

Internal section bar

Intermediate section bar

External section bar

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Electric 036-0409-02

SERVICE MANUAL

2.5-3.5 ton AC page 143

CENTRAL DISPLACEMENT CYLINDER WITH BRAKING EFFECT ON THE LIFTING The oil flows into the cylinder from the “Oil inlet” when the control valve is operated.

Rod Cap

Flowing through channels 1, 2 and 3, it fills chamber A until the inner oil pressure exerts an upward force against the surface C. The outward sliding of the rod is, thus, set off. This movement is enacted by the oil flow from chamber A to chamber B through the above mentioned channels.

Bleeder screw

Chamber A

At the end of the expanding process channels 1 and 2 are plugged by the cap.

Therefore, since the oil flowing between the two chambers passes only through channel 3, it has a lower capacity. The outcome is a slowing-down or “Braking effect”.

Channels 1-2 Unidirectional valves D-E Channels 3

Chamber B

Surface C Oil inlet

The downward sliding of the rod is allowed by the opening of the “Oil inlet” circuit, so that the oil can be retrieved into the tank by means of the control valve.

At the beginning of this phase chamber A contains no oil. A more constant filling is allowed by the two unidirectional valves D and E that, when open, permit avoiding jolts.

Once beyond the cap, the oil flow between the two chambers passes through channels 1 and 2, which are now open.

> Safety valve

<

Unidirectional valves D-E

CENTRAL DISPLACEMENT CYLINDER WITH BRAKING EFFECT ON THE LIFTING

2.5-3.5 ton AC page 144

SERVICE MANUAL

Electric 036-0409-02

SIDE DISPLACEMENT CYLINDER WITH BRAKING EFFECT ON THE LOWERING Channel A (to the central cylinder)

Chamber B bleeder screw

The oil flows into the cylinder from the “Oil inlet” when the control valve is operated.

Flowing through chamber B and channel A it fills first the central cylinders, then chamber A through hole F and the unidirectional valve C. The oil exerts thus an upward force against the surface D, which sets off the outward sliding of the rod.

Rod

This movement is allowed by the oil flow from chamber A to chamber B through hole F and the guide ring.

The downward sliding of the rod is allowed by the opening of the “Oil inlet” circuit, so that the oil can be retrieved into the tank by means of the control valve.

Chamber A bleeder screw

Chamber A Surface D Hole F Profile E Guide ring

Chamber B

Safety valve

>

Unidirectional valve C

Oil inlet

In this phase the oil flows between the two chambers only through the hole F, as valve C is closed.

The downward speed of the rod remains constant until hole F is closed by profile E. The remarkable reduction of oil flow has a slowing-down or “Braking effect”.

Electric 036-0409-02

SERVICE MANUAL

2.5-3.5 ton AC page 145

SIDE TELESCOPIC CYLINDER WITH BRAKING EFFECT IN THE LOWERING (WITH SPHERE)

Rod

Cylinder

Sphere Hole F Channel 2

Seals

Surface C Chamber A

Snap ring Channel 1

<

The oil flows into the cylinder from the “Oil inlet” when the control valve is operated.

Flowing through channels 1 and 2 and thanks to the upward movement of the sphere, the oil fills chamber A until the inner oil pressure exerts an upward force against surface C, obtaining the outward sliding of the rod.

The snap ring is used to prevent the sphere from sliding out of channel 2 while the rod is moving, but freeing, all the same, the passage of the oil between channel 2 and chamber A. The downward sliding of the rod is allowed by the opening of the “Oil inlet” circuit, so that the oil can be retrieved into the tank by means of the control valve.

The drop of oil pressure in chamber A causes the sphere to move to the bottom of channel 2 and stop on the snap ring.

In the beginning of this phase the oil from chamber A flows all the way through channel 1.

Only toward the end of its down-stroke the sphere closes the top of channel 1, thus directing the oil flow uniquely through hole F. This produces the hydraulic braking effect in the lowering.

Oil inlet

Cap Safety valve

2.5-3.5 ton AC page 146

SERVICE MANUAL

TELESCOPIC CYLINDER (WITHOUT BRAKING EFFECT) The cylinder pistons are single-acting types (fig. A).

6 5 4 7

THRUST DIAMETER

In these cylinders a seal (1) has been fitted on the piston (2) that works on the inner surface of the cylinder liner (3).

The rod guide is made by the plug (4) and by the piston through anti-friction rings (5).

The dust control ring (6) prevents any dirt and water from penetrating the cylinder.

Slight leakages that may occur are directed to the tank through the drain pipe connected to the pipe coupling (7).

3

The drain pipe shall reach the oil tank (fig. B) A small quantity of oil will always remain in the loop formed by the pipe before connecting to the tank. It acts as a trap and constantly moisturizes the cylinder liner, when it is completely closed (fig. B).

2 5 1

Fig. A

Fig. B

Electric 036-0409-02

Electric 036-0409-02

SERVICE MANUAL CYLINDER CHECKING METHODS 1ST CHECK Remove the drain pipe from the cylinder (fig. C) Lift the cylinder some times to end stroke, so as to discharge any oil residual.

Put a load on the forks and lift it by at least 200 mm.

Fig. C

After 10 minutes, measure the amount by which the load has lowered. A drop of a few millimetres is quite normal, as in the distributor there are always some leakages.

Now, lift the cylinder to its end stroke, if no oil leaks from the drain pipe coupling, it means that the load lowering is only due to the leakages on the distributor.

In the presence of leakages, it will be necessary to replace the seal. Should this be the case, inspect the cylinder liner.

2nd CHECK (To be carried out if the 1st inspection has been successful and after seal replacement).

Remove the drain pipe from the cylinder.

Lift the cylinder some times to end stroke, so that all the possible remaining oil is discharged.

Put a load on the forks. Lift and lower it for 10 minutes, making sure that the limit stop is never reached.

Lift the cylinder to end stroke.

If any leakages should be still present, the cylinder is damaged and then it must be replaced.

2.5-3.5 ton AC page 147

2.5-3.5 ton AC

SERVICE MANUAL

page 148

Electric 036-0409-02

LUBRICATION OF LIFTING EQUIPMENT D

E

Masts After the first 50 hours - adjust the guide shoes adjusting the Allen screw (D) For the adjustment use a 0.2-0.5 mm thickness gauge, inserted from below and up to the centre of the Allen screw (D) passing behind the roller (E).

Every 50-100 hours - lubricate with grease the mast sliding guides - lubricate the tilting jacks and the mast connections.

A) Tilting jacks 2+2 grease nipples B) Mast connections 1+1 grease nipples

A

Every 250 hours - adjust the guide shoes; - grease the mast guide rollers (E) Every 2 000 hours - check the condition of the guide rollers (E); they must turn freely without jamming and not show excessive wear.

B

F

H

G

Fork carriage and sideshift unit After the first 50 hours - adjust the guide shoes adjusting the Allen screw (G) For the adjustment use a 0.2-0.5 mm thickness gauge, inserted from below and up to the centre of the Allen screw (G) passing behind the roller (H).

Every 50 hours - lubricate the sideshift guides with with grease through the grease nipples.

Every 250 hours - lubricate the fork positioning pins and notches with grease.

- grease the fork carriage guide rollers (F) - adjust the guide shoes Every 2 000 hours - check the condition of the guide rollers; they must turn freely without jamming and not show excessive wear.

Electric

SERVICE MANUAL

036-0409-02

C

2.5-3.5 ton AC page 149

C) Sideshift unit (upper part) 3 grease nipples (lower part) without grease nipples excessive wear.

Make sure that: - the lifting chain stay bolts are free of defects and that the adjusting nuts are locked by the appropriate cotter pins (A);

C

- the fork carriage (B) safety end stops are present and tightly fixed.

- the collars (C) are present and tightly fixed.

E

E

Every 500 hours - check that there is a clearance (D); of 0.5 to 3 mm between the collar and external lifting jack cylinder.

- check that there self-lockin nuts (E) are tight.

D

A

B

Locking torques: - collar self-locking nuts 0.8-1.2 daNm

SAFETY FORK CARRIAGE END STOP The lifting unit is equipped with a mechanical safety end stop, to avoid the accidental escape of the fork carriage from the botton of the mast.

The end stops (A) consists of two Allen bolts. To remove the fork carriage, first of all unscrew the end stops.

2.5-3.5 ton AC page 150

Electric

SERVICE MANUAL

036-0409-02

GUIDE ROLLERS AND GUIDE SHOES REPLACING Guide rollers and guide shoes Mast-Fork carriage replacing

In order to carry out the job proceed as follows:

Picture 1 Picture 1

1)

remove the two forks from the carriage

2)

disconnect the two sideshift hoses on the fork carriage (Picture 1)

3)

tie the fork carriage with a sling (Picture 2)

4)

remove the safety clip of the chain pin on the carriage (Picture 3)

5)

remove the nut stopping the chain pin with a tools as shown in Picture 4. After that put the two chains in the opposite side in order to have more space.

6)

remove the two Allen screws (Picture 5)

7)

remove the complete fork carriagefrom the bottom

8)

remove the guide shoes with two screw drivers (Picture 6) and screw out the Allen a screw D (see page 73) in order to give the possibility at the new guide shoes to go inside completely.

9)

remove the snap ring A and take out the guide roller (Picture 7)

10)

reassembly all parts in the opposite sequence and adjust the guide shoes as shown at page 148.

Picture 2

Picture 3

Picture 4

Picture 5

Picture 6

Picture 7

A

Electric

2.5-3.5 ton AC

SERVICE MANUAL

036-0409-02

page 151

GUIDE SHOES FORK CARRIAGE REPLACING

C

In order to carry out the job proceed as follows:

B

Picture 8

1) remove one of the two side bars B from the fork carriage (Picture 8) 2) take out the mobile plate C (Picture 8)

D

3) replace the upper and lower guide shoes D-E (Picture 9) 4) make sure to introduce the shims F as necessary in order to have a correct clearance of the mobile plate C on the fork carriage

E

5) reassembly all parts in the opposite sequence and lubricate the guide shoes as shown at page 148 .

Picture 7 9 F

B

Picture 10

C D E

B

F

G A

2.5-3.5 ton AC page 152

SERVICE MANUAL

Electric 036-0409-02

MAST CHAINS INSPECTION CHECKING THE CHAINS: Every 500 hours (anyway, chains are to be checked every 3 months) - check the condition of the chains which in any case must not be faulty, worn out or damaged.

To check the links for wear, use the appropriate gauge, paying attention that, when 33 links are counted in a space corresponding to 34, the chains must be replaced.

Every 1 000 hours - remove the chains, clean them thoroughly, refit them inverting the original working position and lubricate them.

Every 10 000 hours - replace the chains and the fixing tie rods The use of original chains will guarantee that the safety requirements stated by the regulations in force are complied with.

POSITIONING THE FORK MOUNTING CARRIAGE Every 500 hours - After testing the chains as described above, with the truck on an even surface and the mast in a vertical position, check the position of the fork carriage plate, as follows: - remove the forks, completely lower the fork carriage and measure the height (X), comparing it with the value shown in the table, correspondig to the capacity in kg of the truck. (e.g. the correct value of (X) for a truck with a capacity of 2000 kg (class II A), must be 76 ±5 mm).

X = 76 mm (A) X = 152 mm (B)

Electric

SERVICE MANUAL

036-0409-02

G

G E

E

F

F D

D

2.5-3.5 ton AC page 153

FORK INSPECTIONS General criteria Fork arms in use must be inspected at intervals of not more than 1 000 hours, and whenever a defect or permanent deformation is detected. If the truck is subject to intensive use, more frequent inspections may be required.

Inspection Fork arm inspection must be carried out carefully by trained personnel to detect any damage, failure, deformation, etc., which may impair safe use.

Surface cracks The fork arm must be thoroughly examined visually for cracks giving special attention to the heel (D) and top (E) and bottom (F) hooks.

If necessary, the forks may be subjected to a non-destructive crack detection process.

Difference in height of fork tips Check the difference in height between the blade tips on each pair of forks, this must not be more than 3% of blade length with the forks fitted on the fork plate.

Positioning lock Check that the fork positioning lock (G) is in good working order.

Legibility of marking If the fork arm marking is not clearly legible, it must be renewed by the original fork supplier.

Fork wear control The fork arm blade and shank must be thoroughly checked for wear, paying special attention to the area around the heel (D). When maximum wear is detected, with thickness reduced to 90% of the original, the fork arm must be replaced.

Fork mounting wear control The horizontal supporting surface of the top hook (E) and the contact surfaces of both hooks (E) and (F) must be checked for wear and any damage.

WITHDRAWAL OF THE FORKS FROM SERVICE <= FORVARD - BACKWARD=> Any fork with defects revealed during the above controls must be withdrawn from service.

MAST GROUP TILTING SETTING Every 500 hours - control the tilting of the masts; the standard values (β) (α) are the following:

1° = 17,4 mm

α = 2°30 FORWARD STANDARD = 43,7 mm β = 10° BACKWARD 2M VT = 176,4 mm = 8° BACKWARD 3M FFL = 140,5 mm = 6° BACKWARD 3M VT-2M FFL = 105,1 mm The tilt angle can easily be checked using a plumb-line dropped from the front outside edge of the top of the fixed masts and measuring the distance between the line and the front edge at a metre from the top of the masts.

N.B. 1 tilting degree corresponds to a 17.4 mm movement on 1 mt.

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SERVICE MANUAL MAINTENANCE TABLES

MAINTENANCE TABLES INDEX OIL AND GREASE SPECIFICATIONS

page 157

TYRE TIGHTENING TORQUES

page 157

RUNNING IN MAINTENANCE

page 158

MAINTENANCE TIMES

page 159

Electric 036-0409-02

SERVICE MANUAL OIL AND GREASE SPECIFICATIONS

47

TYRE TIGHTENING TORQUES

2.5-3.5 ton AC page 157

2.5-3.5 ton AC page 158

SERVICE MANUAL RUNNING IN MAINTENANCE

' &

" ,

LEGENDA In the maintenance table indicating a visual control and cleaning of the parts indicated.

In the maintenance table indicating the replacement of the parts indicated.

In the maintenance table indicating lubrication of the parts indicated.

Inthemaintenancetableindicatingtightening or adjustment of the parts indicated.

Electric 036-0409-02

Electric 036-0409-02

SERVICE MANUAL MAINTENANCE TIMES

2.5-3.5 ton AC page 159

2.5-3.5 ton AC page 160

SERVICE MANUAL MAINTENANCE TIMES

Electric 036-0409-02

Electric 036-0409-02

SERVICE MANUAL MAINTENANCE TIMES

2.5-3.5 ton AC page 161

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SERVICE MANUAL SAFETY DIRECTIONS

SAFETY DIRECTIONS INDEX WORK CLOTHES

page 165

WORK PLACE

page 165

LIFTING THE TRUCK

page 165

ELECTRIC PART

page 166

WELDING

page 167

TRUCK WASHING

page 167

Electric

SERVICE MANUAL

036-0409-02

2.5-3.5 ton AC page 165

SAFETY INFORMATION Work clothes 1 2 3 4

protective gloves overalls safety boots protective goggles

Work place The work place must be lighted and aired.

The area around the truck must be obstacles free Oil signs or grease substances must not be presents on the pavement (danger of sliding).

Lifting the truck Before doing any job, it is obligatory to lift the front wheels with blocks B

to avoid the risk of accident.

1.

Block the steered wheels with chocks (A).

2.

Tilt the mast back and place blocks (B) under their base.

3.

Tilt the mast forwards: the direction wheels must be lifted and free to rotate

A

To carry out correctly all the lifting operation of the truck it is necessary to have the following tools: . a hydraulic jack to 5 ton . metal or hard wood caps before putting the blocks below the must, check the inclination of the floor, the truck must be parked on a flat, horizontal surface.

2.5-3.5 ton AC page 166

SERVICE MANUAL

Electric 036-0409-02

ELECTRIC PART It is obligatory to disconnect the battery before doing any job to avoid the risk of accident.

- Do not connect the chopper to a battery with a nominal voltage different to the voltage stated from the one on the unit plate. If the battery voltage is higher it may cause the MOS failure.

If the battery voltage is less the unit will not run.

- During the battery recharging no units must be connected to the battery as, the unit can be damaged by the overvoltages generated by the charge-battery.

- Supply the unit only with traction battery, do not use rectifier outputs or power supplies.

- With key switched off, the filter capacitors could remain charged for some minutes. For work in surely working conditions, we suggest you . To disconnect the battery and with resting machine and inserted key wait some seconds till when the display will be completely off; Or . Short-circuit the capacitors through a resistor (56 Ohm 1W) across B+ and B- chopper power connections.

Do not wear jewel, necklaces, watches, etc because they can be the cause of short circuit.

Charging of the battery Do not smock (danger of explosion) It is necessary to switch the battery charger off before disconnecting the battery.

Also little spark can cause the battery to explode In order to fill in the battery or control the level of the acid it is necessary to wear gloves and glasses.

It is prohibited to smoke.

Electric 036-0409-02

SERVICE MANUAL

2.5-3.5 ton AC page 167

Welding It is suggests to wear a leather overall, gloves and welding mask.

It is obligatory to wear gloves and protective goggles during the grinding operations because they could cause the projection of metallic particles.

Make sure that these two operations are feasible inside the working area where you are.

When these operations are carried out on a truck, in order to avoid any danger of explosion, pay attention to cover and protect the battery and the the fuel concerned parts Make sure that around the working area there are not any inflamable products.

Disconnect the battery and short-circuit the logic units through a resistor (56 Ohm 1W) between positive (+) and negative (-) before carrying out any arc-weldings on the trucks.

Truck washing During this operation be carefull when using water on all the electric components

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PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE WEIß SEITE PÁGINA INTENCIONALMENTE BLANCA

Cargo Range CESAB S.p.A via Persicetana Vecchia, 10 40132 Bologna - Italy Tel. (0039) 051.20 54 11 Fax (0039) 051.72 80 07 E-mail: cesab@cesab.it