BT Electric Forklift C3E100R C3E130R C3E150R Service Manual - PDF DOWNLOAD

SERVICE MANUAL

C3E100R C3E130R C3E150R

Code 036-0424-01

05/2006

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SERVICE MANUAL

INDEX page 1

036-0424-01

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 S.p.a

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

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INDEX GENERAL INFORMATION ....................................................................... CHAPTER A CHASSIS................................................................................................... CHAPTER 0000 MOTORS / ENGINES ............................................................................... CHAPTER 1000 TRANSMISSION / DRIVE GEAR.............................................................. CHAPTER 2000 BRAKE ...................................................................................................... CHAPTER 3000 STEERING SYSTEM ................................................................................ CHAPTER 4000 ELECTRICAL SYSTEM ............................................................................ CHAPTER 5000 FYDRAULIC/PNEUMATIC SYSTEM ........................................................ CHAPTER 6000 MAST GROUP .......................................................................................... CHAPTER 7000 ATTACHEMENT........................................................................................ CHAPTER 8000 OPTIONS .................................................................................................. CHAPTER 9000 MAINTENANCE TABLES.......................................................................... CHAPTER B SAFETY INFORMATION .......................................................................... CHAPTER C

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CHAPTER A

GENERAL INFORMATION

CHAPTER A page 1

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CHAPTER A page 2

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GENERAL INFORMATION TECHNICAL DATA...........................................................................................................page 3

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TECHNICAL DATA

CHAPTER A page 3

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a [mm]=200

1,0 t.

LOAD CENTER [mm]

CAPACITY [Kg]

500

1000

600

890

700

810

800

730

900

670

1000

620

1,3 t.

LOAD CENTER [mm]

CAPACITY [Kg]

500

1250

600

1120

700

1010

800

920

900

840

1000

780

1,5 t.

LOAD CENTER [mm]

CAPACITY [Kg]

500

1500

600

1340

700

1210

800

1100

900

1010

1000

940

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CHAPTER 0000

CHASSIS

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CHASSIS VEHICLE EXTERIOR VIEW..................................................................................... page 3 VEHICLE MODELS .................................................................................................. page 4 FRAME NUMBER .................................................................................................... page 4 HOW TO USE THIS MANUAL ................................................................................. page 5 DISASSEMBLY · INSPECTION · REASSEMBLY .................................................... page 5 TERMINOLOGY ....................................................................................................... page 6 ABBREVIATIONS ..................................................................................................... page 6 SI UNITS .................................................................................................................. page 7 OPERATING TIPS.................................................................................................... page 8 GENERAL INSTRUCTIONS .................................................................................... page 8 JACK-UP POINT ...................................................................................................... page 9 LIFTING THE VEHICLE ........................................................................................... page 10 MEMBER WEIGHTS ................................................................................................ page 11 TOWING THE VEHICLE .......................................................................................... page 11 ELECTRICAL PARTS INSPECTION........................................................................ page 12 TIGHTENING TORQUE TABLE ............................................................................... page 13 COMPONENTS (Body & Frame) ............................................................................. page 14 BATTERY COVER.................................................................................................... page 18 REMOVAL · INSTALLATION .................................................................................... page 18 COUNTERWEIGHT ................................................................................................. page 19 REMOVAL · INSTALLATION .................................................................................... page 19 OPERATOR’S SEAT ................................................................................................ page 20 REMOVAL · INSTALLATION .................................................................................... page 20 FUSES...................................................................................................................... page 21

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VEHICLE EXTERIOR VIEW

CHAPTER 0000 page 3

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VEHICLE MODELS Vehicle model code

Load Capacity

Control method

Voltage (V)

100

1.0 ton

AC microcomputer controller

24

130

1.25 ton

↑

↑

150

1.5 ton

↑

↑

FRAME NUMBER Vehicle model code

S/N Format

100

CE000000

130

CE000000

150

CE000000

Serial number position

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HOW TO USE THIS MANUAL EXPLANATION METHOD 1.

2.

3.

4.

Operating procedure Operating procedures are described using either pattern A or pattern B. Pattern A: Each step of the operation is explained with its own illustration.

Pattern B: The entire operation is indicated by step numbers in one illustration, followed by cautions, notes, and point operations.

Example of pattern B

DISASSEMBLY · INSPECTION · REASSEMBLY T=N·m

• Some step numbers may be omitted in some illustrations.

• When a part requiring tightening torque instruction is not indicated in the illustration, the part name is described in the illustration frame.

4

1 2 3

7 5

6 T = 46.1 to 48.1 (470 to 490) [34.0 to 35.5]

8

5 9

1

Disassembly Procedure Operation to be explained 1 2 3

Remove the cover. [POINT 1] Remove the bushing. [POINT 2] Remove the gear.

Explanation of operation point with illustration Point Operations [POINT 1] Disassembly: Make match marks before removing the pump cover [POINT 2] Inspection: Measure the bushing inside diameter Limit 19.12 mm.

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1. Matters omitted from this manual (1) This manual omits descriptions of the following jobs, but perform them in actual operation: (a) Cleaning and washing of removed parts as required (b) Visual inspection (partially described)

TERMINOLOGY Caution: Important matters, negligence of which may cause accidents. Be sure to observe them.

Note: Important items, negligence of which may cause accidents, or matters in operating procedure which require special attention.

Standard: Value showing the allowable range in inspection or adjustment Limit: The maximum or minimum value allowed in inspection or adjustment.

ABBREVIATIONS Abbreviation

Meaning

Abbreviation

Meaning

ATT

Attachment

SAE

Society of Automotive Engineers (USA)

EHPS

Electronically controlled fully hydraulic power steering

RH

Right hand

FHPS

Fully hydraulic power steering

SST

Special service tool

LH

Left hand

STD

Standard

L/

Less

T=

Tightening torque

OPT

Option

O/S

Oversize

U/S

Undersize

PS

Power steering

W/

With

T

Number of teeth (

T)

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CHAPTER 0000 page 7

SI UNITS Meaning of SI This manual uses SI units. SI represents the International System of Units, which was established to unify the various systems of units used in the past for smoother international technical communication.

New Units Adopted in SI Conversion rate*1 (1 [conventional unit] = X [SI unit]) 1 kgf = 9.80665 N

Item

New unit

Force*2

N (newton)

Conventional unit kgf

Torque*2 (Moment)

N·m

kgf·cm

1 kgf·cm = 9.80665 N·m

Pressure*2

Bar

kgf/cm2

1 Bar = 1 kgf / cm2

Pressure*2

Pa (pascal)

kgf/cm2

1 kgf/cm2 = 98.0665 kPa = 0.0980665 MPa

↑

↑

mmHg

1 mmHg = 0.133322 kPa

Revolving

rpm

rpm

1 rpm = 1 r/min

Spring con-

N/mm

kgf/mm

Volume

l

cc

Power

W

PS system

1 PS = 0.735499 kW

Heat quantity

W·h

cal

1 kcal = 1.16279 W·h

Specific fuel

g/W·h

g/PS·h

1 kgf/mm = 9.80665 N/mm 1 cc = 1 ml

1 g/PS·h = 1.3596 g/kW·h

<Reference> * 1: X represents the value in SI units as converted from 1 [in conventional units], which can be used as the rate for conversion between conventional and SI units. * 2: In the past, kilogram [kg] representing mass was often used in place of weight kilogram [kgf], which should be used as the unit of force.

Conversion between Conventional and SI Units Equation for conversion Value in SI unit = Conversion rate × Value in conventional unit Value in conventional unit = Value in SI unit ÷ Conversion rate

Conversion rate: Figure corresponding to X in the conversion rate column in the table above

When converting, change the unit of the value in conventional or SI units to the one in the conversion rate column in the table above before calculation. For example, when converting 100 W to the value in conventional unit PS, first change it to 0.1 kW and divide by the conversion rate 0.735499.

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OPERATING TIPS GENERAL INSTRUCTIONS 1. Safe operation (1) After jacking up, always support with wooden blocks or rigid stands.

(2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load capacity.

(3) Always disconnect the battery plug before the inspection or servicing of electrical parts.

2. Skillful operation (1) Prepare the tools, necessary measuring instruments (circuit tester, megohmmeter, oil pressure gauge, etc.) and SSTs before starting operation.

(2) Check the cable color and wiring state before disconnecting any wiring.

(3) When overhauling functional parts, complicated sections or related mechanisms, arrange the parts neatly to prevent confusion.

(4) When disassembling and inspecting a precision part such as the control valve, use clean tools and operate in a clean location.

(5) Follow the specified procedures for disassembly, inspection and reassembly.

(6) Always replace gaskets, packing, O-rings, self-locking nuts and cotter pins with new ones each time they are disassembled.

(7) Use genuine Toyota parts for replacement.

(8) Use specified bolts and nuts and observe the specified tightening torque when reassembling.

(Tighten to the medium value of the specified tightening torque range.) If no tightening torque is specified, use the value given in the “standard tightening torque table”.

3. Protection of functional parts (battery operated vehicles) (1) Before connecting the battery plug after vehicle inspection or maintenance, thoroughly check each connector for any connection failure or imperfect connection.

Failure or imperfect connection of connectors related to controllers, especially, may damage elements inside the controllers.

4. Defect status check Do not start disassembly and/or replacement immediately, but first check that disassembly and/or replacement is necessary for the defect.

5. Waste fluid disposal Always use a proper container when draining waste fluid from the vehicle.

Careless discharge of oil, fuel, coolant, oil filter, battery or other harmful substance may adversely affect human health and the environment. Always collect and sort well, and ask specialized companies for appropriate disposal.

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JACK-UP POINT Always observe the following instructions when jacking up the vehicle: • When the fork is loaded, unload it and park the vehicle on a flat surface. Be sure to avoid an inclined or rough surface.

• Use a jack with ample capacity and jack up the vehicle at the specified jack-up point. Jacking up at any other point is dangerous.

• Always support the load of jacked-up vehicle with wooden blocks at specified points.

Supporting the vehicle with the jack only is very dangerous.

• Never, under any circumstances, put any part of the body (including hands and feet) under the jacked-up vehicle.

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LIFTING THE VEHICLE When hoisting the vehicle, always observe the specified hoist attachment section and method. Never hoist by any other attachment section as it is very dangerous.

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CHAPTER 0000 page 11

MEMBER WEIGHTS Unit: kg Member

Vehicle model code

Weight

100

min. 381 - max. 420

130

min. 524 - max. 590

150

min. 600 - max. 690

Drive motor

All Models

Approx.34

Pump motor (Hydraulic pump + electric motor)

All Models

Approx.40

Rear axle L/Drive motor and wheel

All Models

Approx.53

Counterweight

All models

900

All Models

Approx 450

100

Approx.2550

130

Approx.2820

150

Approx.2930

BATTERY

Mast W/ lift bracket (W/ lift cylinder, L/ fork, Lifting height 4000 mm, V mast Vehicle weight (w/battery)

TOWING THE VEHICLE

Note the cautions below when towing the vehicle.

1. Lift the rear wheels for towing 2. The traveling speed when towing must not exceed the maximum traveling speed of the forklift.

3. Before starting towing, always set the key switch to OFF and the direction switch to the neutral position.

4. Before towing, either remove the fork or take action to prevent the fork from coming into contact with the ground due to bouncing.

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ELECTRICAL PARTS INSPECTION 1. Always disconnect the battery plug before inspecting or servicing electrical parts.

2. Pay sufficient attention when handling electronic parts.

(1) Never subject electronic parts, such as computers and relays, to impact.

(2) Never expose electronic parts to high temperature or moisture.

(3) Do not touch connector terminals, as they may be deformed or damaged due to static electricity.

3. Use a circuit tester that matches the object and purpose of measurement.

Analog type: This type is convenient for observing movement during operation and the operating condition. Measured value is only a reference Digital type: A fairly accurate reading is possible. However, it is difficult to observe operation or movement.

(1) Difference between results of measurement with analog and digital types ∗ The results of measurements using the analog type and the digital type may be different.

Differences between the polarities of the analog type and the digital type are described below.

1)

Analog circuit tester

Forward

Reverse

Example of measurement result Tester range: kΩ range Analog type Continuity Forward 11 kΩ No continuity Reverse

2)

∞

Digital circuit tester Forward

Reverse

Example of measurement result Tester range: 2 MΩ range Digital type No continuity Forward 1 Continuity Reverse 2 MΩ

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CHAPTER 0000 page 13

TIGHTENING TORQUE TABLE The tables here below are valid for screws and bolts without superficial covering, preventively lubricated with oil.

SCREWS WITH “ISO” METRIC COARSE THREAD PRELOADING V (IN)

TORQUE Max (N.m)

Nominal diameter mm

6D

8G

10 K

12 K

6D

8G

10 K

12 K

6,6

8,8

10,9

12,9

6,6

8,8

10,9

12,9

M 4 x 0,7 M 5 x 0,8 M6x1 M7x1 M 8 x 1,25 M 9 x 1,25 M 10 x 1,5 M 12 x1,75 M 14 x 2 M 16 x 2 M 18 x 2,5 M 20 x 2,5 M 22 x 2,5 M 24 x 3 M 27 x 3 M 30 x 3

21781 3502 4974 7142 9025 11870 14519 20797 28351 38750 47480 60430 74850 87309 112815 138321

3865 6229 8849 12753 16088 21190 25506 37082 50620 68866 84366 107910 133416 155979 202086 247212

5435 8780 12459 17854 22661 29921 35905 52189 71123 97119 118701 151565 187371 218763 283509 347274

6524 10497 14911 21386 27174 35610 42968 62588 85347 116739 142245 181485 224649 261927 340407 415944

1,7 3,2 5,7 9,2 13,6 20,1 27,8 46,5 74 113 157 218 294 383 549 755

3 5,8 10 16,6 24,3 36 49 83 132 200 279 388 520 687 991 1354

4,2 8,2 14,3 23 34 50,8 69 117 186 283 392 545 731 961 1393 1893

5,1 9,9 17,1 27,8 41,1 60,5 82 140 223 339 471 653 883 1148 1668 2276

SCREWS WITH “ISO” FINE THREAD PRELOADING V (IN)

TORQUE Max (N.m)

Nominal diameter mm

6D

8G

10 K

12 K

6D

8G

10 K

12 K

6,6

8,8

10,9

12,9

6,6

8,8

10,9

12,9

M8x1 M 10 x1,25 M 12 x1,25 M 12 x1,5 M 14 x 1.5 M 16 x 1,5 M 18 x 1,5 M 20 x 1,5 M 22 x 1,5 M 24 x 2 M 27 x 2 M 30 x 2

9761 15107 23740 21778 30902 41202 53268 67689 82404 94667 122625 154017

17168 26879 40613 38848 54936 73575 95157 118701 147150 168732 218763 272718

24231 37867 56898 54642 77303 103005 133416 168242 206010 237402 307053 384552

29038 45420 68474 65531 92705 123606 159903 202086 247212 284490 367875 461070

14,5 28,4 52 49 78 118 171 239 314 402 589 814

25,5 51 89 87 140 211 304 422 564 721 1050 1442

36,2 72 126 123 196 294 422 598 790 1010 1472 2040

43 85 151 147 235 353 510 716 952 1216 1766 2453

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COMPONENTS Body & Frame

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BATTERY COVER REMOVAL • INSTALLATION

Removal Procedure 1 2 3 4 5 6 7 8

Disconnect the battery plug.

Open the battery cover.

Use string to tie the battery cover W/seat to the head guard rear pillar.

Disconnect the wiring of the seat switch.

Disconnect the battery cover gas spring (on the frame side).

Close the battery cover.

Remove the battery cover hinge set bolt.

Remove the battery cover W/ seat.

Installation Procedure The installation procedure is the reverse of the removal procedure.

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COUNTERWEIGHT REMOVAL • INSTALLATION

Removal Procedure 1 2 3 4 5 6 7

Disconnect the battery plug.

Remove the rear cover and battery cover.

Remove the battery.

Disconnect the controller cables and the contactor group.

Disconnect the hydraulic motor hoses.

Set the hoisting attachment and remove the counterweight set bolt.

Remove the counterweight.

Installation Procedure The installation procedure is the reverse of the removal procedure.

Tightening torque of the 4 bolts of the counterweight = 425 Nm. (Note: Tight the bolts with the sequence V1, V2, V3, V4).

Tightening torque of the 2 bolts of the OHG = 83 Nm.

V4 V3 V1 V2

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OPERATOR’S SEAT REMOVAL • INSTALLATION

Removal Procedure 1 2 3 4

Open the battery cover.

Disconnect the wiring of the seat switch.

Remove the operator’s seat set nuts. (Be careful not to drop the operator’s seat).

Remove the operator’s seat.

Installation Procedure The installation procedure is the reverse of the removal procedure.

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FUSES FUSE INSTALLATION LOCATIONS Fuses F1, F2, F3 and F4 are located in the lower position of the contactor group

Contactor group

NAMES (APPLICABLE FUNCTIONS) AND CAPACITIES

1.0, 1,25, 1.5 t F1

For I/O card -+ 24V

15 A

F2

For optional fuse bar

40 A

F3

For heater

40 A

F4

Key switch

10 A

Caution for fuse replacement Before fuse replacement, be sure to disconnect the battery plug and completely discharge CO (overall condenser) with Approx. 100Ω resistor

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CHAPTER 1000

MOTORS / ENGINES

CHAPTER 1000 page 1

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MOTORS / ENGINES TRACTION MOTOR ................................................................................................. page 3 GENERAL ................................................................................................................ page 3 SPECIFICATIONS .................................................................................................... page 3 REMOVAL • INSTALLATION .................................................................................... page 4 PUMP MOTOR ......................................................................................................... page 7 GENERAL ................................................................................................................ page 7 SPECIFICATIONS .................................................................................................... page 7 REMOVAL • INSTALLATION .................................................................................... page 8

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TRACTION MOTOR GENERAL

SPECIFICATIONS TRACTION MOTOR MANUFACTURER

SAUER DANFOSS

SIZE

Ø 210 x 330,5 mm

POWER

5,1 KW

NOMINAL VOLTAGE

16 V

NOMINAL CURRENT

267 A

FREQUENCY

46 Hz

POWER FACTOR (cos φ)

0,77

EFFICIENCY (η)

0,9

INSULATION CLASS

0

IP

54

SERVICE

S2 - 60’

POLES NUMBER

4

R.P.M.

1335 rpm

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REMOVAL • INSTALLATION T=N·m

T=40 Nm

Removal Procedure 1 Lift the battery cover.

2 Disconnect the battery plug.

3 Remove the seat by screwing off the 4 bolts under the battery cover 4 Remove the rear plastic cover.

5 Remove the battery cover by disassenbling the gas spring and the 2 screw on the OHG. [Point 1] 6 Disconnect the cables of the traction motor.

7 Remove the 6 Allen screws of the traction motor. [Point 2] 8 Connect a chain or a belt on the motor. [Point 3] 9 Remove the the traction motor. [Point 4] Installation Procedure The installation procedure is the reverse of the removal procedure.

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Point Operations [POINT 1] Removal: Remove the components in order to create the working space.

[POINT 2] Removal: Remove the power cables and the wiring of the encoder sensor.

Screw out the 6 screws of the motor.

Installation: After installation, tightening torque of the 6 screws of the motor = 40 Nm

[POINT 3] Removal: Connect a chain or a belt to the motor, as shown on the picture, by a screw of M8 to the threaded hole on the motor shaft.

[POINT 4] Removal: Lift up the motor and put it in horizontal position or in vertical position on a special support as showen in the picture, in order to avoid dangerous movements .

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Installation: After the installation, the tightening torque of the 6 Allen screws traction motor = 40 Nm.

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PUMP MOTOR GENERAL

SPECIFICATIONS LIFTING MOTOR MANUFACTURER

SAUER DANFOSS

SIZE

Ø 177 x 338,5 mm

POWER

7,5 KW

NOMINAL VOLTAGE

16 V

NOMINAL CURRENT

375 A

FREQUENCY

70 Hz

POWER FACTOR (cos φ)

0,82

EFFICIENCY (η)

88

INSULATION CLASS

H

IP

54

SERVICE

S3 - 40%

POLES NUMBER

4

R.P.M.

2030 rpm

PUMP CAPACITY

11 l/m’

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REMOVAL • INSTALLATION

Removal Procedure 1 Lift the battery cover.

2 Disconnect the battery plug.

3 Remove the foot board.

4 Remove the 2 pedals. [Point 1] 5 Drain out the hydraulic oil 6 Disconnect the hoses from the priority valve.

7 Disconnect the inlet connection from the oil pump (tank pump) from the tank output hose.

[Point 2] 8 Remove the hydraulic oil tank. [Point 3] 9 Remove cables of the traction motor. [Point 4] 10 Remove the 4 nuts of the pump motor. [Point 5] 11 Connect a chain or belt on the motor. [Point 6] 12 Remove the pump motor.

Installation Procedure The installation procedure is the reverse of the removal procedure.

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Point Operation [Point 1] Removal: Disconnect the wirings of the two pedals.

Disconnect the brake hose of the brake pedal by closing it to avoid the loosing of the brake oil.Remove the 3 screws per pedal from the front of the frame.

Installation: After installation, tightening torque of the pedal bolts = 24 Nm

[Point 2] Removal: See chapter 14

[Point 3] Removal: Remove the hydraulic oil tank by removing the 2 bolts on the frame.

[Point 4] Removal: Disconnect the 3 cables from the pump motor and the wiring of the encoder sensor Installation: After installation, tightening torque of the cables bolts = 15 Nm

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[Point 5] Removal: Remove the 4 nuts from the fixing brackets of the pump motor with the frame Installation: After installation, tightening torque of the 4 fixing bolts = 24 Nm

[Point 6] Removal: Chain or belt is needed to extract the pump motor from the truck.

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CHAPTER 2000

TRANSMISSION / DRIVE GEAR

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TRANSMISSION / DRIVE GEAR GENERAL ................................................................................................................ page 3 SPECIFICATIONS .................................................................................................... page 4 COMPONENTS........................................................................................................ page 4 REAR AXLE & DRIVE UNIT..................................................................................... page 6 REMOVAL • INSTALLATION .................................................................................... page 6

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SPECIFICATIONS Load capacity Item Total reduction ratio

1.0t

1.25t

1.5t

1:23,4

←

←

←

457 × 178 / 18 x 7-8 / 18 x 7-8

Rear / Front tire size C/SE/PN 457 × 152 / 18 x 7(Cushon / Super Elastic / PNeumatic) 8 / 18 x 7-8

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REAR AXLE & DRIVE UNIT REMOVAL • INSTALLATION T=Nm

Removal Procedure 1 Disconnect the battery plug 2 Connect the chains on the mast [Point 1] 3 Remove the bolts of the mast [Point 2] 4 Remove the mast 5 Remove the pins from the tilting cylinders [Point 3] 6 Remove the seat by remove the 4 bolts under the battery cover 7 Remove the back plastic cover 8 Remove the battery cover by removing the gas spring and the 2 bolts on the OHG [Point 4] 9 Disconnect the cables of the traction motor and remove the 6 screws [Point 5] 10 Connect a chain or belt to the motor [Point 6] 11 Remove the traction motor 12 Remove the 4 screws of the plastic bottom cover of the drive unit [Point 7] 13 Jack up the back of the vehicle [Point 8] 14 Put a hand-pallet under the backward wheel [Point 9] 15 Remove the 6 bolts of the rear axle [Point 10] 16 Extract the rear axle [Point 11]

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Installation procedure The installation procedure is the reverse of the removal procedure.

Note: Pay attention to the teethes of the hydraulic motor and potentiometer during the reassembly of the drive unit.

Note: • Type and quantity of gear oil Type

STD Cold storage type

Mobilube 1SHC 75 W-90 4,2 l

Quantity • Type of grease STD Cold storage type

Mobiltemp SHC 100 Point Operations [POINT 1] Removal: Lower completely down the mast.

Connect the chain on the showed before removing the mast.

Disconnect the hydraulic hoses from the mast (lifting, tilting, side shift, …).

[POINT 2] Removal: Remove the 4 bolts that fix the mast to the frame from the bottom.

Installation: After installation, tightening torque of the 4 screws of the mast = 83 Nm

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[POINT 3] Removal: Remove the 2 screws of the safety plates and then the 2 pins of the tilting cylinders (It is necessary to remove the mast to avoid the vehicle overturning while lifted up on the back side see [POINT 9].

Installation: After installation, tightening torque of the 2 screws of the safety plates for the pins of tilting cylinders = 24 Nm [POINT 4] Removal: Remove the battery cover by removing the gas spring and the 2 bolts on the OHG.

[POINT 5] Removal: Remove the power cables and the wiring of the encoder sensor.

Screw out the 6 screws of the motor.

Installation: After installation, tightening torque of the 6 screws of the motor = 40 Nm

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[POINT 6] Removal: Connect a chain or belt to the motor, as showed on the picture, by a screw of M8 to the treaded hose on the rotor of the motor.

Lift up the motor and put it in horizontal position or in vertical position with a special support, as showed in the picture, in order to avoid dangerous movement of the rotor.

[POINT 7] Removal: Remove the 4 screws of the plastic bottom cover of the drive unit.

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[POINT 8] Removal: Jack up the back of the vehicle from the counterweight by using a chain (required lifting measure about 400 mm).

[POINT 9] Removal: Put a hand-pallet under the backward wheel and lift it up to maintain the rear axle in position

[POINT 10] Removal: Remove the 6 screws of the drive unit.

Installation: After installation, tightening torque of the 6 screws of the drive unit = 140 Nm.

[POINT 11] Removal: Extract the complete drive unit by using the hand-pallet.

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CHAPTER 3000

BRAKE

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BRAKE INDEX BRAKE SYSTEM...................................................................................................... page 3 GENERAL ................................................................................................................ page 3 SPECIFICATIONS .................................................................................................... page 4 COMPONENTS........................................................................................................ page 4 PARKING BRAKE .................................................................................................... page 4 BRAKE PEDAL......................................................................................................... page 5 FRONT BRAKE ........................................................................................................ page 6 BRAKE GROUP ....................................................................................................... page 7 REMOVAL • INSTALLATION .................................................................................... page 7 BRAKE SHOES AND BRAKE CYLINDER............................................................... page 9 REMOVAL • INSTALLATION .................................................................................... page 9 BRAKE PEDAL......................................................................................................... page 12 REMOVAL • INSTALLATION .................................................................................... page 12 BRAKE PEDAL ADJUSTMET .................................................................................. page 13 PARKING BRAKE .................................................................................................... page 14 REMOVAL • INSTALLATION .................................................................................... page 14 PARKING BRAKE ADJUSTMENTS ......................................................................... page 15

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SPECIFICATIONS Model Item

All models

Foot brake type

Mechanical drum brake

Parking brake type

Mechanical drum brake

Brake wheel

Brake shoe

Diameter Thickness

mm

170 40

Area

mm2

6073 (per shoe)

Thickness

mm

5

COMPONENTS PARKING BRAKE

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BRAKE PEDAL

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FRONT BRAKE T = Nm

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CHAPTER 3000 page 7

BRAKE GROUP REMOVAL • INSTALLATION T = Nm T = 83 Nm (± 5%)

T = 140 Nm (± 5%)

Removal Procedure 1) Disconnect the battery plug.

2) Jack up the vehicle and remove the front wheels (item 14,3).

3) Remove the hub wheel cover (item 10). [Point 1] 4) Remove the 2 bushings and the safety washer (item 16B, 17, 16A). [Point 2] 5) Remove the big washer (item 15).

6) Remove the small conical bearing (item 7).

7) Remove the drum (item 2).

8) Remove the big conical bearing (item 6). [Point 3] 9) Remove the Nilos-ring (item 9). [Point 4] 10) Remove the spacer (item 8).

11) Remove the hand brake cable.

12) Drain out the brake oil.

13) Disconnect the hose from the brake cylinder.

14) Remove the 6 bolds and washers of the brake plate from the internal side of the frame (item 11, 12, 13).

15) Remove the brake group (item 4).

Installation Procedure The installation procedure is the reverse of the removal procedre.

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Point Operations [POINT 1] Removal: Remove the hub wheel by play attention to do not damage it.

Installation: Before installation, put 1/3 of appropriate grease inside the cover (around 30gr.) well distributed.

[POINT 2] Removal: Before to remove the bushing (item 16B) it is necessary to bend the teeth of the safety washer (item 17).

Then remove also the bushing (item 16A).

Installation: It is necessary to fix the 2 bushings with the conical surface orientated towards the frame (this is because less friction is required between these parts and avoid any damaging cause by the turning of the bearing-wheel). After installation, tight the bushing (item 16A) with a torque of 60 Nm, then turn the wheel hub 2-3 turns in bought sides in order to adjust the bearings.

Then loose the bushing and tight it again with a torque of 20 Nm (with this operation 0,6-1 Nm of turning torque is obtained).

[POINT 3] Removal: Remove the big conical bearing (item 6).

Installation: After installation, put the appropriate grease with the correct quantity the bearings. On the big conical bearing 6 cover it of grease but do net exceed over the diameter of the Nilos-ring (item 9) located on its back side.

[POINT 4] Removal: Remove the Nilos-ring (item 9). This is used to seal the bearings.

Installation: For the installation it is necessary to replace this part.

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BRAKE SHOES AND BRAKE CYLINDER REMOVAL • INSTALLATION

T = Nm

T = 83 Nm (± 5%)

T = 140 Nm (± 5%)

20 18 18

19

19

Removal Procedure 1) Disconnect the battery plug.

2) Jack up the vehicle and remove the front wheels (item 14,3).

3) Remove the hub wheel cover (item 10).

4) Remove the 2 bushings and the safety washer (item 16B, 17, 16A).

5) Remove the big washer (item 15).

6) Remove the small conical bearing (item 7).

7) Remove the drum (item 2). [Point 1] 8) Remove the big conical bearing (item 6).

9) Remove the Nilos-ring (item 9).

10) Remove the spacer (item 8).

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11) Remove the shoe return springs (item 18) 12) Remove the shoe adjuster springs (item 19) 13) Remove the hand brake cable.

14) Remove the brake shoes. [Point 2] 15) Drain out the brake oil.

16) Remove the 6 bolds and washers of the brake plate from the internal side of the frame (item 11, 12, 13).

17) Remove the brake pipe. [Point 3] 18) Remove the brake group (item 4).

19) Remove the brake cylinder (item 20) Installation Procedure The installation procedure is the reverse of the removal procedre.

Point Operations [POINT 1] Inspection: Measure the internal diameter of the brake drum.

Standard inside diameter: 170 mm.

[POINT 2] Inspection: Measure the brake material thickness of the brake shoes.

Standard thickness: 5 mm.

Limit free thickness: 1 mm.

Installation: After installation, it is necessary to put the self adjusting cylinder in the standard position by turning the two bushings. It is necessary that the diameter of the shoes is about 169 mm.

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[POINT 3] Removal: Remove the brake pipe as showed in the drawing.

Installation: After installation, tightening torque of the brake bolt = 18 Nm

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BRAKE PEDAL REMOVAL • INSTALLATION T = Nm

T = 24 Nm (± 10%)

Removal Procedure 1) Disconnect the battery plug.

2) Disconnect the wiring of the pedal.

3) Drain out the brake oil.

4) Disconnect the brake hose from the master brake cylinder. [Point 1] 5) Remove the 3 screws from the front of the frame.

6) Remove the brake pedal.

Installation procedure The installation procedure is the reverse of the removal procedure T = 28 Nm (± 15%)

Point operations [POINT 1] Installation: After installation, tightening torque of the bolt on the master brake cylinder = 28 Nm.

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BRAKE PEDAL ADJUSTMET

A

1.

After installation drain out the air from the brake system by using the drain plugs on the brake cylinders.

2.

Adjust the pin A in order to have a clearance play of 0.2-0.5 mm between itself and the master brake cylinder.

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PARKING BRAKE REMOVAL • INSTALLATION

Removal Procedure 1) Disconnect the battery plug.

2) Remove the two plastic covers. [Point 1] 3) Disconnect the parking brake cables.

4) Remove the fixing bolts.

5) Remove the parking brake lever.

Installation procedure The installation procedure is the reverse of the removal procedure Point Operations [POINT 1] Removal: Remove the two plastic covers in order to reach the parking brake lever fixing bolts.

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CHAPTER 3000 page 15

PARKING BRAKE ADJUSTMENTS

Adjustment: 1.

2.

3.

4.

Put the cable in the corrent position (see picture) Tight the nut and counter nut (item 8).

Fix the cables in them block (see picture).

Adjusting the nut item 9A verify with the hands that the turnings of the two wheels are: a) Notch 4: possible but hard b) Notch 5: completely blocked

Note: Verify the same behavior in both wheels.

5.

T=13 Nm (± 15%)

6.

7.

In order to reach the 5th notch 115 Nm are required to poll the lever from the handle.

Tight the counter nut item 9B. Pull the lever some times and verify that the conditions of points 4a and 4b are maintained.

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CHAPTER 4000

STEERING SYSTEM

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STEERING SYSTEM POWER STEERING SYSTEM................................................................................. page 3 GENERAL ................................................................................................................ page 3 SCHEMATIC DIAGRAM ........................................................................................... page 4 SPECIFICATIONS .................................................................................................... page 4 POWER STEERING (ORBITROL)........................................................................... page 5 HYDROSTATIC STEERING VALVE ......................................................................... page 6 TROUBLESHOOTING ............................................................................................. page 6 POWER STEERING (ORBITROL)........................................................................... page 8 REMOVAL • INSTALLATION .................................................................................... page 8 INSPECT AND ADJUST THE RELIEF PRESSURE................................................ page 9 PRIORITY VALVE..................................................................................................... page 10 GENERAL ................................................................................................................ page 10 REMOVAL • INSTALLATION .................................................................................... page 12 REAR AXLE ............................................................................................................. page 13 GENERAL ................................................................................................................ page 13 SPECIFICATIONS .................................................................................................... page 15 COMPONENTS........................................................................................................ page 15 REAR AXLE ............................................................................................................. page 15 STEERING HYDRAULIC MOTOR ........................................................................... page 16 STEERING POTENTIOMETER .............................................................................. page 17 STEERING SYSTEM ............................................................................................... page 18 HYDRAULIC MOTOR .............................................................................................. page 19 REMOVAL • INSTALLATION .................................................................................... page 19 STEERING POTENTIOMETER ............................................................................... page 21 REMOVAL • INSTALLATION .................................................................................... page 21 REAR AXLE & DRIVE UNIT..................................................................................... page 23 REMOVAL • INSTALLATION .................................................................................... page 23

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POWER STEERING SYSTEM GENERAL

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SCHEMATIC DIAGRAM

HYDRAULIC MOTOR

ORBITROL

FROM CONTROL VALVE TO CONTROL VALVE

PRIORITY VALVE

FILTER

PUMP

SPECIFICATIONS Load capacity Item

1,0 - 1,25 - 1,5 t

Steering wheel diameter

mm

360

Steering wheel play

mm

20 ~ 50

Power steering type

Hydrostatic steering Dicharge:

Hydrostatic steering valve Rated flow rate: Relief set pressure:

cc (cm3)

50.0

l·min

8

Bar

~ 150

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POWER STEERING (ORBITROL)

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HYDROSTATIC STEERING VALVE TROUBLESHOOTING Only hydraulic related items are listed.

Symptom The steering wheel cannot be rotated

The steering wheel is heavy.

The oil pressure does not rise.

The steering wheel does not return properly.

Probable cause

Action

• The piping is damaged.

Replace

• The steering valve drive shaft is installed incorrectly or damaged.

Inspect and correct or replace.

• Tire pressure is low. (For Pneumatic tire)

Adjusting the tire pressure

• The oil pressure does not rise.

Inspect and adjust the relief pressure.

• The high and low pressure pipes are connected in reverse.

Inspect and correct.

• The high and low pressure pipes are connected in reverse.

Inspect and correct.

• The relief valve is faulty or not closed.

Inspect and correct.

• Oil pump function is deteriorated.

Inspect and correct or replace.

• Priority valve spool fused.

Overhaul

• Hydraulic oil level is low.

Add

• Tire pressure is low. (For Pneumatic tire)

Adjusting the tire pressure

• The steering valve spool does not move Correct or replace the smoothly. steering valve.

• The rear axle sliding motion is improper. Add lubricant or correct.

• The steering valve spool does not move Correct or replace the smoothly. steering valve.

The steering wheel pulls to one side when released

Play is excessive and the vehicle wobbles

Symptom

• The steering valve drive shaft is damaged.

Replace the steering valve.

• The piping is blocked (crushed or clogged).

Inspect and correct or replace.

• Oil moves in the steering valve.

Replace the steering valve.

• The steering valve spool does not move Correct or replace the smoothly. steering valve.S • Air is sucked from the piping.

Inspect and correct or replace.

• The steering shaft is defective.

Inspect and correct.

Probable cause

Action

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The steering wheel shimmies.

The tires are steered opposite to the steering wheel operated direction.

Abnormal noise is generated.

CHAPTER 4000 page 7

• The steering valve drive shaft is installed incorrectly.

Inspect and correct.

• The hydraulic motor does not work propely .

Inspect and correct.

• The teeth of the hydraulic motor or of the crown are damaged. .

Inspect and correct.

• The cylinder piping is connected in reverse

Inspect and correct.

• The relief valve is defective.

Inspect the pressure and correct or adjust.

• Air is sucked from the piping.

Inspect and correct or replace.

• The piping is blocked (crushed or clogged).

Inspect and correct or replace.

• The teeth of the hydraulic motor or of the crown are damaged.

Inspect and correct or replace.

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POWER STEERING (ORBITROL) REMOVAL • INSTALLATION

Removal Procedure 1 Disconnect the battery plug.

2 Remove the direction lever (front and rear).

3 Remove the column covers (upper, lower and rear).

4 Remove the power steering. [Point 1] Installation Procedure The installation procedure is the reverse of the removal procedure.

Note: Add grease at the coupling between the steering shaft and steering valve.

Point Operations [POINT 1] Installation: Install the piping with the angle shown in the illustration to the left.

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CHAPTER 4000 page 9

INSPECT AND ADJUST THE RELIEF PRESSURE. 1.

Connect a manometer on the pressure gauge of the priority valve.

2.

When the steering wheel is rotated to the end, relief state is achieved, so read the pressure on the pressure gauge at that time.

Pressure socket

ADJUSTING SCREW

Standard: All Models 3.

Bar (kgf·cm2)

~ 150

If the relief pressure is out of the standard range, remove the steering valve and adjust at the adjusting section.

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PRIORITY VALVE GENERAL

SERVICE MANUAL

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FRONT VIEW

REAR VIEW

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REMOVAL • INSTALLATION T=Nm

Removal Procedure 1 Disconnect the battery plug.

2 Remove the foot board.

3 Remove the hydraulic oil from the tank.

4 Disconnect the hoses from the priority valve.

5 Remove the priority valve. [Point 1] Installation Procedure The installation procedure is the reverse of the removal procedure.

Point Operations [POINT 1] Installation: Tightening torque of the 4 Allen screws of the priority = 12 Nm.

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REAR AXLE GENERAL

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SPECIFICATIONS Load capacity Item Total reduction ratio Rear / Front tire size C/SE/PN (Cushon / Super Elastic / PNeumatic)

COMPONENTS REAR AXLE

1.0t

1.25t

1.5t

1:23,4

←

←

457 × 152 / 18 x 7-8 / 18 x 7-8

←

457 × 178 / 18 x 7-8 / 18 x 7-8

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STEERING HYDRAULIC MOTOR

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STEERING POTENTIOMETER

Greasing point

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STEERING SYSTEM

SERVICE MANUAL

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CHAPTER 4000 page 19

HYDRAULIC MOTOR REMOVAL • INSTALLATION T=Nm T=140 N.m (±10%)

Removal Procedure 1 Remove the battery cover 2 Disconnect the battery plug 3 Remove the back plastic cover 4 Remove the right side plate of the frame 5 Remove thebattery [Point 1] 6 Disconnect the 2 hoses of the hydraulic motor [Point 2] 7 Remove the hydraulic motor [Point 3]

Installation Procedure The installation procedure is the reverse of the removal procedure.

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Point Operations [POINT 1] Removal: Remove the right side plate of the frame.

Remove the battery from the vehicle by using the appropriated chain or belt.

Note: It is necessary to remove the battery in order to screw ou/in the front side screw of the hydraulic motor.

[POINT 2] Removal: Disconnect the two hoses from the hydraulic motor.

Note: It is suggested to mark the hoses before the disconnection Installation: Tightening torque of the 2 hoses connection = 55 Nm. [POINT 3] Removal: Screw out the 2 Allen of the hydraulic motor. The front side screw has to be removed thought the hole on the frame when the battery is removed.

Installation: After installation, tightening torque of the 2 screws of the hydraulic motor = 140 Nm.

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STEERING POTENTIOMETER REMOVAL • INSTALLATION

Removal Procedure 1 Lift the battery cover 2 Disconnect the battery plug 3 Remove the back plastic cover 4 Remove the battery plug group [Point 1] 5 Remove the steering potentiometer [Point 2] Installation Procedure The installation procedure is the reverse of the removal procedure.

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Point Operations [POINT 1] Removal: Remove the battery plug group to create enough space to reach the potentiometer.

[POINT 2] Removal: Disconnect the wiring the steering potentiometer.

Remove the 3 screws of the potentiometer and remove it.

Installation: After installation, adjustment:

carry

out

the

following

1 turn the potentiometer to the end stroke (left or right), 2 turn the potentiometer 5 turns to the opposite direction then before (right or left), 3 verify that the traction wheel is orientated on the traction side.

Tight the 3 potentiometer screws.

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CHAPTER 4000 page 23

REAR AXLE & DRIVE UNIT REMOVAL • INSTALLATION T=Nm

Removal Procedure 1 Disconnect the battery plug 2 Connect the chains on the mast [Point 1] 3 Remove the bolts of the mast [Point 2] 4 Remove the mast 5 Remove the pins from the tilting cylinders [Point 3] 6 Remove the seat by remove the 4 bolts under the battery cover 7 Remove the back plastic cover 8 Remove the battery cover by removing the gas spring and the 2 bolts on the OHG [Point 4] 9 Disconnect the cables of the traction motor and remove the 6 screws [Point 5] 10 Connect a chain or belt to the motor [Point 6] 11 Remove the traction motor 12 Remove the 4 screws of the plastic bottom cover of the drive unit [Point 7] 13 Jack up the back of the vehicle [Point 8] 14 Put a hand-pallet under the backward wheel [Point 9] 15 Remove the 6 bolts of the rear axle [Point 10] 16 Extract the rear axle [Point 11]

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Installation procedure The installation procedure is the reverse of the removal procedure.

Note: Pay attention to the teethes of the hydraulic motor and potentiometer during the reassembly of the drive unit.

Note: • Type and quantity of gear oil Type

STD Cold storage type

Mobilube 1SHC 75 W-90 4,2 l

Quantity • Type of grease STD Cold storage type

Mobiltemp SHC 100 Point Operations [POINT 1] Removal: Lower completely down the mast.

Connect the chain on the showed before removing the mast.

Disconnect the hydraulic hoses from the mast (lifting, tilting, side shift, …).

[POINT 2] Removal: Remove the 4 bolts that fix the mast to the frame from the bottom.

Installation: After installation, tightening torque of the 4 screws of the mast = 83 Nm

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[POINT 3] Removal: Remove the 2 screws of the safety plates and then the 2 pins of the tilting cylinders (It is necessary to remove the mast to avoid the vehicle overturning while lifted up on the back side see [POINT 9].

Installation: After installation, tightening torque of the 2 screws of the safety plates for the pins of tilting cylinders = 24 Nm [POINT 4] Removal: Remove the battery cover by removing the gas spring and the 2 bolts on the OHG.

[POINT 5] Removal: Remove the power cables and the wiring of the encoder sensor.

Screw out the 6 screws of the motor.

Installation: After installation, tightening torque of the 6 screws of the motor = 40 Nm

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[POINT 6] Removal: Connect a chain or belt to the motor, as showed on the picture, by a screw of M8 to the treaded hose on the rotor of the motor.

Lift up the motor and put it in horizontal position or in vertical position with a special support, as showed in the picture, in order to avoid dangerous movement of the rotor.

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[POINT 7] Removal: Remove the 4 screws of the plastic bottom cover of the drive unit.

[POINT 8] Removal: Jack up the back of the vehicle from the counterweight by using a chain (required lifting measure about 400 mm).

[POINT 9] Removal: Put a hand-pallet under the backward wheel and lift it up to maintain the rear axle in position

[POINT 10] Removal: Remove the 6 screws of the drive unit.

Installation: After installation, tightening torque of the 6 screws of the drive unit = 140 Nm.

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[POINT 11] Removal: Extract the complete drive unit by using the hand-pallet.

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CHAPTER 5000

ELECTRICAL SYSTEM

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ELECTRIC AND ELECTRONIC SYSTEM INDEX BATTERY COMPARTMENT AND REQUIRED WEIGHT......................................... page 5 SERVICE STANDARDS ........................................................................................... page 6 DISPLAY................................................................................................................... page 6 TROUBLESHOOTING ............................................................................................. page 7 BATTERY ................................................................................................................. page 8 REMOVAL • INSTALLATION .................................................................................... page 8 INSPECTION............................................................................................................ page 9 GENERAL ................................................................................................................ page 11 SPECIFICATIONS .................................................................................................... page 12 COMPONENTS........................................................................................................ page 13 BEFORE REPAIR..................................................................................................... page 16 CONNECTOR INSPECTION ................................................................................... page 17 CPU BOARD TRACTION LOGIC UNIT AC2 .......................................................... page 19 CPU BOARD LIFTING LOGIC UNIT PAP AC2 ........................................................ page 21 CPU BOARD CB I/0 CONTROL BOARD................................................................. page 23 CPU BOARD MHYRIO............................................................................................. page 27 CPU BOARD ARMREST BOARD............................................................................ page 29 CONTROLLER ......................................................................................................... page 30 MAIN CONTROLLER ............................................................................................... page 30 OPERATIONAL FEATURE....................................................................................... page 30 DIAGNOSIS.............................................................................................................. page 30 GENERAL PRECAUTIONS ..................................................................................... page 31 PROTECTIONS........................................................................................................ page 31 REMOVAL • INSTALLATION .................................................................................... page 32 MHYRIO LOGIC UNIT.............................................................................................. page 33 OPERATIONAL FEATURE....................................................................................... page 33 ARMREST BOARD .................................................................................................. page 34 REMOVAL • INSTALLATION .................................................................................... page 35 MASTER CONTROLLER I/O - INPUT / OUTPUT CARD ........................................ page 36 REMOVAL • INSTALLATION .................................................................................... page 36 MATERIAL HANDLING AC DRIVER, CONTACTOR PANEL................................... page 37 REMOVAL • INSTALLATION .................................................................................... page 37 INSPECTION............................................................................................................ page 38 CHECK TRACTION MOTOR PHASES BALANCING .............................................. page 39 CHECK LIFTING MOTOR PHASES BALANCING................................................... page 40 REASSEMBLY ......................................................................................................... page 41 DISPLAY................................................................................................................... page 42 ACCELERATOR POTENTIOMETER ADJUSTMENT.............................................. page 44

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BRAKE SWITCH ADJUSTMENT ............................................................................. page 45 FOOT BRAKE........................................................................................................... page 45 PARKING BRAKE..................................................................................................... page 45 BEFORE TROUBLESHOOTING.............................................................................. page 46 CONNECTOR HANDLING ....................................................................................... page 46 WIRE HARNESS AND CONNECTOR INSPECTION PROCEDURE ...................... page 46 SYSTEM CONFIGURATION WITH MECHANIC CONROL VALVE ......................... page 48 SYSTEM CONFIGURATION WITH ELECTRIC CONROL VALVE........................... page 49 DIAGNOSIS CODE LIST.......................................................................................... page 50 WHEN AN ERROR CODE IS DISPLAYED .............................................................. page 56 TRACTION LOGIC UNIT.......................................................................................... page 56 LIFTING LOGIC UNIT .............................................................................................. page 68 MHYRIO LOGIC UNIT.............................................................................................. page 79 ARMREST BOARD .................................................................................................. page 88 DASHBOARD ........................................................................................................... page 91 I/O CONTROL BOARD............................................................................................. page 93

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BATTERY COMPARTMENT AND REQUIRED WEIGHT When the battery is to be purchased locally, always adjust the weight to satisfy the minimum required weight as shown in the table below.

Load capacity

Length X 270 432 486

1,0 t 1,25 t 1,5 t

Minimum required batRemarks tery weight (with case) (Capacity) Kg Height Z 627 372 400-500 ↑ 600 700-875 ↑ 676 800-1000

Compartment dimensions mm Width Y 827 ↑ ↑

Height

th ng e L

Width

Din battery (DIN 43531 / 35 / 36 A, B, C, No)

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SERVICE STANDARDS Specific gravity Specific gravity Discharge end voltage Electrolyte Fluid to be added Insulation resistance

1.280 [20 °C (68 °F)] 1.150 [20 °C (68 °F)] 20.5 V Refined dilute sulfuric acid Distilled water 10MΩ or more

24 V

DISPLAY Battery Charge Indicator The battery charge indicator indicates 10 levels of battery charge on the LCD.

Indicate level Battery charged state 1 2 3 4 5 6 7 8 9 10 E F % 0 to 10 o (exclusive) 10 to 20 o (exclusive) 20 to 30 o (exclusive) 30 to 40 o (exclusive) 40 to 50 o (exclusive) 50 to 60 o (exclusive) 60 to 70 o (exclusive) 70 to 80 o (exclusive) 80 to 90 o (exclusive) 90 to 100 o (exclusive) 100 or more o

Low Remaining Battery Charge Warning This bar consists of 3 green LEDS on the right side, 4 orange LEDS in the middle and 3 red LEDS on the left side; when the battery is charged the first green LED on the right is On; while the battery discharges, the LEDS turn On or Off, one per time, from the right to the left according with the battery charging status.

When the battery is 80% discharged, the first red LED on the left is On, the display shows the alarm code 1C so the battery must be recharged (reserve).

There is an indication on the dashboard and the lifting speed is reduced because there is a current cutback by 50%. The battery charge indicator does not rearm if the battery charging status is between 70% and 100%.

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TROUBLESHOOTING p

Sulfation

Plate corrosion

Plate warpage and active substance freeing

Improper charging Long storage without operations

End of life

Ripeated overdischarge/ overcharge

Short circuit between cells Defect of the electrolyte

Excessive charging current

Insufficient Electrolyte Overdischarge

Defective electrolyte

Damaged separator

Improper water supplay

Crack or chipping of the cells Imperfect terminal connection

Overcharg

Depositined of freed active substance at bottom of the cells Short circuit

Battery defect

Excessive ambient temperature

fouled terminal or connecting plug

Electrolyte leakage and reduction

loosened or corroded connetion

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BATTERY REMOVAL • INSTALLATION

Removal Procedure 1 Unlock the lever group of the control valve and move it forward (only if the mechanical control valve is fitted).

2 Move the steering wheel column forward.

3 Unlock the battery cover.

4 Open the battery cover (move the seat backward in order to lift the battery cover easly).

5 Disconnect the battery plug.

6 Open the battery safety lock. [Point 1] 7 Open the frame right side.

8 Remove the battery. [Point 2] Installation Procedure The installation procedure is the reverse of the removal procedure.

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Point Operations [POINT 1] Removal: Open the battery safety lock (pull the handle and lit it up)

[POINT 2] Removal: Remove the battery from the truck.

INSPECTION 1.

Electrolyte inspection The battery electrolyte is normal when it is transparent. Check turbidity when inspecting the specific gravity.If it cannot be checked clearly, put the electrolyte in a beaker for inspection.

2.

Battery electrolyte specific gravity inspection Use a hydrometer to measure the specific gravity of the electrolyte.

Specific gravity upon complete charging ....

1.280 [20 °C (68 °F)] Specific gravity upon end of discharge ....

1.150 [20 °C (68 °F)]

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The specific gravity of the electrolyte at 20 °C (68 °F) is used.

Equation for converting specific gravity S20=St+0.0007 (t-20) S20: Specific gravity at 20 °C St: Specific gravity at t °C t: Electrolyte temperature upon measurement (°C)

How to use the hydrometer (1) Squeeze the rubber bulb, insert the hydrometer nozzle into the battery element orifice and, releasing the rubber bulb, let the electrolyte to be sucked into its outer tube.

(2) Let the hydrometer float correctly without contact with the outer tube, top or bottom. When the bubbles in the electrolyte disappear, read the scale at the highest point of the electrolyte surface, as shown at left .

(3) After the measurement, wash carefully with clear water the inside and outside of the hydrometer and store it after wiping off the water with clean cloth.

3.

Insulation resistance inspection Measure the resistance between the battery and battery case with an insulation resistance meter (megohmmeter).

Insulation resistance .... 1 MΩ or more NOTE: When the insulation resistance is less than 1 MΩ, wash the battery with water after removing it from the vehicle.

Fully dry the washed battery and measure the insulation resistance again. Install the battery on the vehicle after confirming that the insulation resistance is 1 MΩ or more. * Battery control table Prepare a control table for each battery to record and maintain the inspection results.

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GENERAL It is equipped with traveling/material handling controllers that control traveling and material handling system. They are multi-functional controller that utilize micro computer.

The traveling/material handling controller provides high performance in a wide range by means of inverter control of the AC motor drive system.

The main controller has a self-diagnosis function that automatically detects any abnormality of the main drive/pump circuits, accelerator or any other sensor and displays the corresponding error code together with a warning beep.

At the same time, an action such as disabling traveling, disabling material handling or restriction of traveling speed is automatically taken to ensure safety.

Identification of faulty portion and functional inspection of the main drive/pump circuits, each operating system and sensors are also possible by setting the display to the analyzer (fault analysis) mode.

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SPECIFICATIONS 1,0 - 1,25 - 1,5 t

FUSES

Contactor

FT (for traction logic unit)

355A

FP (for lifting logic unit)

355A

F1 (for I/O card +24V aux)

15A

F2 (for optional fuse bar)

40A

F3 (for heater)

40A

F4 (before the key switch)

10A

CT1 (power supply for all equipment)

SW60B230 “24

CT2 (power supply for the logic unit)

SW280B82 24V

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COMPONENTS

TRACTION LOGIC UNIT

LIFTING LOGIC UNIT

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BATTERY PLUG GROUP

I/O CARD

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MHYRIO (OPTIONAL)

ARMREST BOARD (OPTIONAL) (OPTIONAL)

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BEFORE REPAIR INSPECTION 1. Insulation resistance measurement Note: Always measure before inspecting the traveling/ material handling controller.

(1) Disconnect the battery plug and measure the resistance between battery plug and body.

Measurement terminals Controller side of battery plug-body Standard:

Resistance value depends greatly on the vehicle operating state, place and weather.

(Approx. 10MΩ or more)

Some components can be inspected after they are removed from the vehicle, while others can only be inspected as installed on the vehicle.

The CPU board must be inspected as installed on the vehicle since the battery voltage must be applied.

The explanation here is mainly for inspection of the controller as removed from the vehicle.

Disassembly Procedure • Overhauling the control panel is rarely necessary. In most cases, failed parts is replaced after finding out the cause of the failure from inspection. Therefore, make sure to repair correctly by referring to the figures of configuration.

Caution for part replacement • Observe the specified tightening torque for tightening bolts. Insufficient torque and overlooking of tightening may cause other failure.

• When disconnecting the bars and harness, record the connecting location and place tags.

When connecting them again, be sure to confirm with the record and tags to prevent incorrect connection. Incorrect connection may cause other failure.

• Always apply new silicon grease when reassembling parts originally coated with silicon grease. Otherwise, overheating may occur.

• After installation, check that there is no interference of the bar and harness connection with other portion.

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CONNECTOR INSPECTION When inspecting each board and the cause of the trouble is found, do not immediately replace the board but check the following items.

• Abnormality in related harnesses • Looseness of the related connectors • Bending or damage of connector pin and defective contact of any related connector pin.

If any of the above is the cause of the trouble and the board is replaced with a new one, the new board will be damaged.

Always replace the board after careful inspection.

When the cause of trouble is determined to be in the CPU board or other board measure the applied voltage and resistance. Always disconnect the battery plug before measuring the resistance.

Caution: Disconnect the battery plug before connecting or disconnecting CPU board.

Note: When the CPU board is determined to be the cause of trouble as the result of troubleshooting, always measure the applied voltage and resistance of each related portion when replacing.

(1) Setting Method (a) Key switch OFF and battery plug disconnected. (b) Connect the multemeter to the corresponding connector pin.

Caution: As connection of the wrong connector pin may damage normal portions, make sure to confirm the connector pin number.

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(2) Measurement method and standard list How to read the list CN (pin-colour) ⇔ CN (pin-colour) From ⇔ To.

Description

Standard:

Remarks

Arriving point Starting point JDT (1-BS)

J15 (1-BS)

positive output

colour

12V

condition for measurament

connector pin No connector No

COLOUR CODING C A B L G H M N S R V Z

COLORI arancio azzurro bianco blu giallo grigio marrone nero rosa rosso verde viola/porpora

COLOURS orange blue white dark blue yellow grey brown black pink red green purple

FARBEN orange blau weiß dunkelblau gelb grau braun schwarz pink rot grün violett

COULEURS orange bleu blanc bleu marine jaune gris marron noir rose rouge vert violet

COLORES naranja azul blanco azul intenso amarillo gris castaño negro rosa rojo verde púrpura

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CPU BOARD TRACTION LOGIC UNIT AC2 Basic conditions (battery plug connected, key switch ON) [Standard vehicle & Mini-lever specification vehicle] See the reference names of the connectors in the electrical diagram.

CN (pin-colour) ⇔ CN (pin-colour) From ⇔ To.

Description

Standard:

JDT (1-BS)

J15 (1-BS)

positive output

12V

JDT (2-BV)

J15 (2-BV)

negative GND

GNDV

JDT (3-NV)

J15 (3-NV)

Encoder inpuls (the signal “A” changes the status according to the rotor position)

JDT (4) JDT (5-BL)

⎯ J 15 (4-B)

Unused Encoder inpuls (the signal “B” changes the status according to the rotor position)

Approx. 0,4V Approx.11,6V ⎯ Approx. 0,4V Approx.11,6V

JET (1)

⎯

Unused

⎯

JET (2)

⎯

Unused

⎯

JET (3)

⎯

Unused

⎯

JET (4)

⎯

Unused

⎯

JET (5)

⎯

Unused

⎯

JET (6)

⎯

Unused

⎯

JET (7)

⎯

Unused

⎯

JET (8-V)

J14(2)

steering potentiometer C POT

1-4,5V

JET (9-AG)

J14(3)

Steering potentiometer +V POT

10V

JET (10-HN)

J14(1)

steering potentiometer GND POT

GND

JET (11)

⎯

Unused

⎯

JET (12)

⎯

Unused

⎯

JET (13)

⎯

Unused

⎯

JET (14)

⎯

Unused

⎯

JBT (1)

⎯

Unused

⎯

JBT (2)

⎯

Unused

⎯

JFT (1-R04)

J35/8 (1-R04) JFP (1-R04) J50 (2-R04) J132 (1-R04)

Key input

(+) battery voltage

JFT (2-Z)

J50 (5-Z)

Positive of the contactor CT2

+ 24V

Remarks

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CN (pin-colour) ⇔ CN (pin-colour) From ⇔ To. JFT (3)

ELECTRIC

⎯

Description Unused

Standard: ⎯

JFT (4-NL)

JFP (4-NL) J20 (1-NL)

Input seat microswitch

JFT (5-LV)

JFP (9-LV)

Negative input for “Safety”

GND

JFT (6-SL)

J2 (2-SL)

Analogic termic sensor TS1 (+)

See page 4-17

JFT (7)

⎯

JFT (8-Z)

J50 (6-Z)

JFT (9)

Unused

(+) battery voltage

(+) battery voltage

Negative of the contactor CT2

GND

⎯

Unused

GND

JFT (10)

⎯

Unused

⎯

JFT (11)

⎯

Unused

⎯ ohm

JFT (12-RL)

J2 (2-RL)

Analogic termic sensor TS1 (-)

JCT (1-HG)

J34 (23-HG)

CAN L

Signal LOW

JCT (2-HG)

JCP (1-HG)

OUTPUT CAN L

Signal LOW

JCT (3-AN)

J34 (35-AN)

CAN H

Signal HIGH

JCT (4-AN)

JCP (3-AN)

OUTPUT CAN H

Signal HIGH

JAT (1)

−

Console

JAT (2)

−

Console

JAT (3)

−

Console

JAT (4)

−

Console

JAT (5)

−

Console

JAT (6)

−

Console

JAT (7)

−

Console

JAT (8)

−

Console

Remarks

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CPU BOARD LIFTING LOGIC UNIT PAP AC2 Basic conditions (battery plug connected, key switch ON) [Standard vehicle & Mini-lever specification vehicle] See the reference name of the connector in the electrical diagram.]

Connector. ⇔ Connector From ⇔ To

Description

Standard:

JDP (1-SZ)

J13 (1-SZ)

Positive output

12V

JDP (2-GN)

J13 (2-GN)

Negative GND

GNDV

JDP (3-AV)

J13 (3-AV)

Encoder inpuls (the signal “A” changes the status according to the rotor position)

JDP (4) JTD (5-HV)

⎯ J13 (4-HV)

Unused Encoder inpuls (the signal “B” changes the status according to the rotor position)

Approx. 0,4V Approx.11,6V ⎯ Approx. 0,4V Approx.11,6V

JEP (1)

⎯

Unused

⎯

JEP (2)

⎯

Unused

⎯

JEP (3)

⎯

Unused

⎯

JEP (4)

⎯

Unused

⎯

JEP (5)

⎯

Unused

⎯

JEP (6)

⎯

Unused

⎯

JEP (7)

⎯

Unused

⎯

JEP (8)

⎯

Unused

⎯

JEP (9)

⎯

Unused

⎯

JEP (10)

⎯

Unused

⎯

JEP (11)

⎯

Unused

⎯

JEP (12)

⎯

Unused

⎯

JEP (13)

⎯

Unused

⎯

JEP (14)

⎯

Unused

⎯

JEP (1)

⎯

Unused

⎯

JBP (1-H)

JBP (2-H)

Lifting logic unit selector

⎯

JBP (2-H)

JBP (1-H)

Lifting logic unit selector

⎯

JFP (1-R04)

J35/8 (1-R04) JFT (1-R04) J50 (2-R04) J132 (1-R04)

Key input

(+) battery voltage

JFP (2)

⎯

Unused

⎯

JFP (3)

⎯

Unused

⎯

Remarks

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Connector. ⇔ Connector From ⇔ To

Description

Standard:

JFP (4-NL)

JFT (4-NL) J20 (1-NL)

Input seat microswitch

JFP (5-H)

JFP (11-H)

Negative input for “Safety”

GND

JFP (6-CN)

J3 (2-CN)

Analogic termic sensor TS2 (+)

See page 4-29

JFP (7-MV)

J93 (2-MV)

Output

(+) battery voltage

⎯

Unused

GND

Negative output for “Safety”

GND

Unused

⎯

JFP (8) JFP (9-LV)

JFT (5-LV)

JFP (10)

(+) battery voltage

JFP (11-H)

JFP (5-H)

Negative output for “Safety”

GND

JFP (12-SV)

J3 (1-SV)

Analogic termic sensor TS1 (-)

ohm

JCP (1-HG)

JCT(2-H)

OUTPUT CAN L

Signal LOW

JCP (2-HG)

J131 (1-HG)

OUTPUT CAN L

Signal LOW

JCP (3-AN)

JCT (4-AN)

INPUT CAN H

Signal HIGH

JCP (4-AN)

J131 (2-AN)

OUTPUT CAN H

Signal HIGH

JAP (1)

−

Console

JAP (2)

−

Console

JAP (3)

−

Console

JAP (4)

−

Console

JAP (5)

−

Console

JAP (6)

−

Console

JAP (7)

−

Console

JAP (8)

−

Console

Remarks

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CPU BOARD CB I/0 CONTROL BOARD Basic conditions (battery plug connected, key switch ON) [Standard vehicle & Mini-lever specification vehicle] See the reference names of the connectors in the electrical diagram.]

Connector. ⇔ Connector From ⇔ To

Description

Standard:

24V

J34 (1-MN)

J93 (2-MN)

OUTPUT for backing light LR4 10W (the light is controlled when the traction encoder turns backward)

J34 (2-HN)

J32 (2-HN)

N POT traction potentiometer P2

GND

J34 (3-V)

J32 (1-V)

C POT traction potentiometer P2

1,2V-3,2V

J34 (4)

−

AN AUX

−

J34 (5-AG)

J32 (3-AG)

VCC traction potentiometer P2

10V

J34 (6-L)

ALL GND

Negative

GND

J34 (7-N)

ALL GND

Negative

GND

J34 (8-N)

ALL GND

Negative

GND

J34 (9-B)

J11(2-B)

HORN OUT signal to enable to horn

GND

J34 (10-N)

ALL GND

Negative

GND

J34 (11-R07)

J34 (24-R07) J40 (20-R07) J40 (21-R07) J48 (1-R07) J50 (1-R07) J22 (1-R07)

INPUT

(+) battery voltage

J34 (12-CR)

J131 (4-CR) J137 (5-CR)

OUTPUT voltage for the CANBUS

24V

J34 (13-AM)

J91 (2-AV)

OUTPUT for stop lights LL2 & LR2 21W (the light are controlled when the traction encoder reduced the rpm)

24V

J34 (14-NZ)

J30 (3-NZ)

Parking brake switch SW7

open 5V closed 0V

J34 (15-BZ)

J31 (2-BZ)

Brake pedal switch SW6

open 5V closed 0V

J34 (16-BM)

J35 (4-BM)

Horn signals PB4

open 5V closed 0V

J34 (17-RA)

J4 (RA)

Oil brake switch SW3

open 0V closed 5V

Remarks

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Connector. ⇔ Connector From ⇔ To

Description

Standard:

J34 (18-BN)

J33 (9-BN) double pedal version

Backward switch control SW5

closed 0V open 5V

J34 (19-RN)

J33 (8-RN) double pedal version J35 (3-RN) J39 (7-RN) J48 (10-RN) J101 (3-RN)

Backward switch SW5 (pedal) Backward switch SW10 (hand direction lever) Backward switch SW17 (hand direction lever control valve)

open 5V closed 0V

J34 (20-BH)

J33 (3-BH) double pedal version

switch control SW4

closed 0V open 5V

J34 (21-HG)

J137 (1-HG)

CAN L

Signal LOW

J34 (22-HG)

J132 (4-HG)

CAN L

Signal LOW

J34 (23-HG)

JCP (1-HG)

CAN L

Signal LOW

J34 (24-R07)

J34 (11-R07) J40 (21-R07) J40 (20-R07) J50 (1-R07)

Feeding for the cards

J34 (25-LG)

J33 (5-LG)

Configuration. It selects the configuration double pedal or hand direction lever.

GND

J34 (26-N)

ALL GND

Pump temperature switch

GND

J34 (27-N)

ALL GND

Traction temperature switch

GND

J34 (28-RG)

J35 (6-RG) J36 (2-RG)

S-P-H program selector PB3

open 5V closed 0V

J34 (29-CL)

J35 (5-CL) J37 (3-CL)

Speed reduction PB2

open 5V closed 0V

J34 (30-RH)

J33 (2-RH) double pedal version J35 (2-RH) J39 (5-RH) J48 (5-RH) J101 (2-RH)

Forward switch SW4 (Pedal) Forward switch SW4 (Hand direction lever) Forward switch SW16 (Hand direction lever control valve).

open 5V closed 0V

J34 (31-LS)

J32 (6-LS)

ENABLE switch controlSW8

closed 0V open 5V

J34 (32-RV)

J32 (5-RV)

ENABLE switch

open 5V closed 0V

J34 (33-AN)

J137 (2-AN)

CAN H

Signal HIGH

(+) battery voltage

Remarks

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Connector. ⇔ Connector From ⇔ To

Description

Standard:

J34 (34-AN)

J132 (3-AN)

CAN H

Signal HIGH

J34 (35-AN)

JCP (4-AN)

CAN H

Signal HIGH

J40 (1-GZ)

J48 (12-GZ) J42 (3-GZ)

Lifting microswitch SW11

open 5V closed 0V

J40 (2)

−

Unused

J40 (3-ZH)

J48 (3-ZH) J44 (3-ZH)

Sideshift microswitch SW

open 5V closed 0V

J40 (4-AB)

J48 (4-AB) J45 (3-AB)

4th Way

open 5V closed 0V

J40 (5)

−

Unused

J40 (6-L)

ALL NEGATIVE

Negative

GND

J40 (7-AG)

J48 (7-AG) J41 (1-AG)

VCC lifting potentiometer P3

5V

J40 (8-HG)

J48 (8-HG) goes to the resistance CAN L R3 1Kohm and to J48 (13-AN)

Low Signal

J40 (9-HN)

J48 (9-HN) J41 (3-HN)

N POT negative of the lifting potentiometer

J40 (10-AR)

J48 (2-AR) J43 (3-AR)

Tilting forward SW12

J40 (11-V)

J48 (11-V) J41 (2-V)

C POT

J40 (12)

−

AUX IN 3 _ Unused

−

J40 (13)

−

AUX IN 1_ Unused

−

J40 (14)

−

AUX IN 2_ Unused

−

J40 (15-AN)

J48 (13-AN) goes to the resistance CAN H R3 1Kohm and to J48 (8-HG)

J40 (16)

−

J40 (17-N)

ALL negative

J40 (18)

−

J40 (19-BC)

J23 (1-BC) J24 (1-BC)

AUX IN 1_Unused

GND open 5V closed 0V 0V-5V

Signal HIGH −

Negative

GND

AUX IN 4_Unused

24V

AUX OUT 2_Lowering valve (optional EV12)

-

Remarks

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Connector. ⇔ Connector From ⇔ To

Description

Standard:

J40 (20-R07)

J34 (11-R07) J40 (21-R07) J40 (24-R07) J50 (1-R07)

(+) 24V AUX

(+) battery voltage

J40 (21-R07)

J34 (11-R07) J40 (20-R07) J40 (24-R07) J50 (1-R07)

(+) 24V AUX

(+) battery voltage

J40 (22)

−

AUX OUT 3_ Unused

24V

J40 (23)

−

AUX OUT 4_ Unused

24V

Remarks

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CPU BOARD MHYRIO Basic conditions (battery plug connected, key switch ON) [Mini-lever specification vehicle] See the reference names of the connectors in the electrical diagram.

Connector. ⇔ Connector From ⇔ To

Description

Standard:

JCM (1-GN)

J107 (2-GN)

Input lowering valve EVP1

JCM (2-G)

J107 (1-G) J108 (1-G)

Feeding lowering valve EVP1 and lifting valve EV2

JCM (3-BG)

J108 (2-BG)

Input lifting valve EV2

JCM (4-BM)

J109 (2-BM)

Input tilt forward valve EVP3

JCM (5-M)

J109 (1-M) J110 (1-M)

Feeding tilt forward valve EVP3 and tilt backward valve EVP4

JCM (6-MN)

J110 (2-MN)

Input tilt backward valve EVP4

JCM (7-ZN)

J111 (2-ZN)

Input left sideshift valve EVP5

JCM (8-Z)

J111 (1-Z) J112 (1-Z)

Feeding left sideshift valve EVP5 and right sideshift valve EVP6

JCM (9)

−

5th way

−

JCM (10)

−

5th way

−

JCM (11)

−

Unused

−

JCM (12-BV)

J113 (2-BV)

Input 4th way EV7

JCM (13-V)

ϑ113 (1−ς) J114 (1-V)

Feeding 4th way EV7

JCM (14-NV)

J114 (2-NV)

Input 4th way EV8

JCM (15-BZ)

J112 (2-BZ)

Input right sideshift valve EV6

JCM (16)

-

5th way

−

JCM (17)

-

5th way

−

JCM (18)

-

Unused

JCM (19-BC)

J117 (2-BC)

Input drain valve EVP

JCM (20-C)

J117 (1-C)

Feeding drain valve EVP

JCM (21)

−

Unused

JCM (22)

−

Unused

JCM (23-N)

J150 (3-N) J48 (14-N)

Negative

JAM (1)

−

Console

JAM (2)

−

Console

GND

Remarks

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Connector. ⇔ Connector From ⇔ To

Description

Standard:

JAM (3)

−

Console

JAM (4)

−

Console

JAM (5)

−

Console

JAM (6)

−

Console

JAM (7)

−

Console

JAM (8)

−

Console

J140 (1-R07)

J48 (1-R07)

Feeding

24V

J140 (2-R07)

J140 (1-R07)

Feeding

24V

J140 (3-N)

JCM (23-N)

Negative (-) Batt.

GND

J140 (4-HG)

J48 (8-HG)

CAN LOW

J140 (5)

−

Unused

J140 (6)

−

Unused

J140 (7)

−

Unused

J140 (8)

−

Unused

J140 (9)

−

Unused

J140 (10)

−

Unused

J140 (11)

−

Unused

J140 (12)

−

Unused

J140 (13-AN) J140 (14)

J48 (13-AN) −

CAN HIGH Unused

Low signal

High signal

Remarks

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CPU BOARD ARMREST BOARD Basic conditions (battery plug connected, key switch ON) [Mini-lever specification vehicle] See the reference name of the connector in the electrical diagram Connector. ⇔ Connector From ⇔ To

Description

Standard:

J138 (1-N)

J131 (3-N) J138 (3-N)

Negative

GND

J138 (2-HG)

J131 (1-HG)

CAN L

Signal LOW

J138 (3-N)

J131 (3-N) J138 (1-N)

Negative

GND

J138 (4-AN)

J131 (2-AN)

CAN H

Signal HIGH

J138 (5-CR)

J131 (4-CR)

Input

24V

J138 (6)

−

Unused

-

J138 (7)

−

Unused

-

J139 (1-V)

J138 (1-V)

Negative

GND

J139 (2-M)

J138 (2-M)

CAN L

Signal LOW

J139 (3-V)

J138 (3-V)

Negative

GND

J139 (4-B)

J138 (4-B)

CAN H

Signal HIGH

J139 (5-G)

J138 (5-G)

Input

24V

Remarks

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CONTROLLER MAIN CONTROLLER Inverter for AC asyncronous 3-phase motors Regenerative braking functions Can-bus interface Digital control based upon a microcontroller Voltage 24 Maximum current 500A (RMS) for 3' Operating frequency 8kHz External temperature range -30°C ÷ 40°C Maximum inverter temperature (at full power)100°C

OPERATIONAL FEATURE - Speed control.

- Very good behaviour on 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.

- Very good 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 numeric display.

- Modification of parameters through the programming instrument panel interface.

- 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) truck stopped: the power steering starts only if the steering is moved.

2) truck in movement: the power steering starts after 1km/h and the RpM of the lifting motor are proportional to the speed of the steering rotation.

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, phases’ voltages, contactor drives, can-bus interface, if the switch sequence for operation is correct and if the output of the accelerator unit is correct.

2 Standby diagnosis at rest that checks: watchdog circuit, phases’ voltages, contactor driver, current sensor, can-bus interface.

3 Diagnosis during operation that checks: watchdog circuits, contactor driver, current sensors, canbus interface.

4 Continuous diagnosis that checks: temperature of the inverter.

Diagnosis is provided in two ways.

- the diagnostic ERROR DISPLAY placed to the dashboard that shows the code number for a given alarm.

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

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GENERAL PRECAUTIONS - 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 the battery charge, disconnect the INVERTER from the battery.

- Supply the INVERTER 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 capacitors remain 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 - 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 100°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 starts.

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

Drive requests must be made after closing the key switch.

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REMOVAL • INSTALLATION Before starting the job, measure the voltage between (+) and GND; if there is any voltage, insert a resistor at approx. 100Ω between (+) and GND to discharge the capacitor.

TRACTION LOGIC UNIT

LIFTING LOGIC UNIT

Removal Procedure 1 Remove the rear platic 2 Move the seat forward.

3 Move the lever of the mechanic control valve forward (only with mechanic control valve version) 4 Open the battery cover 5 Disconnect the battery plug.

6 Disconnect the wiring and the power cables of the main controller.

7 Remove the main controller.

Installation Procedure The installation procedure is the reverse of the removal procedure.

Whenever one of the logic units has been disassembled, rimember to restore the thermic transmission paste layer between the logic unit and the heat radiant structure, the counterweight. This white colour product consisting of powdered metal oxides (ceramic) compounded in a silicone oil base. It must be spreaded in a thiny film on one of the two assembly surfaces and then you can proceed to the reassembly.

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MHYRIO LOGIC UNIT OPERATIONAL FEATURE It works to 24 V and it is located on the left side of the truck below the left tilting cylinder. The Mhyrio card receives the digital inputs from the CAN and it converts them in analogic signals to control the solenoid valves with.

JCM

J140

In the front it has three connectors: - connector JCM is used to control the solenoid valves.

- connector J140 is used for the CAN and the feeding.

N (black cable) negative (pin 3 connector J140) R07 (red) positive to 24V (pin 1 connector 140 ) R07 (red) positive to 24V (pin 2 connector 140 ) AN (light blu/black cable) CAN H (high) (pin 13 connector J140) HG (grey/yellow cable) CAN L (low) (pin 4 connector J140)

Voltage supplied to the ON-OFF valve coil: battery voltage Voltage supplied to the proportional valve coil: aproximatelly 12 V

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ARMREST BOARD The armrest board, located in the bottom side of the seat arm, is present in fingertips / joysticks truck version.

The fingertips / joysticks version requires also the use of an additional logic unit (Mhyrio) FUNCTIONS It controls and converts from analogic to digital the fingertips / joysticks potentiometers signals in order to drive, via Mhyrio, the electric distibutor, equipped with solenoid valves.

It also controls the signals of the forward / backward directions lever.

J138 = connector for the can bus comunication and the feeding.

J400 J401 J402 J403 J138 J404 J405

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REMOVAL • INSTALLATION

Removal Procedure 1 Lift the battery cover 2 Disconnect the battery plug 3 Remove the foot board.

4 Disconnect the wiring loom 5 Remove the fixing screws 6 Remove Mhyrio control valve.

Installation Procedure The installation procedure is the reverse of the removal procedure.

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MASTER CONTROLLER I/O - INPUT / OUTPUT CARD The card is located on the left side of the truck under the footboard. It controls and converts analogical signals to digital signals and vice versa.

REMOVAL • INSTALLATION

Removal Procedure 1 Remove the footboard.

2 Disconnect the connectors on the IO master card.

3 Remove the fixing screwes.

4 Replace the card.

Installation Procedure The installation procedure is the reverse of the removal procedure.

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MATERIAL HANDLING AC DRIVER, CONTACTOR PANEL REMOVAL • INSTALLATION Caution: Before starting the job, measure the voltage between (+) and GND; if there is any voltage, insert a resistor at approx. 100Ω between (+) and GND to discharge the capacitor.

Removal Procedure 1 Remove the rear platic 2 Move the seat forward.

3 Move the lever of the mechanic control valve forward (only with mechanic control valve version) 4 Open the battery cover 5 Remove the two fixing screws of the battery connector group 6 Disconnect the popwer cables from the contactors 7 Remove the contactors Installation Procedure The installation procedure is the reverse of the removal procedure.

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INSPECTION 1.

MB (power supply contactor) Inspection method Disconnect the connector from the wiring loom, and measure the resistance of the coil.

Portion Measurement Standard Tester range to be terminals inspected Approx.

Both termi111 Ω (at Coil CT1 nals of the coil 20°C)

Ω ×1

Approx.

Both termi25 Ω (at nals of the coil 20°C)

Ω ×1

Coil CT2

2.

F1 F2 F3 F4

FUSE Inspection method Disconnect the fuse and measure the insulation resistance Portion Measurement Standard Tester range to be terminals inspected FUSES

Both terminals of fuse

0Ω

Ω ×1

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CHECK TRACTION MOTOR PHASES BALANCING When traveling or material handling operation seems abnormal, it is possible to accurately judge if the controller is functioning correctly or not by measuring the motor phase balancing.

Measuring method Procedure using a clamp amperometer (1) Remove the rear plastic.

(2) Jack up the front wheels.

(3) Connect a clamp amperometer (4) Selct a direction,shift the direction switch to the forward (or backward) position, and start the machine with low speed.

(5) Check the value of the current of each phase .

(6) If the value of one phase is higher or lower respect the others it means that the system is not balanced and the motor goes jerkling. In this situation the logic unit must be replace Measuring method Procedure using a multemeter (7) Remove the rear plasic.

(8) Jack up the front wheels.

(9) Set the multemeter in Volt AC. (10) Connect the negative of the multemeter on the battery negative.

(11) Connect the positive on one of the phase of the logic unit.

(12) Check the value of the voltage of each phase.

(13) If the value of one phase is higher or lower respect the others it means that the system is not balanced and the motor goes jerkling. In this situation the logic unit must be replace.

In order to compere the value of the phases it is necessary to use the same tool and not different type of multemeters or clamp amperometers for each phases. This because the tool have different tollerance respect each others.

Measuring method Procedure using a multemeter

Measuring method Procedure using a clamp amperometer

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CHECK LIFTING MOTOR PHASES BALANCING Measuring method Procedure using a clamp amperometer (1) Remove the rear plastic.

(2) Jack up the front wheels.

(3) Connect a clamp amperometer (4) Selct a direction,shift the direction switch to the forward (or backward) position, and start the machine with low speed.

(5) Check the value of the current of each phase .

(6) If the value of one phase is higher or lower respect the others it means that the system is not balanced and the motor goes jerkling. In this situation the logic unit must be replace Measuring method Procedure using a clamp amperometer (7) Remove the rear plasic (8) Jack up the front wheels (9) Set the multemeter in Volt AC (10) Connect the negative of the multemeter on the battery negative (11) Connect the positive on one of the phase of the logic unit (12) Check the value of the voltage of each phase (13) If the value of one phase is higher or lower respect the others it means that the system is not balanced and the motor goes jerkling. In this situation the logic unit must be replace In order to compere the value of the phases it is necessary to use the same tool and not different type of multemeters or clamp amperometers for each phases. This because the tool have different tollerance respect each others.

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REASSEMBLY Contactor Panel Assembly Drawing T=N·m

Caution: Be sure to install insulating sheets without fail.

• Failure to install the insulating sheet under the MB contactor will cause a critical failure.

• Check the insulation resistance between the bracket and each P terminal after controller reassembly.

Standard: 10 MΩ or more

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DISPLAY If the cause of trouble is judged to exist in the display, measure the voltage at the connector to which voltage is applied.

Connector No. ⇔ Connector No. J131 (4-CR)

J137 (5-CR)

Conditions Feeding

Standard: 24V

Parking brake ON warning light Brake fluid low level warning light.

This warning light comes ON when the level of brake fluid in the tank has reached the minimum level.

Lifting speed reduction due to flat battery ‘Present man device’ warning light: The pilot light comes ON when the driver leaves the driving seat without switching OFF the truck; under these conditions, the traction and the lifting movement are disabled.

Drive motor temperature warning light: - lights up when the temperature is 130°C (See page 4-17).

Lifting motor temperature warning light: - lights up when the temperature is 130°C (See page 4-29).

Diagnostic code alphanumeric display: When a malfunction occurs in the truck, this display identifies the error through a corresponding code (See page 5000-51).

Forward/backward indication lights.

Steering wheel position.

Remarks

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Speed reduction indication light: When the reduction speed is selected the blue light is on.

Adjustable electronic hour meter: It is activated by insertion of the ignition key and it conts the real working time of the truck. It shows the working hoursand hours fractions (in tenth).

Selected setting display: Indicates the running setting selected: This bar consists of 3 green LEDS on the right side, 4 orange LEDS in the middle and 3 red LEDS on the left side; when the battery is charged the first green LED on the right is On; while the battery discharges, the LEDS turn On or Off, one per time, from the right to the left according to the battery charging status. When the battery is 80% discharged, the first red LED on the left side is On, the display shows the alarm code 1C (See page 5000-67), the lifting speed is reduced.

Note: the battery charge indicator does not rearm if the battery charging status is between 70% and 100%.

Light sensor: It changes automatically the light intensity of the LEDS in the dashboard according to the light of the environment.

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ACCELERATOR POTENTIOMETER ADJUSTMENT 1.

2.

3.

Check the ON/OFF condition of the switch SW8 (single pedal) SW4 - SW5 (double pedal).

Measurement terminals

Status

Pedal not operated

∞Ω

Pedal operated

Continuity

Standard:

4.

Adjustment of Accelerator Potentiometer (P2) Installation (1) Before installing a new traction potentiometer it is suggest to check it with an anlalogical multemeter. Move slowly the wiper until the maximum stroke and in the same time check if the multemeter increases or decreases the value proportionally with the movement.

(2) Install the potentiometer and connect it to the wiring loom of the machine.

(3) After closing the microswitch the voltage on the wiper of the potentiometer has to be aproximately 1,6V and 3,2V to the maximum stroke. This measure is referred to its negative.

(4) Once the potentiometer is well fixed do the Vacc setting.

(5) After adjusting the switch ON/OFF operation, apply yellow paint to the head of a set screw.

Measurement terminals

Status

J32 (3-AG)

10V

J32 (2-HN)

GND

J32 (1-V)

1,6V - 3,2V

Standard::

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BRAKE SWITCH ADJUSTMENT FOOT BRAKE 1.

2.

3.

4.

Aproximately 1mm Clearence of the brake pedal in neutral position

5.

Adjust brake pedal play.

Aproximately 1mm Adjust brake rod length.

Check continuity of the switch for reduction spee Standard: Not operated: OFF (∞ Ω ) Operated: ON (0Ω) Check that the switch for the regenerative brake turns ON (OFF) when the brake pedal is depressed from the neutral position without any play.

Standard: Not operated: ON (0Ω ) Operated: OFF (∞ Ω )

If the standard is not met, adjust the switch position.

PARKING BRAKE 1.

2.

Check the ON/OFF operation of the parking brake limit switch.

Standard: Lever returned to original position: ON (0Ω) Lever pulled: OFF (∞ Ω) If the standard is not met, adjust the switch installation location.

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BEFORE TROUBLESHOOTING CONNECTOR HANDLING 1.

2.

3.

4.

5.

6.

Disconnect the battery plug before connecting or disconnecting each connector or terminal.

When disconnecting a connector, do not pull it at the harness but hold the connector itself and pull it after unlocking it.

To connect, push the connector fully until it is locked in position.

Bring a tester probe into contact with a connector terminal from the rear side of the coupler (harness side).

If insertion from the rear side is impossible, as in the case of a waterproof connector, bring the tester probe carefully into contact with the terminal so as not to cause deformation of the connector terminal.

Do not touch connector terminals directly with your hand.

When bringing tester probes into contact with live terminals, prevent two tester probes from coming into contact with each other.

WIRE HARNESS AND CONNECTOR INSPECTION PROCEDURE When any trouble occurs, first inspect the connectors and wire harness of the related circuit according to the following procedure: Continuity check 1. Disconnect the connectors at both ends of the corresponding harness.

2. Measure the resistance between corresponding terminals of the connectors at both ends.

Standard:10 W or less Note: Measure while lightly shaking the wire harness up and down and sideways.

Reference: Open circuit at the wire harness occurs rarely partway through a vehicle wiring but mostly at connectors.

Inspect especially the sensor connectors with sufficient care.

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Short circuit check 3. Disconnect the connectors at both ends of the corresponding harness.

4. Measure the resistance between the corresponding connector terminal and GND. Always inspect the connectors at both ends.

Standard: 1 MΩ or more Note: Measure while lightly shaking the wire harness up and down and sideways.

5.

Measure the resistance between a terminal corresponding to the connector terminal and N1.Always inspect the connectors at both ends.

Standard: 1 MΩ or more Note: The wiring may short-circuit due to pinching by the body or defective clamping.

Visual and contact pressure checks • Disconnect the connectors at both ends of the corresponding harness.

• Visually inspect that there is neither rust nor foreign matter trapped at connector terminals.

• Inspect that there is no loosening or damage at the locked portion. Also, lightly pull the wire harness from the connector to check that it does not come off.

• Insert a male terminal same as that of the terminal to a female connector and check the extracting force.

Defective contact may exist at a terminal where the extracting force is less than that of other terminals.

Note: Even if there is rust or foreign matter trapped at the terminal, or the contact pressure between male and female terminals is low, abnormal contact condition may be changed to normal by disconnecting and reconnecting the connector.In that case, repeat connector connection and disconnection several times. If defect is perceived even once, terminal contact may be defective.

The above information, concerning the inspection of the connectors, are referred to specific type as shown in the drawing. The same procedure must be apply for all type found on the machines.

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SYSTEM CONFIGURATION WITH MECHANIC CONROL VALVE

READER

DASHBOARD

I/O CONTROL BOARD Mechanical control valve

MASTER OF THE SYSTEM

Potentiometers, micro switches.

Steering potentiometer

LIFTING LOGIC UNIT

TRACTION LOGIC UNIT

Encoder

CAN BUS

Encoder

ANALOGICAL

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SYSTEM CONFIGURATION WITH ELECTRIC CONROL VALVE

DASHBOARD

READER MASTER OF THE SYSTEM

Joysticks

MHYRIO

I/O CONTROL BOARD

ARMREST BOARD

Electric control valve

MASTER OF THE LIFTING LOGIC UNIT

Potentiometers, micro switches.

Steering potentiometer

LIFTING LOGIC UNIT

TRACTION LOGIC UNIT

Encoder

CAN BUS

Encoder

ANALOGICAL

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DIAGNOSIS CODE LIST When an Error Code is Displayed Displayed code

Alarm Specification

Error mode

Page

01

WATCHDOG

TRACTION LOGIC UNIT: self-diagnostic test.

57

02

EEPROM KO

TRACTION LOGIC UNIT: fault in the area of memory. 57

03

LOGIC FAILURE #3 TRACTION LOGIC UNIT: logic defect.

04

LOGIC FAILURE #2

TRACTION LOGIC UNIT: fault in the hardware section

57

05

LOGIC FAILURE #1

TRACTION LOGIC UNIT: protection against undervoltage/overvoltage.

58

06

VMN LOW

TRACTION LOGIC UNIT: failure in the VMN test.

58

07

VMN HIGH

TRACTION LOGIC UNIT: failure in the VMN test.

59

08

CONTACTOR OPEN

TRACTION LOGIC UNIT: failure on the contactor driver.

59

09

STBY I HIGH

TRACTION LOGIC UNIT: failure on the current sensor.

60

10

CAPACITOR CHARGE

TRACTION LOGIC UNIT: capacitors not charged.

60

11

HIGH TEMPERATURE

TRACTION LOGIC UNIT: logic unit’s temperature higher than 75°C.

60

12

MOTOR TEMPERATURE

TRACTION LOGIC UNIT: sensor of traction motor opened.

61

13

ENCODER ERROR

TRACTION LOGIC UNIT: fault of the encoder’s circuit.

62

14

THERMIC SENSOR KO

TRACTION LOGIC UNIT: internal sensor of the logic unit out of range.

63

15

SAFETY

TRACTION LOGIC UNIT: protection activated.

63

16

CAN BUS KO

TRACTION LOGIC UNIT: it is detecting a no comuni63 cation of another card.

17

WAITING FOR NODE

TRACTION LOGIC UNIT: it is detecting a delay in data transfer.

64

18

AUX OUTPUT KO

TRACTION LOGIC UNIT: failure on the contactor driver.

64

19

DRIVER SHORTED

TRACTION LOGIC UNIT: failure on the contactor driver.

64

20

CONTACTOR DRIVER

TRACTION LOGIC UNIT: failure on the contactor driver.

64

21

COIL SHORTER

TRACTION LOGIC UNIT: failure on the contactor driver.

65

22

UNUSED

UNUSED

65

23

INCORRECT START

TRACTION LOGIC UNIT: incorrect starting procedure.

65

24

UNUSED

UNUSED

65

57

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When an Error Code is Displayed Displayed code

Alarm Specification

25

WRONG SET BAT- TRACTION LOGIC UNIT: battery voltage out of TERY range.

26

REMOTE INPUT

TRACTION LOGIC UNIT: incorrect starting procedure.

66

27

UNUSED

UNUSED.

66

28

STEER SENSOR KO

TRACTION LOGIC UNIT: steering potentiometer out of range.

66

29

FORW + BACK

TRACTION LOGIC UNIT: incorrect starting procedure.

66

30

UNUSED

UNUSED.

66

31

WATCHDOG

LIFTING LOGIC UNIT: self-diagnostic test.

69

32

EEPROM KO

LIFTING LOGIC UNIT: fault in the area of memory.

69

33

LOGIC FAILURE #3 LIFTING LOGIC UNIT: logic defect.

69

34

LOGIC FAILURE #2 LIFTING LOGIC UNIT: fault in the hardware section

69

35

LOGIC FAILURE #1

LIFTING LOGIC UNIT: protection against undervoltage/overvoltage.

70

36

VMN LOW

LIFTING LOGIC UNIT: failure in the VMN test.

70

37

VMN HIGH

LIFTING LOGIC UNIT: failure in the VMN test.

71

38

CONTACTOR OPEN

LIFTING LOGIC UNIT: unused

71

39

STBY I HIGH

LIFTING LOGIC UNIT: failure on the current sensor.

71

40

CAPACITOR CHARGE

LIFTING LOGIC UNIT: capacitors not charged.

72

41

HIGH TEMPERATURE

LIFTING LOGIC UNIT: logic unit’s temperature higher 72 than 75°C.

42

MOTOR TEMPERATURE

LIFTING LOGIC UNIT: sensor of lifting motor opened. 73

43

ENCODER ERROR LIFTING LOGIC UNIT: fault of the encoder’s circuit.

74

44

THERMIC SENSOR KO

LIFTING LOGIC UNIT: internal sensor of the logic unit out of range.

75

45

SAFETY

LIFTING LOGIC UNIT: protection activated.

75

46

CAN BUS KO

LIFTING LOGIC UNIT: it is detecting a no comunication of another card.

75

47

WAITING FOR NODE

LIFTING LOGIC UNIT: it is detecting a delay in data transfer.

76

48

AUX OUTPUT KO

LIFTING LOGIC UNIT: failure on the contactor driver.

76 Unused.

49

DRIVER SHORTED

LIFTING LOGIC UNIT: failure on the contactor driver.

76 Unused.

50

CONTACTOR DRIVER

LIFTING LOGIC UNIT: failure on the contactor driver.

76 Unused

Error mode

Page 66

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When an Error Code is Displayed Displayed code

Alarm Specification

Error mode

51

COIL SHORTER

LIFTING LOGIC UNIT: failure on the contactor driver.

76 Unused

52

UNUSED

UNUSED

76

53

INCORRECT START

LIFTING LOGIC UNIT: incorrect starting procedure.

76

54

UNUSED

UNUSED

76

55

WRONG SET BATLIFTING LOGIC UNIT: battery voltage out of range.

TERY

77

56

REMOTE INPUT

LIFTING LOGIC UNIT: incorrect starting procedure.

77

57

WAITING MHYRIO

LIFTING LOGIC UNIT: it is detecting a delay in data transfer of Mhyrio logic unit.

77

58

I=0 EVER

LIFTING LOGIC UNIT: failure on the current sensor.

77

59

SEAT KO

LIFTING LOGIC UNIT: one of the logic unit traction or 78 lifting does not see the seat microswitch closed.

80

UNUSED

UNUSED

81

INCORRECT START

I/O CONTROL BOARD: incorrect starting procedure.

94

82

UNUSED

I/O CONTROL BOARD: UNUSED

94

83

PEDAL WIRE KO

I/O CONTROL BOARD: failure on the acceleration potentiometer signal at rest.

94

84

BAD MICROSWITCH

I/O CONTROL BOARD: general alarm of broken micro switch.

94

85

WARN CONFIG ERROR

UNUSED.

95

86

BAD VACC

I/O CONTROL BOARD: failure on the acceleration potentiometer signal at rest.

95

87

ERR SEAT

I/O CONTROL BOARD: does not see the seat microswitch closed.

95

88

UNUSED

I/O CONTROL BOARD: UNUSED.

95

89

PARKING SELECTED

I/O CONTROL BOARD: failure on parking brake.

95

90

UNUSED

I/O CONTROL BOARD: UNUSED.

91

CONFIG ERROR

I/O CONTROL BOARD: configuraion problem.

96

92

BOOT ERROR

I/O CONTROL BOARD: comunication problem

96

93

NOT REP ERROR

I/O CONTROL BOARD: comunication problem

97

94

CHKSUM ERROR

I/O CONTROL BOARD: replace the I/O Control Board.

91

1A

UNUSED

TRACTION LOGIC UNIT: UNUSED.

67

1C

BATTERY LOW

TRACTION LOGIC UNIT: battery discharged.

67

1E

CONTACTOR CLOSED

TRACTION LOGIC UNIT: failure on the contactor driver.

67

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When an Error Code is Displayed Displayed code

Alarm Specification

Error mode

Page

2A

CHOPPER NOT CONFIG.

TRACTION LOGIC UNIT: UNUSED.

67

2C

GAIN ACQUISITION

TRACTION LOGIC UNIT: the logic unit is during the acquisition data phase.

68

2E

HANDBRAKE

TRACTION LOGIC UNIT: failure on the brake switch. 68

3A

UNUSED

UNUSED.

3C

UNUSED

UNUSED.

3E

UNUSED

UNUSED.

4A

UNUSED

LIFTING LOGIC UNIT: UNUSED.

78

4C

BATTERY LOW

LIFTING LOGIC UNIT: battery discharged.

78

4E

UNUSED

LIFTING LOGIC UNIT: UNUSED.

78

5A

CHOPPER NOT CONFIG.

LIFTING LOGIC UNIT: UNUSED.

78

5C

GAIN ACQUISITION

LIFTING LOGIC UNIT: the logic unit is during the acquisition data phase.

79

5E

UNUSED

LIFTING LOGIC UNIT:UNUSED

79

8A

PARAM LOAD ERROR

I/O CONTROL BOARD: replace the IO Control Board 95

8B

TRAC IN ALARM

I/O CONTROL BOARD: general alarm

95

8C

TRAC STAFFING ERR

I/O CONTROL BOARD: comunication problem with the traction logic unit.

96

8E

UNUSED

I/O CONTROL BOARD: UNUSED

96

8F

FW + BW

I/O CONTROL BOARD: double request activated

96

A1

EEPROM KO

MHYRIO: fault in the area of memory in which the adjustment parameters are stored

80

A2

EV DRIVEN SHORT

MHYRIO: one of the on/off valves driver is shorted

80

A3

CAN BUS KO

MHYRIO: failure of the can bus comunication

80

A4

FF VALVES

MHYRIO: problem in the hardware circuit.

81

A5

UNUSED

MHYRIO: UNUSED

81

A6

EVPG1 DRIV SHORT

MHYRIO: one of the valve drivers is shorted

81

A7

EVPG2 DRIV SHORT

MHYRIO: one of the valve drivers is shorted

82

A8

EVPG3 DRIV SHORT

MHYRIO: one of the valve drivers is shorted

82

A9

EVPG4 DRIV SHORT

MHYRIO: one of the valve drivers is shorted

83

AA

WRONG SET BATMHYRIO: set battery programmed TERY

83

AB

HI SIDEDRIVER KO

83

MHYRIO: problem in the hardware circuit.

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When an Error Code is Displayed Displayed code

Alarm Specification

Error mode

Page

AC

EVPG1 DRIVER KO

MHYRIO: one of the valve drivers is open

84

AD

EVPG2 DRIVER KO

MHYRIO: one of the valve drivers is open

84

AE

EVPG3 DRIVER KO

MHYRIO: one of the valve drivers is open

85

AF

EVPG4 DRIVER KO

MHYRIO: one of the valve drivers is open

85

B0

COIL SHORTED

MHYRIO: if a short is present across the coil, the alarm is signalled.

86

B1

UNDER VOLTAGE

MHYRIO: undervoltage condition

86

B2

EVP DRIVER KO

MHYRIO: the valve’s driver is open

87

B3

EV DRIVER KO

MHYRIO: one of the On/Off valves drivers is open

87

B4

WATCHDOG

MHYRIO: it is a self-diagnosing test within the logic.

88

B5

EVP DRIVER SHORTED

MHYRIO: the valve’s driver is shorted

88

B1

UNUSED

DASH: UNUSED

92

B2

UNUSED

DASH: UNUSED

92

B3

UNUSED

DASH: UNUSED

92

B4

UNUSED

DASH: UNUSED

92

B5

UNUSED

DASH: UNUSED

92

B6

MHYRIO KO

DASH: the dasboard does not see the Mhyrio logic unit

92

B8

UNUSED

DASH: UNUSED

92

C1

STOP OPEN

I/O CONTROL BOARD: failure on the stop lights.

97

C2

ANT OPEN OR POST OPEN

I/O CONTROL BOARD: failure on the working lights

97

C3

UNUSED

I/O CONTROL BOARD: UNUSED

97

C4

RETRO OPEN

I/O CONTROL BOARD: failure on the reverse lights

97

C5

UNUSED

I/O CONTROL BOARD: UNUSED

97

C6

UNUSED

I/O CONTROL BOARD: UNUSED

97

C7

UNUSED

I/O CONTROL BOARD: UNUSED

97

C8

CIC OPEN OR LAMP OPEN

I/O CONTROL BOARD: failure on the reverce sound alarm or rotary lamp

98

D1

TRAC KO

DASH: the dasboard does not see the traction logic unit.

92

D2

SIO KO

DASH:the dasboard does not see the IO control board.

92

D3

UNUSED

DASH: UNUSED

92

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When an Error Code is Displayed Displayed code

Alarm Specification

Error mode

D4

PUMP KO

DASH:he dasboard does not see the lifting logic unit. 93

D5

UNUSED

DASH: UNUSED

93

D6

UNUSED

DASH: UNUSED

93

D7

UNUSED

DASH: UNUSED

93

D8

JOY KO

DASH: the dasboard does not see the armrest board 93

E1

INCORRECT START

ARM CARD: incorrect starting procedure.

89

E2

BAD LIFT POT

ARM CARD: failure on the lifting potentiometer.

89

E3

BAD TILT POT

ARM CARD: failure on the tilting potentiometer.

89

E4

BAD SIDESH. POT ARM CARD: failure on the sideshift potentiometer.

89

E5

BAD IV POT

ARM CARD: failure on the 4th way potentiometer.

89

E6

BAD V POT

ARM CARD: failure on the 5th way potentiometer.

90

E7

DEFAULT RESTORED

ARM CARD: warning alarm.

90

E8

INVALID RESTORE ARM CARD: failure of the restore default parameter STATE operation.

90

E9

EEPROM INCONSISTENCY

90

EA

MHYRIO OR PUMP ARM CARD: this alarm shows that an alarm in ALARM present in both Mhyrio logic unit and lifting logic unit.

90

EB

MATCHING ERROR

ARM CARD: control of the neutral position of the potentiometers.

91

EC

CHKSUM ERROR

ARM CARD: replace the Armrest Board.

91

ED

MHYRIO STUFFING ERR

ARM CARD: comunication problem.

91

EE

PUMP STUFFING ERR

ARM CARD: comunication problem.

91

EF

FW + BW

ARM CARD: incorrect starting procedure.

91

ARM CARD: replace the Armrest Board.

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WHEN AN ERROR CODE IS DISPLAYED TRACTION LOGIC UNIT 01

WATCHDOG

Condition for error detection The test is made in both running and standby situation. It is a self-diagnosing test of the logic.

This alarm could also be caused by the canbus malfunctioning.

Therefore, before replacing the controller check the canbus.

02

EEPROM KO

Condition for error detection Fault in the area of memory in which the adjustment parameters are stored; this alarm inhibists the truck operation, but the controller will use default parameters.

If the defect persist when the key is switched OFF and ON again, replace the logic unit.

If the alarm disappears, remember that the parameters previusly stored have been deleted and replaced with the default value.

03

LOGIC FAILURE #3

Condition for error detection Logic defect. Replace the logic unit.

04

LOGIC FAILURE #2

Condition for error detection 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 logic unit.

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CHAPTER 5000 page 57

LOGIC FAILURE #1

Condition for error detection This alarm signals that the interruption of protection against under voltage /over voltage has been triggered.

- UNDER voltage: the logic unit keeps under control the input of key. If the voltage has a peak down the alarm is signalled.

- OVER voltage: the logic unit keeps under control the voltage on the internal capacitors. If that voltage has a peak up (breaking effect) the alarm is signalled.

The possible reasons are: a. Under voltage / over voltage of the battery, or loss of voltage after the ignition key or after the battery connector. b. Battery demage. c. Fault in the hardware section of the logic board which controls the over voltage protection. Logic defect. Replace the traction unit. d. The alarm appears also when one or more phases of the motor doesn't present a correct insulation. Check the motor insulation (with battery disconnected): it must be higher than 10 Mohm. Otherwise check the insulation of the power cables to the motor.

06

VMN LOW

Condition for error detection Failure in the VMN test.

This test starts when the ignition key is turned ON and there is no consuption of ampere. The alarm appears if there is a leakage of current on one or more phases; check the connections of the 3 power cables from the logic unit to the traction motor and the cables condition. In order to point out if the fault is produced by an internal or external cause proceed as follow: connect the traction logic unit to the lifting motor and check if the alarm “06” appears on the display.

YES: repace the logic unit NO: check the traction motor insulation.

Two of the phases of the motor are kept under control by shunts. If the logic unit detects a leakage of current keeps the truck stopped.

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VMN HIGH

Condition for error detection Failure in the VMN test.

This test starts when the ignition key is turned ON and there is no consuption of ampere. The alarm appears if one or more pover cables are not connected; check the connections of the 3 power cables from the logic unit to the traction motor and the cables condition. In order to point out if the fault is produced by an internal or external cause proceed as follow: connect the traction logic unit to the lifting motor and check if the alarm “07” appears on the display.

YES: repace the logic unit NO: check the traction motor insulation.

Two of the phases of the motor are kept under control by shunts. If the logic unit detects a leakage of current keeps the truck stopped.

08

CONTACTOR OPEN

Condition for error detection Failure on the contactor driver CT2.

- Check main contactors coils and relevant wirings.

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CHAPTER 5000 page 59

STBY I HIGH

Condition for error detection Failure on the current sensor.

- Replace the traction logic units.

10

CAPACITOR CHARGE

Condition for error detection When the key is switch ON, the inverter tries to charge the capacitors through a power resistance, and check if the capacitors are charged within a timeout. If they do not charge, an alarm is signalled; the main contactor is not closed.

- Check the negative connection.

- Check voltage in the input of the key: battery voltage must be present.

- Execute a bridge between the key terminals.

- Replace the traction unit .

11

HIGH TEMPERATURE

Condition for error detection Chopper temperature is higher than 75°C. The maximum current is reduced proportionally to the temperature increase. The chopper stops at 100°C. If the alarm is signalled when the chopper is cold: - Replace the logic unit.

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12

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MOTOR TEMPERATURE

Condition for error detection This warning is signalled when the motor temperature sensore reaches 130°C. After 130°C the logic unit reduces linearly the current until 150°C (= I max /2).

After 150°C it cuts completely the current.

If the alarm appears when the motor is cold check: _ if the wiring loom of the temperature sensor is well connected. _ if the temperature sensor is always open or it always has a resistance higher then relevant resistence it has to 130°C (see table here below).

AMBIENT TEMPERATURE RESISTANCE (°C) (°F) (%/K) MIN. TYP.

MAX

-40 -30 -20 -10 0 10 20 25 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300

379 411 446 483 522 563 607 629 652 700 750 801 855 912 970 1030 1096 1164 1235 1309 1385 1463 1544 1628 1714 1803 1894 1988 2085 2184 2286 2390 2496 2600 2700 2791

-40 -22 -4 14 32 50 68 77 86 104 122 140 158 176 194 212 230 248 266 284 302 320 338 356 374 392 410 428 446 464 482 500 518 536 554 572

0.84 0.83 0.82 0.80 0.79 0.77 0.75 0.74 0.73 0.71 0.70 0.68 0.66 0.64 0.63 0.61 0.60 0.58 0.57 0.55 0.54 0.53 0.52 0.51 0.49 0.48 0.47 0.46 0.45 0.44 0.44 0.42 0.41 0.38 0.34 0.29

340 370 403 437 474 514 555 577 599 645 694 744 797 852 910 970 1029 1089 1152 1216 1282 1350 1420 1492 1566 1641 1719 1798 1879 1962 2046 2132 2219 2304 2384 2456

359 391 424 460 498 538 581 603 626 672 722 773 826 882 940 1000 1062 1127 1194 1262 1334 1407 1482 1560 1640 1722 1807 1893 1982 2073 2166 2261 2357 2452 2542 2624

TEMP. ERROR (K) ±6.48 ±6.36 ±6.26 ±6.16 ±6.07 ±5.98 ±5.89 ±5.84 ±5.79 ±5.69 ±5.59 ±5.47 ±5.34 ±5.21 ±5.06 ±4.9 ±5.31 ±5.73 ±6.17 ±6.63 ±7.1 ±7.59 ±8.1 ±8.62 ±9.15 ±9.71 ±10.28 ±10.87 ±11.47 ±12.09 ±12.73 ±13.44 ±14.44 ±15.94 ±18.26 ±22.12

Reduction of current Reduction of current Reduction of current

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CHAPTER 5000 page 61

ENCODER ERROR

Condition for error detection Encoder failure.

This alarm indicates that the encoder information is not correct or is not present.

The encoder transmits signals only when the motor is running. The alarm is detected by the logics when it exceeds 20Hz. Therefore, if an error signal appears on the dashboard and the operator uses the reset key with the machine stopped, the alarm disappears however, it remains stored in the logic.

If the alarm signal starts before reaching 20Hz, the problem can be attributed to a possible wrong insulation of a power cable on the frame: without the encoder correct signals, the machine remains still or moves very slowly. To determine whether the problem is to be attributed to the encoder or to the logic,proceed as follow.

Set the SLIP CONTROL on OFF and speeding up slowly.

Please note that the engine speed increase does not necessary mean that the problem is linked to the encoder. Any of the following components may have a fault: _ The logic internal circuit _ The wiring _ The encoder You may use a digital or analogue TESTER to determine where the problem is located.

Speed sensor basic electric diagram.

The figure shows only one signal (A).

The encoders used have two equal signals, with a despacement of 90°(A-B).

1. Connect the positive of the tester (red pin) to the encoder positive terminal.

2. Connect the COM of the tester (black pin) to the encoder signal (A).

According to the engine position, the following values will be displayed: low signal: 0.5-1.5 Volt high signal: 10.5-11.5 Volt Intermediate values cannot be read as the motoris stopped.

If the motor is running, the multemeter will automatically read the Mv (medium value) Mv= 5.5-6.5 Volt Carrying out this test directly on the logic connector, you can determine if signals are good - see above-mentioned description - or if the channels are opened or in short circuit If the signals are good, the problem should be attributed to the electronic control.

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THERMIC SENSOR KO

Condition for error detection Thermic sensor of the logic unit out of range.

- Replace the logic unit.

15

SAFETY

Condition for error detection Truck locked.

PIN 5 connector JFT = negative input. When the negative is not present the logic unit stops the machine with the alarm safey. It can appear according to the following situation: (1) the wire LV PIN 5 connector JFT is not well connected.

(2) the lifting logic unit detect an alarm and cuts the negative to the PIN 5 connector JFT in order to desable the traction.In this situation check the status of the lifting logic unit.

16

CAN BUS KO

Condition for error detection Failure of the can bus comunication. The alarm appears if the traction logic unit does not receive the information of I/O card or lifting logic unit.

- Check the dashboard’s alarms, before replacing any cards, in order to identify exactly the card which does not comunicate.

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CHAPTER 5000 page 63

WAITING FOR NODE

Condition for error detection Failure of the can bus comunication. The alarm appears if the traction logic unit receives the information of I/O card or lifting logic unit in delay.

- Check if the alarm appears in combination wih others alalms. If yes this is only a consequent.

- Check the dashboard’s alarms, before replacing any cards.

If the alarm appears alone: - check the can bus connector: all wires must be well connected in both the side of the wiring loom.

The alarm can be generated by a false contact.

- if the above tests are negative replace the traction logic unit.

18

AUX OUTPUT KO

Condition for error detection Failure on the contactor driver.

- Replace the traction logic unit .

19

DRIVER SHORTED

Condition for error detection Failure on the contactor driver.

- Check the main contactors coils and relevant wirings.

-If it is not due to external causes, replace the logic unit..

20

CONTACTOR DRIVER

Condition for error detection Failure on the contactor driver.

- Replace the logic unit.

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COIL SHORTED

Condition for error detection Failure on the contactor driver CT2.

- Check the main contactors coils and relevant wirings.

- Control that there are no short-circuits in the wiring and that the resistance value of the coil is correct (25 ohm).

- If it is not due to external causes replace the logic unit.

22

VACC NOT OK

Condition for error detection Failure on the acceleration potentiometer signal at rest. The alarm points out that the voltage value detected on the accelerator potentiometer is 1Volt higher than the least value programmed with the Vacc function. Check: - The traction potentiometer (it could be damaged or not correctly calibrated) - The traction potentiometer wiring.

- Carry out the Vacc setting again.

23

INCORRECT START

Condition for error detection - Seat switch open during traction.

24

UNUSED

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CHAPTER 5000 page 65

WRONG SET BATT

Condition for error detection When the key is turned ON, the controller checks the battery voltage and compares it with the “SET BATTERY” parameter setting. If the actual value is 20% higher or lower than the nominal value, there is a fault. .- Check the status of the battery and if neccessary replace it with a correct one.

26

REMOTE INPUT

Condition for error detection General incorrect starting procedure.

27

UNUSED

28

STEERING SENSOR KO

Condition for error detection This alarm signals that the steering potentiometer is out of range. There is a fault in the following conditions: - the “Set steer 0 pos” (straight wheels programmation) parameter is wrong (lower than “Set steer min” or higher than “Set steer max”).

- the feedback signal of the steering potentiometer is outside the window defined by the “Set steer min” and the “Set steer max” parameters.

In the first case, repeat the steering potentiometer acquisition. In the second case, check the steering potentiometer and its wiring again. In case, repeat once again the steering potentiometer acquisition

29

FORW + BACK

Condition for error detection Incorrect starting sequence.

Check: - Microswitch for forward/backward directions and relevant wires.

30

UNUSED

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1A

UNUSED

1C

BATTERY LOW

Condition for error detection Battery discharge.

2A

CHOPPER NOT CONF

Condition for error detection Traction unit has an erroneous configuration.

1E

CONTACTOR CLOSED

Condition for error detection Failure on the contactor driver. The logic unit cuts the current supply to the coil but the pins remain close.

Check: - the main contactors coils and the relevant wirings.

- clean the tips of the contactor.

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2C

CHAPTER 5000 page 67

GAIN ACQUISITION

Condition for error detection This warning communicates that the logic is in phase of input acquisition. In this phase the logic doesn't work.

2E

HANDBRAKE

Condition for error detection Failure on parking brake switch. It is open.

Check: - the status of the parking brake microswitch and the relevant cables.

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LIFTING LOGIC UNIT 31

WATCHDOG

Condition for error detection The test is made in both running and standby situation. It is a self-diagnosing test of the logic.

This alarm could also be caused by the canbus malfunctioning.

Therefore, before replacing the controller check the canbus.

32

EEPROM KO

Condition for error detection Fault in the area of memory in which the adjustment parameters are stored; this alarm inhibists the truck operation, but the controller will use default parameters.

If the defect persist when the key is switched OFF and ON again, replace the logic unit.

If the alarm disappears, remember that the parameters previusly stored have been deleted and replaced with the default value.

33

LOGIC FAILURE #3

Condition for error detection Logic defect. Replace the logic unit.

34

LOGIC FAILURE #2

Condition for error detection 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 logic unit.

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CHAPTER 5000 page 69

LOGIC FAILURE #1

Condition for error detection This alarm signals that the interruption of protection against under voltage /over voltage has been triggered.

- UNDER voltage: the logic unit keeps under control the input of key. If the voltage has a peak down the alarm is signalled.

- OVER voltage: the logic unit keeps under control the voltage on the internal capacitors. If that voltage has a peak up (breaking effect) the alarm is signalled.

The possible reasons are: a. Under voltage / over voltage of the battery, or loss of voltage after the ignition key or after the battery connector. b. Battery demage. c. Fault in the hardware section of the logic board which controls the over voltage protection. Logic defect. Replace the lifting unit. d. The alarm appears also when one or more phases of the motor doesn't present a correct insulation. Check the motor insulation (with battery disconnected): it must be higher than 10 Mohm. Otherwise check the insulation of the power cables to the motor.

36

VMN LOW

Condition for error detection Failure in the VMN test.

This test starts when the ignition key is turned ON and there is no consuption of ampere. The alarm appears if there is a leakage of current on one or more phases; check the connections of the 3 power cables from the logic unit to the lifting motor and the cables condition. In order to point out if the fault is produced by an internal or external cause proceed as follow: connect the lifting logic unit to the traction motor and check if the alarm “36” appears on the display.

YES: repace the logic unit NO: check the traction motor insulation.

Two of the phases of the motor are kept under control by shunts. If the logic unit detects a leakage of current keeps the truck stopped.

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VMN HIGH

Condition for error detection Failure in the VMN test.

This test starts when the ignition key is turned ON and there is no consuption of ampere. The alarm appears if one or more pover cables are not connected; check the connections of the 3 power cables from the logic unit to the traction motor and the cables condition. In order to point out if the fault is produced by an internal or external cause proceed as follow: connect the lifting logic unit to the traction motor and check if the alarm “37” appears on the display.

YES: repace the logic unit NO: check the traction motor insulation.

Two of the phases of the motor are kept under control by shunts. If the logic unit detects a leakage of current keeps the truck stopped.

38

UNUSED

39

STBY I HIGH

Condition for error detection Failure on the current sensor.

- Replace the lifting logic units.

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CHAPTER 5000 page 71

CAPACITOR CHARGE

Condition for error detection When the key is switch ON, the inverter tries to charge the capacitors through a power resistance, and check if the capacitors are charged within a timeout. If they do not charge, an alarm is signalled; the main contactor is not closed.

- Check the negative connection.

- Check voltage in the input of the key: battery voltage must be present.

- Execute a bridge between the key terminals.

- Replace the lifting unit .

41

HIGH TEMPERAURE

Condition for error detection Chopper temperature is higher than 75°C. The maximum current is reduced proportionally to the temperature increase. The chopper stops at 100°C. If the alarm is signalled when the chopper is cold: - Replace the logic unit.

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MOTOR TEMPERATURE

Condition for error detection This warning is signalled when the motor temperature sensore reaches 130°C. After 130°C the logic unit reduces linearly the current until 150°C (= I max /2).

After 150°C it cuts completely the current.

If the alarm appears when the motor is cold check: _ if the wiring loom of the temperature sensor is well connected. _ if the temperature sensor is always open or it always has a resistance higher then relevant resistence it has to 130°C (see table here below).

AMBIENT TEMPERATURE (°C) (°F) (%/K) -40 -40 0.84 -30 -22 0.83 -20 -4 0.82 -10 14 0.80 0 32 0.79 10 50 0.77 20 68 0.75 25 77 0.74 30 86 0.73 40 104 0.71 50 122 0.70 60 140 0.68 70 158 0.66 80 176 0.64 90 194 0.63 100 212 0.61 110 230 0.60 120 248 0.58 130 266 0.57 140 284 0.55 150 302 0.54 160 320 0.53 170 338 0.52 180 356 0.51 190 374 0.49 200 392 0.48 210 410 0.47 220 428 0.46 230 446 0.45 240 464 0.44 250 482 0.44 260 500 0.42 270 518 0.41 280 536 0.38 290 554 0.34 300 572 0.29

RESISTANCE MIN. 340 370 403 437 474 514 555 577 599 645 694 744 797 852 910 970 1029 1089 1152 1216 1282 1350 1420 1492 1566 1641 1719 1798 1879 1962 2046 2132 2219 2304 2384 2456

TYP. 359 391 424 460 498 538 581 603 626 672 722 773 826 882 940 1000 1062 1127 1194 1262 1334 1407 1482 1560 1640 1722 1807 1893 1982 2073 2166 2261 2357 2452 2542 2624

MAX 379 411 446 483 522 563 607 629 652 700 750 801 855 912 970 1030 1096 1164 1235 1309 1385 1463 1544 1628 1714 1803 1894 1988 2085 2184 2286 2390 2496 2600 2700 2791

TEMP. ERROR (K) ±6.48 ±6.36 ±6.26 ±6.16 ±6.07 ±5.98 ±5.89 ±5.84 ±5.79 ±5.69 ±5.59 ±5.47 ±5.34 ±5.21 ±5.06 ±4.9 ±5.31 ±5.73 ±6.17 ±6.63 ±7.1 ±7.59 ±8.1 ±8.62 ±9.15 ±9.71 ±10.28 ±10.87 ±11.47 ±12.09 ±12.73 ±13.44 ±14.44 ±15.94 ±18.26 ±22.12

Reduction of current Reduction of current Reduction of current

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CHAPTER 5000 page 73

ENCODER ERROR

Condition for error detection Encoder failure.

This alarm indicates that the encoder information is not correct or is not present.

The encoder transmits signals only when the motor is running. The alarm is detected by the logics when it exceeds 20Hz. Therefore, if an error signal appears on the dashboard and the operator uses the reset key with the machine stopped, the alarm disappears however, it remains stored in the logic.

If the alarm signal starts before reaching 20Hz, the problem can be attributed to a possible wrong insulation of a power cable on the frame: without the encoder correct signals, the machine remains still or moves very slowly. To determine whether the problem is to be attributed to the encoder or to the logic,proceed as follow.

Set the SLIP CONTROL on OFF and speeding up slowly.

Please note that the engine speed increase does not necessary mean that the problem is linked to the encoder. Any of the following components may have a fault: _ The logic internal circuit _ The wiring _ The encoder You may use a digital or analogue TESTER to determine where the problem is located.

Speed sensor basic electric diagram.

The figure shows only one signal (A).

The encoders used have two equal signals, with a despacement of 90°(A-B).

1. Connect the positive of the tester (red pin) to the encoder positive terminal.

2. Connect the COM of the tester (black pin) to the encoder signal (A).

According to the engine position, the following values will be displayed: low signal: 0.5-1.5 Volt high signal: 10.5-11.5 Volt Intermediate values cannot be read as the motoris stopped.

If the motor is running, the multemeter will automatically read the Mv (medium value) Mv= 5.5-6.5 Volt Carrying out this test directly on the logic connector, you can determine if signals are good - see above-mentioned description - or if the channels are opened or in short circuit If the signals are good, the problem should be attributed to the electronic control.

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THERMIC SENSOR KO

Condition for error detection Thermic sensor of the logic unit out of range.

- Replace the logic unit.

45

SAFETY

Condition for error detection Truck locked.

PIN 5 connector JFP = negative input. When the negative is not present the logic unit stops the machine with the alarm safey. It can appear according to the following situation: (1) the wire H PIN 5 connector JFP is not well connected.

(2) if the above wire is well connected replace the lifting logic unit.

46

CAN BUS KO

Condition for error detection Failure of the can bus comunication. The alarm appears if the lifting logic unit does not receive the information of I/O card ether traction logic unit or armrest board.

- Check the dashboard’s alarms, before replacing any cards, in order to identify exactly the card which does not comunicate.

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CHAPTER 5000 page 75

WAITING FOR NODE

Condition for error detection Failure of the can bus comunication. The alarm appears if the lifting logic unit receives the information of I/O card ether traction logic unit or armrest board or Mhyrio in delay.

- Check if the alarm appears in combination wih others alalms. If yes this is only a consequent.

- Check the dashboard’s alarms, before replacing any cards.

If the alarm appears alone: - check the can bus connector: all wires must be well connected in both the side of the wiring loom.

The alarm can be generated by a false contact.

- if the above tests are negative replace the lifting logic unit.

48

UNUSED

49

UNUSED

50

UNUSED

51

UNUSED

52

VACC NOT OK

Condition for error detection Failure on the lifting acceleration potentiometer signal at rest. The alarm points out that the voltage value detected on the accelerator potentiometer is 1Volt higher than the least value programmed with the Vacc function. Check: - The lifting potentiometer (it could be damaged or not correctly calibrated) - The lifting potentiometer wiring.

- Carry out the Vacc setting again.

53

INCORRECT START

Condition for error detection - Seat switch open when the pump is running.

54

UNUSED

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WRONG SET BATT

Condition for error detection When the key is turned ON, the controller checks the battery voltage and compares it with the “SET BATTERY” parameter setting. If the actual value is 20% higher or lower than the nominal value, there is a fault.

- Check the status of the battery and if neccessary replace it with a correct one.

56

REMOTE INPUT

Condition for error detection General incorrect starting procedure.

57

WAITING MHYRIO

Condition for error detection Failure of the can bus comunication. The alarm appears if the lifting logic unit receives the information of Mhyrio in delay.

- Check if the alarm appears in combination wih others alalms. If yes this is only a consequent.

- Check the dashboard’s alarms, before replacing any cards.

If the alarm appears alone: - check the can bus connector: all wires must be well connected in both the side of the wiring loom.

The alarm can be generated by a false contact.

- if the above tests are negative replace the lifting logic unit.

58

I=0

Condition for error detection Failure on the current sensor.

- Replace the lifting unit.

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59

SEAT KO

Condition for error detection The logic unit does not see the seat microswitch.

Check: - the status of the seat microswitch - the input in the pins JFP Pin4 and JFT Pin4.

- if the signal is OK replace the logic unit.

60

UNUSED

4A

UNUSED

4C

BATTERY LOW

Condition for error detection Battery discharge.

5A

CHOPPER NOT CONF

Condition for error detection Lifting unit has an erroneous configuration.

4E

UNUSED

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5C

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GAIN ACQUISITION

Condition for error detection This warning communicates that the logic is in phase of input acquisition. In this phase the logic doesn't work.

5E

UNUSED

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MHYRIO LOGIC UNIT A1

EEPROM KO

Condition for error detection Fault in the area of memory in which the adjustment parameters are stored; this alarm inhibists the truck operation, but the controller will use default parameters.

If the defect persist when the key is switched OFF and ON again, replace the logic unit.

If the alarm disappears, remember that the parameters previusly stored have been deleted and replaced with the default value.

A2

EV DRIVER SHORT

Condition for error detection It is referred to the 5th way.

One of the on/off valves driver is shorted; check the external connection, if it is ok, the problem is in the hardware circuit.

- Replace the logic unit

A3

CAN BUS KO

Condition for error detection Failure of the can bus comunication. The alarm appears if the lifting logic unit does not receive the information of I/O card ether traction logic unit or armrest board.

- Check the dashboard’s alarms, before replacing any cards, in order to identify exactly the card which does not comunicate.

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A4

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FF VALVES

Condition for error detection Problem in the hardware circuit.

- Replace the logic unit.

A5

UNUSED

A6

EVPG1 DRIV SHORT

Condition for error detection It is referred to the lifting valve EV2.

One of the valve drivers is shorted; check the external connection, if it is ok, the problem is in the hardware circuit.

- Replace the logic unit

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A7

CHAPTER 5000 page 81

EVPG2 DRIV SHORT

Condition for error detection It is referred to the tilting forward or backward valve EVP3 or EVP4.

One of the valve drivers is shorted; check the external connection, if it is ok, the problem is in the hardware circuit.

- Replace the logic unit

A8

EVPG3 DRIV SHORT

Condition for error detection It is referred to the side shift valve EV5 or EV7.

One of the valve drivers is shorted; check the external connection, if it is ok, the problem is in the hardware circuit.

- Replace the logic unit

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EVPG4 DRIV SHORT

Condition for error detection It is referred to the 4th way valves EV7 or EV8.

One of the valve drivers is shorted; check the external connection, if it is ok, the problem is in the hardware circuit.

- Replace the logic unit

AA

WRONG SET BATTERY

Condition for error detection This fault is signalled if the battery voltage is non consistent with the set battery programmed in the 'set option' menu.

AB

HI SIDEDRIVER KO

Condition for error detection The high side driver which supply the valves coils positive is shorted or open.

Problem in the hardware circuit.

- Replace the logic unit.

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AC

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EVPG1 DRIVER KO

Condition for error detection It is referred to the lifting valve EV2.

One of the valves drivers is open; check the external connection, if it is ok, the problem is in the hardware circuit.

- Replace the logic unit

AD

EVPG2 DRIVER KO

Condition for error detection It is referred to the tilting forward or backward valve EVP3 or EVP4.

One of the valve drivers is open; check the external connection, if it is ok, the problem is in the hardware circuit.

- Replace the logic unit

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EVPG3 DRIVER KO

Condition for error detection It is referred to the side shift valve EV5 or EV7.

One of the valve drivers is open; check the external connection, if it is ok, the problem is in the hardware circuit.

- Replace the logic unit

AF

EVPG4 DRIVER KO

Condition for error detection It is referred to the 4th way valves EV7 or EV8.

One of the valve drivers is open; check the external connection, if it is ok, the problem is in the hardware circuit.

- Replace the logic unit

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B0

CHAPTER 5000 page 85

COIL SHORTER

Condition for error detection ON/OFF valves drive are protected against coil short circuit; if a short is present across the coil, the alarm is signalled.

- check the status of the ON-OFF valves.

B1

UNDER VOLTAGE

Condition for error detection This fault is signalled if an undervoltage condition is detected in the MHYRIO power supply.

- Connector J138 pin 5 = 24V

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B2

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EVP DRIVER KO

Condition for error detection It is referred to the drain valve EVP. The valve’s driver is open: problem in the hardware circuit.

- Replace the logic unit

B3

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EV DRIVER KO

Condition for error detection One of the On/Off valves drivers is open.

- Replace the logic unit

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B4

CHAPTER 5000 page 87

WATHDOG

Condition for error detection The test is made in both running and standby. It is a self-diagnosing test within the logic.

- Replace the logic unit

B5

EVP DRIVER SHORT

Condition for error detection It is referred to the drain valve EVP. The valve’s driver is shorted: problem in the hardware circuit.

- Replace the logic unit.

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ARMREST BOARD E1

INCORRECT START

Condition for error detection Incorrect starting procedure of the armrest board.

- check if one of the potentiometers are activated before switching the key ON. - check if the hand direction lever on the armrest board is activated before switching the key ON or before closing the seat microswitch.

If the Armrest is not present on the machine the alarm is sent out by the IO Control Board. See page See page 5000-93

E2

BAD LIFT POT

Condition for error detection Failure on the lifting potentiometer in the fingertips / joysticks group.

Check, and if necessary replace the relevant fingertip / joystick.

If the Armrest is not present on the machine the same alarm is sent out by the IO Control Board.

E3

BAD TILT POT

Condition for error detection Failure on the tilting potentiometer in the fingertips / joysticks group.

Check, and if necessary replace the relevant fingertip / joystick

E4

BAD SIDESH POT

Condition for error detection Failure on the sideshift potentiometer in the fingertips / joysticks group.

Check, and if necessary replace the relevant fingertip / joystick.

E5

BAD IV POT

Condition for error detection Failure on the 4th way potentiometer in the fingertips / joysticks group.

Check, and if necessary replace the relevant fingertip / joystick.

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E6

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BAD V POT

Condition for error detection Failure on the 5th way potentiometer in the fingertips / joysticks group.

Check, and if necessary replace the relevant fingertip / joystick.

E7

DEFAULT RESTORED

Condition for error detection Warning alarm.

The machine is in the acquisition status of the default parameters.

Wait until the end of the acquisition and do the reset of the key.

E8

INVALIDE RESTORE STATE

Condition for error detection Failure of the restore default parameter operation.

- Repeat the operation.

E9

EEPROM INCONSISTENCY

Condition for error detection Replace the Armrest Board.

EA

MHYRIO OR PUMP ALARM

Condition for error detection This alarm shows that an alarm in present in both Mhyrio logic unit and lifting logic unit - check the other alarm which appear on the dispaly in order to identify where the problem is located.

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MATCHING ERROR

Condition for error detection The Armrest Board does the control of the neutral position of the potentiometers.

If the alarm appears: - check the status of the potentiometer.

- Do again the potentiometer acquisition - If all is Ok, repace the card.

EC

CHKSUM ERROR

Condition for error detection Replace the Armrest Board.

ED

MHYRIO STUFFING ERROR

Condition for error detection The Armrest Board has comunication problem with Mhyrio board.

Check on the dashboard other alarms.

EE

PUMP STUFFING ERROR

Condition for error detection The Armrest Board does not receive the information from the lifting logic unit.

If the Armrest is not present on the machine the same alarm is sent out by the IO Control Board.

EF

FW + BW

Condition for error detection Double speed request selected.

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DASHBOARD B1

UNUSED

B2

UNUSED

B3

UNUSED

B4

UNUSED

B5

UNUSED

B6

MHY KO

Condition for error detection This alarm signals that the Mhyrio logic unit that controls the electric control valve does not communicate.

- check the feeding; 24V must be present on the connector J48 pin1.

- if the feeding is OK and it is not possible to work with it replace the Mhyrio logic unit.

B8

UNUSED

D1

TRAC KO

Condition for error detection This alarm signals that the TRACTION logic unit does not communicate.

- check the feeding; 24V must be present on the connector JFT pin1.

- if the feeding is OK and it is not possible to work with it replace the TRACTION logic unit.

D2

SIO KO

Condition for error detection This alarm signals that the IO control board does not communicate.

- check the feeding; 24V must be present on the connector J34 pin24.

- if the feeding is OK and it is not possible to work with it replace the IO control board.

D3

UNUSED

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PUMP KO

Condition for error detection This alarm signals that the LIFTING logic unit does not communicate.

- check the feeding; 24V must be present on the connector JFP pin1.

- if the feeding is OK and it is not possible to work with it replace the LIFTING logic unit

D5

UNUSED

D6

UNUSED

D7

UNUSED

D8

JOY KO

Condition for error detection This alarm signals that the ARMREST BOARD does not communicate.

- check the feeding; 24V must be present on the connector J138 pin5.

- if the feeding is OK and it is not possible to work with it replace the ARMREST BOARD.

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I/O CONTROL BOARD 81

INCORRECT START

Condition for error detection Incorrect starting sequence.

The pedal or hand direction lever has been activated before switching the truck on.

Check: - forward, backward microswitches and relevant cables

82

UNUSED

83

PEDAL WIRE KO

Condition for error detection Failure on the acceleration potentiometer signal at rest. Check: - traction potentiometer (could be damaged or not correctly calibrated); - traction potentiometer wiring.

84

BAD MICRO SWITCH

Condition for error detection Microswtich of the travel pedal or of the hand direction lever demaged.

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85

UNUSED

86

BAD VACC

Condition for error detection It is necessary to do again the acquisistion of the value of the travel potentiometer.

The alarm appears if the potentiometer is out of range.

87

ERR SEAT

Condition for error detection One of the function is activated while the seat microswitch is open.

88

UNUSED

89

PARKING SELECTED

Condition for error detection Parking brake switch closed and travel request activated.

8A

PARAM LOAD ERROR

Condition for error detection The alarm appears after switching the truck on, not during traveling, or pressing the pushbotton for changing the program.

- Replace the IO Control Board.

8B

TRAC IN ALARM

Condition for error detection General alarm.

The IO Control Board detects an alarm of the traction logic unit.

Check on the dashboard others alarms.

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8C

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TRUCK STUFFING ERROR

Condition for error detection Comunication problem with the traction logic unit.

Check on the dashboard others alarms.

8E

UNUSED

8F

FW + BW

Condition for error detection Double request activated.

The micro switches of forward and backward direction are closed in the same time.

91

CONF ERROR

Condition for error detection Error of the configuration of the truck.The alarm is signalled after switching the machine on.

The truck remains in the pre-operational status. All function are deactivated.

The truck does the configuration automatically once all components are connected.

If on the truck is not present or not connected only one of the following components the alarm is signalled: _ Mhyrio _ Armrest board.

92

BOOT ERROR

Condition for error detection The alarm is signalled after switching the machine on.

The truck remains in the pre-operational status. All function are deactivated.

The IO Control Board does not received information from lifting or traction logic unit or both.

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NOT REP ERROR

Condition for error detection Not replay error.

I/O Control Board is waiting for information coming from dashboard.

The machine remains in the preoperational status and all functions are disabled.

Check: - insulation of the machine - Replace the dashboard.

94

CHKSUM ERROR

Condition for error detection Software error.

- Replace the I/O Control Board.

C1

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STOP OPEN

Condition for error detection Failure on the stop lights.

- Check the bulbs of the stopstreetlights and the relevant cables.

C2

UNUSED

C3

UNUSED

C4

RETRO OPEN

Condition for error detection Failure on the reverse lights.

- Check the bulbs of the backup streetlights and the relevant cables.

C5

C1 + C4

C6

UNUSED

C7

UNUSED

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C8

UNUSED

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HYDRAULIC/PNEUMATIC SYSTEM HYDRAULIC CIRCUIT (MECCHANIC CONTROL VALVE) ..................................... page 5 HYDRAULIC CIRCUIT (ELECTRIC CONTROL VALVE) ......................................... page 6 COMPONENTS........................................................................................................ page 7 STEERING SYSTEM ............................................................................................... page 7 HYDRAULIC SYSTEM (WITH MECCHANIC DISTRIBUTOR) ................................ page 7 HYDRAULIC SYSTEM (WITH ELECTRIC DISTRIBUTOR) .................................... page 8 2M T.V. MAST........................................................................................................... page 9 2M F.F.L. MAST ........................................................................................................ page 9 3M F.F.L. MAST ........................................................................................................ page 10 HYDRAULIC OIL AND FILTER ................................................................................ page 11 REMOVAL • INSTALLATION .................................................................................... page 11 NATURAL DROP TEST ON LIFTING ...................................................................... page 13 NATURAL FORWARD TILTING TEST ..................................................................... page 13 OIL LEAK TEST ....................................................................................................... page 14 LIFTING CYLINDERS .............................................................................................. page 14 TILTING CYLINDERS .............................................................................................. page 14 GENERAL ................................................................................................................ page 15 COMPONENTS........................................................................................................ page 1 SERVICE PUMP ...................................................................................................... page 17 REMOVAL • INSTALLATION .................................................................................... page 17 TEST METHOD........................................................................................................ page 18 MAST PERFORMANCE TABLE (LIFTING) ............................................................. page 18 MECHANIC CONTROL VALVE................................................................................ page 19 GENERAL ................................................................................................................ page 19 CONTROL VALVE .................................................................................................... page 19 MECHANIC CONTROL VALVE (3 LEVERS) ........................................................... page 20 MECHANIC CONTROL VALVE (4 LEVERS)) ......................................................... page 21 MECHANIC CONTROL VALVE WITH HAND DIRECTION LEVER (3 LEVERS) .... page 22 MECHANIC CONTROL VALVE WITH HAND DIRECTION LEVER (4 LEVERS)) ... page 23 HYDRAULIC DIAGRAM ........................................................................................... page 24 SPECIFICATIONS .................................................................................................... page 24 MECHANIC CONTROL VALVE................................................................................ page 25 REMOVAL • INSTALLATION .................................................................................... page 25 MAXIMUM PRESSURE VALVE ADJUSTMENT (RELIEF VALVES ADJUSTMENT)page 27 MAST PERFORMANCE TABLE .............................................................................. page 28 LEVER CONTROL VALVE ....................................................................................... page 29 REMOVAL • INSTALLATION .................................................................................... page 29 ELECTRIC CONTROL VALVE (FOR FINGERTIPS AND JOYSTICKS) .................. page 30

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SERVICE MANUAL

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GENERAL................................................................................................................. page 30 OIL CONTROL VALVE ............................................................................................. page 30 ELECTIC CONTROL VALVE (3 LEVERS) .............................................................. page 31 ELECTIC CONTROL VALVE (4 LEVERS) .............................................................. page 31 HYDRAULIC CIRCUIT DIAGRAM............................................................................ page 32 SPECIFICATIONS .................................................................................................... page 32 ELECTRIC CONTROL VALVE ................................................................................. page 33 REMOVAL • INSTALLATION .................................................................................... page 33 MAXIMUM PRESSURE VALVE ADJUSTMENT (RELIEF VALVES ADJUSTMENT)page 34 MAST PERFORMANCE TABLE............................................................................... page 35 LIFT LOCK UNLOCKING SCREW........................................................................... page 36 FINGERTIPS (WITHOUT HAND DIRECTION LEVER) ........................................... page 37 GENERAL................................................................................................................. page 37 COMPONENTS ........................................................................................................ page 38 REMOVAL · INSTALLATION .................................................................................... page 39 JOYSTICK (WITH HAND DIRECTION LEVER)....................................................... page 40 GENERAL................................................................................................................. page 40 LEVER ...................................................................................................................... page 41 GENERAL................................................................................................................. page 41 COMPONENTS ........................................................................................................ page 42

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SERVICE MANUAL

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HYDRAULIC CIRCUIT (MECCHANIC CONTROL VALVE)

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SERVICE MANUAL

HYDRAULIC CIRCUIT (ELECTRIC CONTROL VALVE)

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COMPONENTS STEERING SYSTEM

HYDRAULIC SYSTEM (WITH MECCHANIC CONTROL VALVE)

CHAPTER 6000 page 7

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HYDRAULIC SYSTEM (WITH ELECTRIC CONTROL VALVE)

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2M T.V. Mast

2M F.F.L. Mast

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3M F.F.L. Mast

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CHAPTER 6000 page 11

HYDRAULIC OIL AND FILTER REMOVAL • INSTALLATION

A, B C

D

Removal Procedure 1 Place and stop the truck on a flat surface, with the mast in vertical position and the forks lowered.

2 Disconnect the battery plug.

3 Remove the foot board.

4 Remove the tank cap (A).

5 Remove the oil filter cartridge (B) [Point 1].

6 Check and clean the tank breather valve (C).

7 Replace the oil.

8 Replace the oil filter cartridge.

Installation procedure The installation procedure is the reverse of the removal procedure.

Note: Check the state of the seals and that there are no oil leaks.

Check the oil level in the tank using the dip-stick (D) with the mast in vertical position and the forks lowered NOTE: With the double foot pedal and hand direction lever (single pedal) the hydraulic oil filter is on the middle position of the tank (see drawing).

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With the balanced pedal the hydraulic oil filter is on the left side of the tank (see drawing).

Point Operations [POINT 1] Two different procedures can be followed to remove the hydraulic oil from the tank: 1.

Remove the drain plug under the tank.

2.

Remove the oil filter cartridge and then use a pump in order to drain out the hydraulic oil.

DRAIN PLUG

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CHAPTER 6000 page 13

NATURAL DROP TEST ON LIFTING 1.

Set the mast in the vertical position with the standard load on the fork.

2.

Lift the fork at 2,5 to 3 m and take the measure between the fork and the ground with meter and leave the key switch ON.

3.

Take again the measure between the forks and the ground after 10 minutes.

Limit: A = 100 mm

NATURAL FORWARD TILTING TEST 1.

Set the mast in the vertical position with the standard load on the fork, lift the fork at 2,5 to 3 m and leave the key switch ON.

2.

The tilt angle can 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 the 1 m from top of the mast.

3.

After 10 minutes carry out the same measurement (1° = 17,4 mm).

Limit: Forward angle stroke (°) <= 0,5 (°/min) Time (10 min)

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OIL LEAK TEST LIFTING CYLINDERS 1.

2.

3.

4.

Set the mast in the vertical position with the standard load on the fork.

Lift the fork at 2,5 to 3 m and take the measure between the forks and the ground with a meter and leave the key switch ON. Take again the measure between the fork and the ground after 10 minutes Limit: A = 100 mm If oil leakages are present on the body of the lifting cylinders, check if the cylinder connections are well tight and replace the cylinder if necessary.

TILTING CYLINDERS 1.

Set the mast in the vertical position with the standard load on the forks, lift the forks at 2,5 to 3 m and leave the key switch ON.

2.

The tilt angle can 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 1 m from the top of the mast.

After 10 minutes carry out the same measurement (1° = 17,4 mm).

3.

Limit: Forward angle stroke (°) <= 0,5 (°/min) Time (10 min) 4. If the truck is out of the above limit lower completely down the mast and turn the key switch OFF. 5. Invert the tilting hoses with the sideshift hoses (if present) on the control valve. This operation is necessary to understand if there is any internal leakage inside the tilting cylinder or inside the control valve.

6. Turn the key switch ON and repeat the test from point 1 to 3; after that: a) Test result within the limit = replace the control valve. b) Test result out of the limit = replace the tilt cylinders.

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GENERAL

Vehicle model

10 up to 15

Service pump name

Gear pump

Service pump type

WSP 20-8 (Casappa)

Drive system

Direct motor drive

Delivery (pump at 1500 rpm)

l/min

12,45

Theoretical discharge

cm3

8,74

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COMPONENTS

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CHAPTER 6000 page 17

SERVICE PUMP REMOVAL • INSTALLATION T=Nm

FIXING BOLTS

Removal Procedure 1 Disconnect the battery plug.

2 Remove the foot board .

3 Remove the tank cap.

4 Drain out the hydraulic oil.

5 Disconnect the hoses of the priority valve.

6 Disconnect inlet connection of the oil pump (tank - pump) from the connection of the tank.

7 Remove the oil pump set bolts of the pump motor .

Installation Procedure The installation procedure is the reverse of the removal procedure.

Tightening torque of the fixing bolts = 45 Nm. Note: • Apply chassis grease at the spline section of the oil pump before installation. Clean the flange that meets the motor before installation.

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TEST METHOD A bench test should be conducted for strict testing, but as it is generally impossible in practical service operation, install the oil pump on the vehicle and judge the oil pump discharge performance by means of cylinder operation.

• Check that the battery charge is sufficient by observing the battery charge indicators.

• Check that the oil control valve set relief pressure is as specified .

Lift relief pressure Bar

175 - 235

• Measure the time of full stroke of the lift cylinder with the hydraulic oil temperature at 50 to 55 °C (122 ~ 131°F) and calculate the lifting speed.

However, due to soft start by material handling chopper circuit, lifting speed is 10 ~ 20 mm/ sec (2.0 ~ 3.9fpm) lower than the value obtained from the table.The lifting speed can be calculated more accurately by measuring the full stroke operation time excluding the soft start period.

The lifting speed may differ depending on the conditions of the battery, hydraulic oil temperature and mast adjustment.

The values below are based on a certain condition.

MAST PERFORMANCE TABLE (lifting) Q1 max. load

Q2 max. load at max. height

Perform the test with the electrolyte density from 1.18 to 1.26 and the electrolyte temperature from 20° to 50° 1.0t Load

FFL

Kg

m/sec

Q1

0,30

min

max

0,60

TV

amp max

bar 330

max

m/sec 135

amp

0,30

min

max

0,60

bar

max

370

max

145

max

410

max

175

max

410

max

175

max

450

max

205

max

450

max

205

max

480

max

235

lowering Q1

Lifting end stroke (max. pressure valve adjustment)

1.25t Load

FFL

Kg

m/sec

Q1

0,28

min

max

0,60

TV

amp max

bar 360

max

m/sec 160

amp

0,29

min

max

0,60

bar

lowering Q1

Lifting end stroke (max. pressure valve adjustment)

1.5t Load

FFL

Kg

m/sec

Q1

0,27

min

max

0,60

TV

amp max

bar 400

max

m/sec 180

amp

0,27

min

max

0,60

bar

lowering Q1

Lifting end stroke (max. pressure valve adjustment)

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MECHANIC CONTROL VALVE GENERAL CONTROL VALVE

CHAPTER 6000 page 19

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SERVICE MANUAL

MECHANIC CONTROL VALVE (3 levers)

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MECHANIC CONTROL VALVE (4 levers)

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MECHANIC CONTROL VALVE WITH HAND DIRECTION LEVER (3 levers)

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MECHANIC CONTROL VALVE WITH HAND DIRECTION LEVER (4 levers) )

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HYDRAULIC DIAGRAM

SPECIFICATIONS Model Item Type RELIEF PRESSURE bar Others

ELECTRIC

Lift Tilt

All Models Mechanic 175 ÷ 235 160 Built-in lift and tilt lock valves

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CHAPTER 6000 page 25

MECHANIC CONTROL VALVE REMOVAL • INSTALLATION Note: Operate the control lever to bring the mast and fork to the vertical and lowermost positions, respectively, to release the residual pressure in the material handling system before starting removal.

T=Nm

Removal Procedure 1 Disconnect the battery plug.

2 Remove the foot board and tilt cover.

3 Disconnect the piping and wiring.

4 Remove the set pin for the control valve and lever [Point 1].

5 Remove the control valve.

Installation Procedure The installation procedure is the reverse of the removal procedure.

Note: • Adjust the limit switch after installing the oil control valve (See [Point 1]).

• Apply grease to oil control valve lever linkage.

• Check the hydraulic oil level, and add if insufficient.

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Point Operations [POINT 1] Removal Remove the elastic pin per each lever.

Adjustment (microswitch): After the installation perform the following adjustments: COMMAND ROD

1.

MICROSWITCH

Fix the microswitch in rest position as showed in the drawing according to the following points:

• The castor of the microswitch has to be in contact with the surface of the command rod • The microswitch lever has to be in contact wit the push button of the microswitch, without activating it.

COMMAND ROD LEVER CASTOR

2.

Tight the microswitch in order to have the possibility to move it on the buttonhole of the support.

3.

Adjust the microswitch position in order to activate it to the minimum stroke of the microswitch lever and by releasing the latter the microswitch has to return in rest position. The activation of the microswitch could be detected:

PUSH BUTTON

• by eyes (by checking the angular stroke on the microswitch lever) • by ears (by listening to the closing of the contacts) • by multimeter (by checking its signals) 4.

Tight the microswitch screws with a tightening torque of 0,39-0,59 Nm.

P

Adjustment (lifting potentiometer P): After the installation perform the adjustment of the ifting potentiometer see Chapter 3 Display.

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MAXIMUM PRESSURE VALVE ADJUSTMENT (RELIEF VALVES ADJUSTMENT) • Always follow the procedure below for adjustment.Careless adjustment may cause high-pressure generation, resulting in damage to hydraulic units such as the oil pump.

• No adjustment is needed when the relief valve is not disassembled.

• Check the maximum pressure if the relief valve is replaced according to the mast fitted on the vehicle.

Side Shift relief valve

Tilting relief valve

Lifting relief valve

1 Remove the plug of the pressure gauge on the priority valve and connect a manometer.Pressure manometer end stroke: 200 bar or more.

2 Loosen the counter nut on the relief valve on adjust the screw (Allen screw for lifting, square screw for tilting, side shift and other lever).

3 Adjust the oil pressure as follows: (a) (b) (c)

(d)

Turn the key switch ON Lift the mast to the end stroke and check the pressure on the manometer (without load) Adjust the pressure if necessary knowing that: screwing in = increasing of pressure screwing out = decreasing of pressure Tight the counter nut when the detected pressure reach the correct value according to the table below

4 Repeat the point 3 by using the other function (tilting, side shift, …) once per time.

5 Remove the monometer and screw in the plug.

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MAST PERFORMANCE TABLE Q1 max. load

Q2 max. load at max. height

Perform the test with the electrolyte density from 1.18 to 1.26 and the electrolyte temperature from 20° to 50° 1.0t Load

FFL

Kg

m/sec

Q1

0,30

min

max

0,60

TV

amp max

bar 330

max

m/sec 135

amp

0,30

min

max

0,60

bar

max

370

max

145

max

410

max

175

lowering Q1

Lifting end stroke (max. pressure valve adjustment)

1.25t Load

FFL

Kg

m/sec

Q1

0,28

min

max

0,60

TV

amp max

bar 360

max

m/sec 160

amp

0,29

min

max

0,60

bar

max

410

max

175

max

450

max

205

max

450

max

205

max

480

max

235

lowering Q1

Lifting end stroke (max. pressure valve adjustment)

1.5t Load

FFL

Kg

m/sec

Q1

0,27

min

max

0,60

TV

amp max

bar 400

max

m/sec 180

amp

0,27

min

max

0,60

bar

lowering Q1

Lifting end stroke (max. pressure valve adjustment)

Test to be done at 1 m height with Q1 load Tilting angle value tolerance: ± 0.5° Std tilt = 3° FW; => 6° BW degrees/sec

amp

bar

BW - FW

1,5

3

max

55

max

40

FW - BW

1,5

3

max

140

max

120

Tilting end stroke Lever control valve

max

150

max

160

Tilting end stroke Electric control valve

max

240

max

240

Std side shift stroke 100 mm: visual check

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CHAPTER 6000 page 29

LEVER CONTROL VALVE LEVER REMOVAL • INSTALLATION

Removal Procedure 1 Disconnect the battery plug.

2 Lifting lever only if direction switch is present: disconnect the wiring of the switch.

3 Loosen the set bolt.

4 Remove the control valve lever.

Installation Procedure The installation procedure is the reverse of the removal procedure.

Note: Apply grease to control valve lever link portions.

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ELECTRIC CONTROL VALVE (FOR FINGERTIPS AND JOYSTICKS) GENERAL OIL CONTROL VALVE

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ELECTRIC CONTROL VALVE (3 levers)

ELECTRIC CONTROL VALVE (4 levers)

CHAPTER 6000 page 31

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HYDRAULIC CIRCUIT DIAGRAM

SPECIFICATIONS Model Item Type RELIEF PRESSURE Others

Bar

All Model Electric 175 ÷ 235 With proportional and ON/OFF solenoid valves

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CHAPTER 6000 page 33

ELECTRIC CONTROL VALVE REMOVAL • INSTALLATION Note: Operate the control lever to bring the mast and fork to the vertical and lowermost positions, respectively, to release the residual pressure in the material handling system before starting removal.

T=Nm

Removal Procedure 1 Disconnect the battery plug.

2 Remove the foot board and tilt cover.

3 Disconnect the piping and wiring.

4 Remove the control valve.

Installation Procedure The installation procedure is the reverse of the removal procedure.

Note: Check the hydraulic oil level, and add if insufficient.

Caution: Cover the brake with cloth to prevent hydraulic oil adhesion.

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MAXIMUM PRESSURE VALVE ADJUSTMENT (RELIEF VALVES ADJUSTMENT Note: • Always follow the procedure below for adjustment.Careless adjustment may cause high-pressure generation, resulting in damage to hydraulic units such as the oil pump.

• No adjustment is needed when the relief valve is replaced according to the mast fitted on the vehicle.

Relief valve

Unloking screw

1. Remove the plug of the pressure gauge on the priority valve and connect a manometer.

Pressure manometer end stroke: 200 bar or more 2. Loosen the counter nut on the relief valve and adjust the bolt (only for lifting section).

3. Adjust the oil pressure. a. Turn the key switch ON. b. Lift the mast to the end stroke and check the pressure on the manometer (without load) c. Adjust the pressure if necessary knowing that:screwing in = increasing of pressure screwing out = decresing of pressure d. Tight the counter nut when the detected pressure reaches the correct value according to the table below.

4. Remove the monometer and screw in the plug.

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MAST PERFORMANCE TABLE Q1 max. load

Q2 max. load at max. height

Perform the test with the electrolyte density from 1.18 to 1.26 and the electrolyte temperature from 20° to 50° 1.0t Load

FFL

Kg

m/sec

Q1

0,30

min

max

0,60

TV

amp max

bar 330

max

m/sec 135

amp

0,30

min

max

0,60

bar

max

370

max

145

max

410

max

175

lowering Q1

Lifting end stroke (max. pressure valve adjustment)

1.25t Load

FFL

Kg

m/sec

Q1

0,28

min

max

0,60

TV

amp max

bar 360

max

m/sec 160

amp

0,29

min

max

0,60

bar

max

410

max

175

max

450

max

205

max

450

max

205

max

480

max

235

lowering Q1

Lifting end stroke (max. pressure valve adjustment)

1.5t Load

FFL

Kg

m/sec

Q1

0,27

min

max

0,60

TV

amp max

bar 400

max

m/sec 180

amp

0,27

min

max

0,60

bar

lowering Q1

Lifting end stroke (max. pressure valve adjustment)

Test to be done at 1 m height with Q1 load Tilting angle value tolerance: ± 0.5° Std tilt = 3° FW; => 6° BW degrees/sec

amp

bar

BW - FW

1,5

3

max

55

max

40

FW - BW

1,5

3

max

140

max

120

Tilting end stroke Lever control valve

max

150

max

160

Tilting end stroke Electric control valve

max

240

max

240

Std side shift stroke 100 mm: visual check

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LIFT LOCK UNLOCKING SCREW T = Nm

Lift lock unlocking screw

1 Loosen the unlocking nut.

2 Loosen the lift lock unlocking bolt and operate the lift lever to manually lower the forks.

Note: Always retighten the unlocking bolt after repair.If the lift lock unlocking bolt is left loose, much hydraulic oil is released from the oil pump and the lifting speed is significantly decreased, resulting in difficulty in smooth operation.

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FINGERTIPS GENERAL

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CHAPTER 6000 page 37

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COMPONENTS

SERVICE MANUAL

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CHAPTER 6000 page 39

REMOVAL · INSTALLATION

Removal Procedure 1 Disconnect the battery plug.

2 Disconnect the wiring.

3 Remove the slide adjusting bolt. [Point 1] 4 Remove the fingertips box.

Installation Procedure The installation procedure is the reverse of the removal procedure.

Point Operations [POINT 1] Removal Remove the adjusting knob (A) and the elastic ring (B), then remove their relevant pins.

B

B

A

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JOYSTICK GENERAL

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LEVER GENERAL

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CHAPTER 6000 page 41

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COMPONENTS

SERVICE MANUAL

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CHAPTER 7000

MAST GROUP

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MAST GROUP 2M TV MAST ............................................................................................................ page 3 COMPONENTS........................................................................................................ page 3 MAST (2M T.V.) ........................................................................................................ page 3 FORK CARRIAGE.................................................................................................... page 4 CHAIN AND CHAIN WHEEL.................................................................................... page 4 REMOVAL • INSTALLATION .................................................................................... page 5 MAST AND FORK CARRIAGE ROLLERS (All kind of masts) ................................. page 7 REMOVAL • INSTALLATION .................................................................................... page 7 MAST AND FORK CARRIAGE ROLLERS (All kind of masts) ................................. page 9 REMOVAL • INSTALLATION .................................................................................... page 9 MAST AND FORK CARRIAGE ROLLERS (All kind of masts) ................................. page 11 INSPECTION • ADJUSTEMENT.............................................................................. page 11 MAST CHAINS ......................................................................................................... page 13 INSPECTION • ADJUSTEMENT.............................................................................. page 13 FORK........................................................................................................................ page 14 REMOVAL • INSPECTION ....................................................................................... page 14 2M F.F.L. - 3M F.F.L. MAST ...................................................................................... page 16 COMPONENTS MAST (2M F.F.L.)........................................................................... page 16 FORK CARRIAGE (2M F.F.L. - 3M F.F.L.) ................................................................ page 17 CHAIN & CHAIN WHEEL (2M F.F.L.) ....................................................................... page 18 CHAIN & CHAIN WHEEL (3M F.F.L.) ....................................................................... page 18 LIFT CYLINDER ....................................................................................................... page 19 GENERAL ................................................................................................................ page 19 SPECIFICATIONS .................................................................................................... page 20 SIDE/REAR LIFTING CYLINDER (2M VT AND 3M FFL) ........................................ page 20 CENTRALl LIFTING CYLINDER (2M FFL AND 3M FFL) ........................................ page 20 SIDE/REAR LIFTING CYLINDER (2M FFL) ............................................................ page 20 COMPONENTS........................................................................................................ page 21 LIFTING CYLINDER (2M VT)................................................................................... page 21 SIDE/REAR LIFTING CYLINDER (2M FFL) ............................................................ page 21 SIDE/REAR LIFTING CYLINDER (3M FFL) ............................................................ page 22 CENTRALl CYLINDER (2M FFL AND 3M FFL) ....................................................... page 22 SIDE/REAR CYLINDER ........................................................................................... page 23 REMOVAL • INSTALLATION .................................................................................... page 23 CENTRAL CYLINDER.............................................................................................. page 26 REMOVAL • INSTALLATION .................................................................................... page 26 LOWERING VALVE (HAWE, FOR ALL MASTS)...................................................... page 28 SPECIFICATIONS .................................................................................................... page 28

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SERVICE MANUAL

CHAPTER 7000 page 3

MAST PERFORMANCE TABLES ............................................................................ page 29 REMOVAL • INSTALLATION .................................................................................... page 30 TILT CYLINDER ....................................................................................................... page 31 GENERAL................................................................................................................. page 31 SPECIFICATIONS .................................................................................................... page 31 COMPONENTS ........................................................................................................ page 31 REMOVAL • INSTALLATION .................................................................................... page 32

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ELECTRIC

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2M TV MAST COMPONENTS MAST (2M T.V.)

1,0-1,5 t A.C.

SERVICE MANUAL

CHAPTER 7000 page 5

1,0-1,5 t A.C.

CHAPTER 7000 page 6

SERVICE MANUAL

FORK CARRIAGE

CHAIN AND CHAIN WHEEL

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SERVICE MANUAL

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CHAPTER 7000 page 7

REMOVAL • INSTALLATION T=Nm

T=24 Nm (± 10%) T = 83 Nm (± 15%)

Removal Procedure 1 Put the mast in vertical position 2 Disconnect the battery plug.

3 Connect the chains on the mast. [Point 1] 4 Disconnect the hydraulic hoses from the mast (lifting, sideshift, ...).

5 Remove the bolts of the mast. [Point 2] 6 Remove the pins from the tilting cylinders. [Point 3] 7 Remove the mast.

Installation Procedure The installation procedure is the reverse of the removal procedure.

Note: Apply appropriate grease to the mast support bushing, mast support cap interior surfaces and tilting cylinder front pins.

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Point Operations [POINT 1] Removal: Connect the chain on the showed before removing the mast.

[POINT 2] Removal: Remove the 4 bolts that fix the mast to the frame from the bottom.

Installation: After installation, tightening torque of the 4 screw of the mast = 83 Nm.

[POINT 3] Removal: Remove the 2 screws of the safety plates and then the 2 pins of the tilting cylinders.

Installation: After installation, tightening torque of the 2 screw of the safety plates for the pins of tilting cylinders = 24 Nm.

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MAST AND FORK CARRIAGE ROLLERS (All kind of masts) REMOVAL • INSTALLATION

Removal Procedure 1 Remove the roller pad. [Point 1] 2 Remove the elastic ring. [Point 2] 3 Remove the roller by using the appropriate extractor.

Installation Procedure The installation procedure is the reverse of the removal procedure.

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Point Operations [POINT 1] Removal: Remove the roller pad by using two screw drivers.

[POINT 2] Removal: Remove the elastic ring with the clamp

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CHAPTER 7000 page 11

MAST AND FORK CARRIAGE ROLLERS (All kind of masts) INSPECTION • ADJUSTEMENT

Check: 1 Check the clearance between roller pad and inner mast profile Y.

82 mm ± 0,1

81,8 mm - 0,1

Long life roll bearing :

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Adjustment: 2 Adjust it by turning the adjusting screw showed in the picture.

Check: 1 Check the clearance between roller pad and inner mast profile X. Standard clearance: 0,2 - 0,4 mm.

Adjustment: 2 It is not possible to adjust this clearance.

In order to have the correct clearance it is necessary to replace the roller.

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CHAPTER 7000 page 13

MAST CHAINS INSPECTION • ADJUSTEMENT Inspection: 1 To check If the chain links are worn out, use the appropriate rule.

2 The chains must be replaced when, in a portion correspondig to 34 pitches, only 33 pitches are found.

Note: Perform measurement without removing the chain from the vehicle.

Inspect elongation over the entire chain length as it may be localized.

Adjustment: 1 Park the vehicle on a flat surface and set the mast in vertical position.

2 Remove the forks.

I

3 Check if the measure X is respected according to the tables.

4 Adjust to eliminate any chain sag by turning adjusting-nylon nut.

5 Check to see if the chain tension is equal on left and right sides.

6 Check that the chain is not twisted.

7 Check that the lifting higher meets the st dard.

8 In the upper position, check that the end stroke plate is not in contact with the fork carriage.

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TABLE ISO 2328 - 1993 Rate Lifting load (kg) "X" (± 5) IA 0 ÷ 999 76 mm II A 1000 ÷ 2500 76 mm III A 2500 ÷ 4999 76 mm IV A 5000 ÷ 8000 127 mm VA 8001 ÷ 10999 127 mm TABLE ISO 2328 - 1993 Rate Lifting load (kg) "X" (± 5) IB 0 ÷ 999 114 mm II B 1000 ÷ 2500 152 mm III B 2500 ÷ 4999 203 mm IV B 5000 ÷ 8000 254 mm VB 8001 ÷ 10999 257 mm

FORK REMOVAL • INSPECTION Removal: 1 Lift the fork to approx. 20 cm from the ground..

2 Place a wood block under the notched section of the fork rail.

3 Unlock the fork by lifting the fork stopper pin and shift one fork per time to the fork carriage bottom notch.

4 Slowly lower the fork for removal.

G

E

F D

Installation: The installation procedure is the reverse of the removal procedure.

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

1 Surface cracks The fork arm must be thoroughly examined visually or 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.

2 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.

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CHAPTER 7000 page 15

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

4 Legibility of marking.

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

5 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.

6 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.

7 Withdrawal of the forks from service Any fork with defects revealed during the above controls must be withdrawn from service.

Note: Any component or system tampering can endanger the vehicle safety.

Any repair and replacement operation should be performed by personnel adequately trained and authorised.

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SERVICE MANUAL

2M F.F.L. - 3M F.F.L. MAST COMPONENTS MAST (2M F.F.L.)

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ELECTRIC

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SERVICE MANUAL

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FORK CARRIAGE (2M F.F.L. - 3M F.F.L.)

CHAPTER 7000 page 17

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CHAPTER 7000 page 18

SERVICE MANUAL

CHAIN & CHAIN WHEEL (2M F.F.L.)

CHAIN & CHAIN WHEEL (3M F.F.L.)

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CHAPTER 7000 page 19

LIFT CYLINDER GENERAL 1,0-1.5t

CENTRAL CYLINDER

SIDE/REAR CYLINDER

2 displacement cylinders without braking effect

2M TV

/

2 displacement cylinders with braking effect on lifting

2 displacement cylinders with braking effect on lowering

2 displacement cylinders with braking effect on lifting

2 displacement cylinders with braking effect on lowering

2M FFL

3M FFL

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SPECIFICATIONS SIDE/REAR LIFTING CYLINDER (2M VT and 3M FFL) Load capacity Item Cylinder type Cylinder bore Piston rod outside diameter Others

mm mm

1,0 t

1,25 t

1,5 t

42 36

Single-acting type ← ← Parachute valve

← ←

CENTRAL LIFTING CYLINDER (2M FFL and 3M FFL) Load capacity Item Cylinder type Cylinder bore Piston rod outside diameter Others

mm mm

1,0 t

1,25 t

1,5 t

45 38

Single-acting type ← ← Parachute valve

← ←

1,0 t

1,25 t

1,5 t

35 25

Single-acting type ← ← Parachute valve

← ←

SIDE/REAR LIFTING CYLINDER (2M FFL) Load capacity Item Cylinder type Cylinder bore Piston rod outside diameter Others

mm mm

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COMPONENTS LIFTING CYLINDER (2M VT)

SIDE/REAR LIFTING CYLINDER (2M FFL)

CHAPTER 7000 page 21

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CHAPTER 7000 page 22

SERVICE MANUAL

SIDE/REAR LIFTING CYLINDER (3M FFL)

CENTRAL CYLINDER (2M FFL and 3M FFL)

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CHAPTER 7000 page 23

SIDE/REAR CYLINDER REMOVAL • INSTALLATION

A

C

B

Removal Procedure 1 Set the mast in the vertical position and fully lower the forks.

2 Fix a belt or chain on the mast profile.

3 Disconnect the battery plug.

4 Disconnect the cylinder pipe-hose and the pipe clips C. [Point 1] 5 Remove the upper fixing bolt A and the lower fixing bolt B. [Point 2] 6 Lift the mast in order to free the cylinders.

7 Extract the cylinder from the mast.

Installation Procedure The installation procedure is the reverse of the removal procedure.

Note: After installing the lifting cylinders, follow the steps below: 1. Without load repeat full stroke lifting and lowering of the cylinder to bleed air and check normal functioning.

2. Check the hydraulic oil level and add if insufficient.

3. Inspect lifting cylinders for uneven lifting, and make any necessary adjustment.

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Point Operations [POINT 1] Removal: Remove the pipe-hose clips C. C

[POINT 2] Removal: Remove the upper fixing bolt A. A

Removal: Remove the upper fixing bolt B.

B

Installation: After installation, perform adjustment if necessary in order to have following clearance of the upper fixing bolds of the cylinders A = 4 (0 / -0,3) mm.

2M TV and FFL

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3M FFL

CHAPTER 7000 page 25

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CHAPTER 7000 page 26

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CENTRAL CYLINDER REMOVAL • INSTALLATION

A

B

Removal Procedure 1. Set the mast in vertical position and fully lower the forks.

2. Disconnect the battery plug.

3. Remove the lifting chain and roller from the cylinder. [Point 1] 4. Disconnect the cylinder hose.

5. Remove the bottom fixing bolt B. [Point 2] 6. Remove the upper fixing cylinder bracket A. [Point 3] 7. Remove the central cylinder.

Installation procedure The installation procedure is the reverse of the removal procedure.

Note: After installing the lifting cylinders, follow the steps below: 1) 2)

Without load repeat full stroke lifting and lowering of the cylinder to bleed air and check normal functioning.

Check the hydraulic oil level and add if insufficient.

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CHAPTER 7000 page 27

Point Operations [POINT 1] Removal: Remove the chain and then the Allen screw in order to take away the roller on his support.

[POINT 2] Removal: Remove the botton fixing bolt B.

B

[POINT 3] Removal: Remove the two screws of the upper fixing cylinder bracket A.

A

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LOWERING VALVE (HAWE, for all masts) SPECIFICATIONS

S

Hawe valve setting Mast type

Hawe valve type

s (mm)

2M TV

sb 25 c

16

2M FFL

sb 25 c

17,5

3M FFL

sb 25 c

17,5

3M TV

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CHAPTER 7000 page 29

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MAST PERFORMANCE TABLE Q1 max. load

Q2 max. load at max. height

Perform the test with the electrolyte density from 1.18 to 1.26 and the electrolyte temperature from 20° to 50° 1.0t Load

FFL

Kg

m/sec

Q1

0,30

min

max

0,60

TV

amp max

bar 330

max

m/sec 135

amp

0,30

min

max

0,60

bar

max

370

max

145

max

410

max

175

max

410

max

175

max

450

max

205

max

450

max

205

max

480

max

235

lowering Q1

Lifting end stroke (max. pressure valve adjustment)

1.25t Load

FFL

Kg

m/sec

Q1

0,28

min

max

0,60

TV

amp max

bar 360

max

m/sec 160

amp

0,29

min

max

0,60

bar

lowering Q1

Lifting end stroke (max. pressure valve adjustment)

1.5t Load

FFL

Kg

m/sec

Q1

0,27

min

max

0,60

TV

amp max

bar 400

max

m/sec 180

amp

0,27

min

max

0,60

bar

lowering Q1

Lifting end stroke (max. pressure valve adjustment)

Test to be done at 1 m height with Q1 load Tilting angle value tolerance: ± 0.5° Std tilt = 3° FW; => 6° BW degrees/sec

amp

bar

BW - FW

1,5

3

max

55

max

40

FW - BW

1,5

3

max

140

max

120

Tilting end stroke Lever control valve

max

150

max

160

Tilting end stroke Electric control valve

max

240

max

240

Std side shift stroke 100 mm: visual check

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REMOVAL • INSTALLATION Note: The explanation here is for the flow regulator valve for all the mast.

A

Removal Procedure 1 Set the mast in vertical position and lift it up to reach the valve.

2 Disconnect the battery plug.

3 Fix the mast with a chain-belt or with wood blocks in order to avoid the mast lowering.

4 Disconnect the flexible hose that connected to the control valve A. 5 Remove the lowering valve.

Installation Procedure The reassembly procedure is the reverse of the disassembly procedure.

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TILT CYLINDER GENERAL T = Nm

T = 300 Nm

SPECIFICATIONS Cylinder type

Double acting type

Cylinder bore

mm

65

Piston rod outside diameter

mm

32

COMPONENTS

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CHAPTER 7000 page 32

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REMOVAL • INSTALLATION T = Nm

T = 24 Nm T = 300 Nm

Removal Procedure 1 Remove the foot board.

2 Set the mast in vertical position.

3 Disconnect the hose. (After releasing the residual pressure in the tilt cylinder by operating the tilt lever several strokes).

4 Remove the tilting cylinder front pin. [Point 1] 5 Remove the tilting cylinder rear pin. [Point 2] 6 Remove the tilting cylinder.

Note: If both tilting cylinders are removed fix the mast with a chain in order to avoid the mast overturning.

Installation Procedure The installation procedure is the reverse of the removal procedure.

Note: • Apply grease to the insertion portions of the tilting cylinder front and rear pins before installation.

• After installation, slowly tilt the mast forward and backward a few times to check normal functioning.

• Check the hydraulic oil level and add if insufficient.

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CHAPTER 7000 page 33

Point Operations [POINT 1] Removal: Remove the safety screw and then the tilting cylinder front pin.

T = 24 Nm

[POINT 2] Removal: Remove the safety screw and then the tilting cylinder rear pin.

T = 24 Nm

ADJUSTMENT Note: • Adjust the mast forward and backward tilting angle (to prevent uneven tilting) when the tilting cylinder and mast are replaced.

• After adjustment perform SAS matching.

Adjustment: Turn the tilting cylinder rod with a spanner on the appropriate sense and then tight counter nut with a tightening torque of 300 Nm.

T = 300 Nm

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CHAPTER 8000

ATTACHEMENT

CHAPTER 8000 page 1

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CHAPTER 8000 page 2

SERVICE MANUAL

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CHAPTER 9000

OPTIONS

CHAPTER 9000 page 1

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CHAPTER B

MAINTENANCE TABLES

CHAPTER B page 1

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CHAPTER B page 2

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MAINTENANCE TABLES OIL AND GREASE SPECIFICATIONS STANDARD TYRES TIGHTENING TORQUES RUNNING-IN MAINTENANCE TIMES TABLES MAINTENANCE TIMES TABLES

page 3 page 3 page 3 page 4 page 5

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CHAPTER B page 3

036-0424-01

OIL AND GREASE SPECIFICATIONS FOR NORMAL ENVIRONMENTS type

specifications

q.ty PARTS INVOLVED

AGIP ARNICA 46

ISO-L-HV FZG (test to stage 11)

MOBILUBE 1 SCH 75W-90 LS

SAE 75W-90API GL4-GL5, MT1 4,2 L Transmission reduction gears SAE J 1730-JAN 80 DOT 4 TYPE ------ Hydraulic brake system

AGIP BRAKE FLUID DOT 4

18 L Hydraulic, lifting and steering system,

MOBILGREASE

Lithium base ASTM

------ Mast securing joints - sideshift unit -

SPECIAL

275-305 NLGI Nr.2

steering joint - general lubrication

Dropping point 180°

with grease nipples - Mast guides FOR COLD CLIMATES AND COLD-STORAGE CELLS

type

specifications

AGIP ARNICA 22 MOBILTEMP SHC 100

q.ty PARTS INVOLVED

ISO-L-HV FZG (tests to stage 10) 18 L Hydraulic, lifting and steering system, ------ Mast securing joints - sideshift unit Thickening Infusible ASTM 265-295 NLGI Nr.2

steering joint - general lubrication

Dropping point >260°

with grease nipples - Mast guides

STANDARD TYRES Type (C) (SE - PN)

Front / Rear Front / Rear Front / Rear

Syze 457 x 152 457 x 178 18 x 7 - 8 (16PR)

Air Pressure

10 bar

TIGHTENING TORQUES Nm 140 140 40 140 283 83 8÷12 300 83 18 28 13 22 380

WHEEL TORQUE steering wheels driving wheels DRIVE UNIT TORQUE electric motor securing gear unit securing complete unit securing to the frame VARIOUS TORQUES mast-securing U-bolts jack collar self-locking nuts tilting jack securing nuts brake shoe securing service brake:output hose screw screw on the brake pump securing screw of the parking brake cable oil inlet plug counterweight locking screws

Truck 1,0 - 1,3 t.

1,5 t.

1,0 - 1,3 - 1,5 t.

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RUNNING-IN MAINTENANCE TIMES TABLES 50 7/',

after # hours FOR MEDIUM/INTENSE USE after # days/months FOR OCCASIONAL USE LIFTING UNIT - MASTS guide pads - masts and sideshift unit slides

&

lifting oil filter

'

chain security bolts

& , ,

DRIVE UNIT(S) transmission reduction gear oil - differential gear oil CHASSIS AND COMMANDS bolts in general wheel tightness

LEGEND

'

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

&

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

"

In the maintenance table showing lubrification of the parts indicated.

,

In the maintenance table showing tightening or adjustment of the parts indicated.

The servicing periods are divided into hours, considering an average working day of 8 hours of effective operation.

If the truck is used on average for less than 8 hours per day, refer to the schedules expressed in days/months

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CHAPTER B page 5

MAINTENANCE TIMES TABLES 8

50

250

500

1000

2000

5000 10000 after # hours FOR MEDIUM/INTENSE USE -/24 -/60 after # days/months FOR OCCASIONAL USE LIFTING EQUIPMENT - MASTS carriage - sideshift unit

1/-

7/-

-/1

-/3

-/6

-/12

-

-

-

-

',

-

-

-

-

-

'"

-

-

-

forks positioning pins

-

-

-

'

-

-

-

-

mast guide pads

-

-

-

-

'

-

-

-

mast, carriage and chain rollers

-

-

-

-

-

-

&

-

tilting jacks supply pipes

-

-

-

-

-

&

-

-

lifting oil filter

-

-

-

'

-

&

-

-

lifting system oil

-

-

-

-

'

-

-

-

mast guides, mast and jack fixing

-

-

-

-

',

-

-

-

lifting jack retaining collars

-

-

-

'

-

-

-

-

fork carriage position

-

-

-

-

'

-

-

-

forks

-

-

-

'

-

-

-

-

mast inclination

-

-

-

-

',"

-

-

-

mast fixing to the frame

-

-

-

-

'"

-

-

&

lifting chains

-

-

-

-

'"

-

-

&

chain stay bolts

-

-

-

-

-

-

-

&

-

-

-

-

'

-

-

-

high pressure hydraulic pipe system hydraulic seals and connection

-

-

-

'

-

-

-

-

tilting jacks nuts DRIVE UNIT system seal

-

-

-

-

'

-

-

-

-

-

-

'

-

&

-

-

-

-

-

-

,

-

-

-

transmission reduction gear oil differential gear oil transmission complete unit

-

-

-

-

-

&

-

-

brake shoes wear

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CHAPTER B page 6

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MAINTENANCE TIMES TABLES 8

50

250

500

1000

2000

5000 10000 after # hours FOR MEDIUM/INTENSE USE -/24 -/60 after # days/months FOR OCCASIONAL USE ELECTRICAL SYSTEM electronic control

1/-

7/-

-/1

-/3

-/6

-/12

-

-

-

-

'

-

-

-

-

'

-

-

-

-

safety control circuit

-

-

-

-

'

-

-

-

lead terminals - lead insulation

-

'

-

-

-

-

-

-

-

-

-

'

-

-

-

-

-

-

-

-

',

-

-

-

BATTERY - specific gravity and charge level ELECTRIC MOTORS - external cleaning motor supports CHASSIS AND CONTROLS steering and pipe systems seal

-

-

-

-

'

-

-

&

-

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SERVICE MANUAL

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CHAPTER C

SAFETY INFORMATION

CHAPTER C page 1

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CHAPTER C page 2

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SAFETY INFORMATION SAFETY INFORMATION.......................................................................................... page 3 WORK CLOTES ....................................................................................................... page 3 WORK PLACE.......................................................................................................... page 3 LIFTING THE TRUCK .............................................................................................. page 3 ELECTRIC PART...................................................................................................... page 5 CHANGING THE BATTERY..................................................................................... page 5 WELDING................................................................................................................. page 6 TRUCK WASHING ................................................................................................... page 6

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CHAPTER C page 3

SAFETY INFORMATION WORK CLOTHES • 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) • If the fork is loaded, unload it and park the vehicle on a flat surface. Be sure to avoid an inclined or rough surface.

LIFTING THE TRUCK Always observe the following instructions when lifting up the vehicle: • Use metal or hard wood blocks; use a jack with ample capacity and lift up the vehicle at the specified lift-up point. Lifting up at any other point is dangerous.

• Always support the load of lifted-up vehicle with wooden blocks at specified points.

Supporting the vehicle with the jacks only is very dangerous. Before putting the blocks under the must, check the inclination of the floor, the truck must be parked on a flat, horizontal surface.

• Never, under any circumstances, put any part of the body (including hands and feet) under the lifted-up vehicle.

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• Block the steering wheel with chocks (A)

A • Before doing any job, it is obligatory to lift the front wheels with blocks to avoid the risk of accident. Tilt the mast back and place blocks (B) under their base.Tilt the mast forwards: the front wheels must be lifted and free to rotate.

B

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CHAPTER C page 5

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 from the voltage stated on the unit plate. If the battery voltage is higher, it may cause the MOS failure. If the battery voltage is lower, the unit does not run.

• During the battery recharging no units must be connected to the battery as the unit can be damaged by the overvoltage generated by the battery charger.

• Supply the unit only with the traction battery, do not use any output rectifiers or power supplies.

• With the key switched off, the filter capacitors could remain charged for some minutes. To ensure safe working conditions, we advise: • To wait some seconds with the machine stopped and the key inserted until the display turns completely off to disconnect the battery.

Or • To short-circuit the capacitors through a resistor (56 Ohm 1W) between the B+ and Bchopper power connections.

• Do not wear jewellery, necklaces, watches, etc because they can be causes of short circuit.

CHARGING OF THE BATTERY • Do not smoke (danger of explosion).

• It is necessary to switch the battery charger off before disconnecting the battery.

• Also little sparks 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

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WELDING • Wear a leather overall, gloves and a 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 performable inside the working area where you are.

• When these operations are carried out on a truck, in order to avoid the danger of explosion, cover and protect the battery and the parts in contact with fuel carefully.

• Make sure that around the working area there are not any inflammable products.

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

TRUCK WASHING • During this operation be careful when using water on electric components.

CESAB S.p.A via Persicetana Vecchia, 1040132 Bologna - Italy Tel.(0039) 051.20 54 11 Fax (0039) 051.72 80 07 E-mail: cesab@cesab.it