Caterpillar NO12N2F(P) NO20N2(P) NO25N2(P) Service Manual - PDF DOWNLOAD

SERVICE MANUAL

NO12N2F(P) NO20N2(P) NO25N2(P)

English

639785-EN A

Service Manual

Only adequately trained persons are allowed to carry out service operations. The terms of the warranty prescribe appropriate maintenance of the truck. Use original spare parts.

It is recommended that you sign a maintenance agreement with the truck dealer, who can also supply spare parts. Only professional service ensures long-term, trouble-free truck operation.

Service program monitoring becomes easier if you enter the service dates in a service logbook. Contact our service organisation or your truck dealer for qualified, authorized and efficient maintenance service.

Copyright © 2018 M&)(. All rights reserved.

CAT, CATERPILLAR, BUILT FOR IT, their respective logos, "Caterpillar Yellow", the "Power Edge" trade dressas well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

Unauthorized copying and lending are prohibited.

Mitsubishi Logisnext Asia Pacific Pte. Ltd No. 1, Tuas West Street Singapore 637444

MCFA

MCFE B.V

2121 W. Sam Houston Pkway. N. Houston, TX 77043–2305 USA

Hefbrugweg 77 1332 AM Almere The Netherlands

Approvals and version history REVISION

DATE

DESCRIPTION OF CHANGE

APPROVED BY

A

28-08-2018

First issue

R&D

These are the original instructions.

Copyright © 2018 by MCFE. All rights reserved.

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Service Manual

Contents 1 Foreword........................................................................................................10 2 How to read this manual................................................................................. 11 2.1 Safety-related signs ................................................................................ 11 2.2 Symbols and abbreviations...................................................................... 11 2.3 Other symbols and abbreviations .............................................................13 2.4 Units......................................................................................................14 3 Safety instructions .........................................................................................15 3.1 General safety instructions ......................................................................15 3.1.1 Safety requirements for industrial trucks......................................15 3.1.2 Repairs and structural modifications ...........................................15 3.1.3 Service area safety....................................................................16 3.1.4 Personal safety .........................................................................17 3.1.5 Work safety...............................................................................17 3.1.6 Operating temperature...............................................................18 4 General information .......................................................................................19 4.1 Intended use ..........................................................................................19 4.2 Identification plates on the truck ...............................................................19 4.3 Overview of the truck ..............................................................................20 4.3.1 Operating position .....................................................................20 4.3.2 Operating direction ....................................................................21 4.3.3 Operating devices .....................................................................21 4.3.4 Control panel ............................................................................22 4.3.5 Side control panel......................................................................23 4.3.6 Emergency stop button ..............................................................23 4.3.7 Operation modes.......................................................................23 4.3.8 Truck display.............................................................................24 4.3.8.1 Standard display ......................................................24 4.3.8.2 Keypad for standard display (optional) .......................28 4.3.8.2.1 Activate the truck with a PIN code (optional).....28 4.3.8.2.2 Program a new PIN code................................28 4.3.8.3 Color display (optional) .............................................29 4.3.8.3.1 Display control buttons ...................................30 4.3.8.4 Hierarchy of the truck display menus..........................30 4.3.8.5 Main view of the truck display ....................................31

4.3.9 4.3.10

4.3.8.6

Truck display icons ...................................................31

4.3.8.7 4.3.8.8

Battery discharge indicator........................................32 Parking brake indicator .............................................33

4.3.8.9 4.3.8.10

Center information area ............................................34 Message area ..........................................................34

4.3.8.11

Selection view..........................................................38

Operator presence sensing platform ...........................................40 Backrest ...................................................................................41 4.3.10.1 Seat/backrest (option)...............................................41 4.3.10.2

4.3.11

Copyright © 2018 by MCFE. All rights reserved.

Optional controls in the backrest................................42

Load handling device.................................................................42 4.3.11.1 Standard forks .........................................................42

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4.3.11.2 4.3.12

Simplex mast unit .....................................................43

Second level order picking (optional)...........................................43 4.3.12.1 Climbing rails and steps ............................................44 4.3.12.2

Lifting platform .........................................................44

5 Mechanical maintenance................................................................................46 5.1 Lifting points...........................................................................................46 5.2 Jack points.............................................................................................46 5.3 Hoist points ............................................................................................46 5.4 Transportation ........................................................................................47 5.5 Order spare parts ...................................................................................47 5.6 Truck covers...........................................................................................48 5.6.1 Remove the front cover..............................................................48 5.6.2 Open the battery cover ..............................................................49 5.6.3 Remove the load backrest..........................................................50 5.6.4 Remove the back cover .............................................................50 5.7 Drive unit ...............................................................................................50 5.7.1 Remove the drive unit ................................................................51 5.7.1.1 Remove the steering motor of the drive unit................52 5.7.1.2 Remove the traction motor and transmission gear from the drive unit ............................................................53

5.8 5.9 5.10

5.11 5.12

5.13

5.14

5.15 5.16

5.17

5.7.1.3

Remove the traction motor from transmission gear .....54

5.7.1.4

Assemble the traction motor and transmission gear connection ...............................................................54

5.7.1.5 Remove the transmission gear ..................................55 5.7.2 Remove the magnetic brake.......................................................57 Transmission gear ..................................................................................57 Slewing bearing......................................................................................58 Pump motor ...........................................................................................59 5.10.1 Remove the pump motor (standard models) ................................59 5.10.2 Remove the pump motor (Lifting platform models) .......................60 Truck wheels ..........................................................................................62 Traction wheel ........................................................................................63 5.12.1 Remove the traction wheel ........................................................63 5.12.2 Assemble the traction wheel.......................................................65 5.12.3 Replace the wheel shaft bolts .....................................................66 Load wheels...........................................................................................68 5.13.1 Disassemble the load wheel .......................................................68 5.13.2 Assemble the load wheel ...........................................................68 Castor wheel ..........................................................................................69 5.14.1 Adjust the castor wheel ..............................................................69 5.14.2 Remove the castor wheel...........................................................70 5.14.3 Disassemble the castor wheel ....................................................70 5.14.4 Assemble the castor wheel.........................................................71 Lifting system and fork carriage ...............................................................71 5.15.1 Disassemble the linkage mechanism ..........................................72 Steering wheel .......................................................................................75 5.16.1 Remove the steering wheel ........................................................75 5.16.2 Replace the gas spring of the steering wheel ...............................77 5.16.2.1 Install a new gas spring.............................................79 Color display ..........................................................................................80 5.17.1 Change the color display............................................................80

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5.17.1.1

Remove the color display ..........................................80

5.17.1.2 Install the color display..............................................81 5.18 Simplex mast unit ...................................................................................83 5.18.1 Maintenance of the mast unit......................................................83 5.18.1.1 Daily maintenance....................................................83 5.18.1.2 5.18.1.3 5.18.2

5.18.3 5.18.4

Monthly maintenance ...............................................84 Annual maintenance (1000 h)....................................84

Lubricant recommendations .......................................................84 5.18.2.1 Mast chains .............................................................84 5.18.2.2 Mast channels..........................................................84 Remove the mast unit ................................................................84 Disassemble the mast unit .........................................................86 5.18.4.1 Remove the lifting carriage........................................87 5.18.4.2

Remove the main rollers of the lifting carriage.............88

5.18.4.3 5.18.4.4

Remove the mast cylinder.........................................88 Disassemble the chain yoke......................................89

5.18.5

Inspect the forks........................................................................90 5.18.5.1 Welded forks............................................................90

5.18.6

Mast chains ..............................................................................91 5.18.6.1 Inspect the mast chains ............................................91

5.18.7

5.18.6.2 5.18.6.3

Measure the elongation of the mast chains.................92 Maintenance of the mast chains ................................94

5.18.6.4

Inspect the tension of the mast chains........................98

5.18.6.5 5.18.6.6

Adjust the mast chains..............................................98 Disassemble the chains ............................................98

5.18.6.7 Replace the mast chains...........................................99 Lifting cylinder ......................................................................... 102 5.18.7.1 Replace the lifting cylinder ...................................... 102 5.18.7.2 Sealing housing of the lifting cylinder ....................... 105 5.18.7.3

Disassemble the lifting cylinder................................ 105

5.18.7.4 Bleed the mast cylinder........................................... 106 5.19 Operator presence sensing platform ...................................................... 108 5.19.1 Remove the operator sensing platform floor .............................. 109 5.19.2 Replace the operator platform sensor ....................................... 109 5.19.3 Replace the rubber stoppers .................................................... 111 5.20 Lifting platform...................................................................................... 112 5.20.1 Remove the lifting platform....................................................... 112 5.20.2 Remove the floor of the lifting platform ...................................... 115 5.20.3 Remove the battery of a lifting platform truck ............................. 116 5.20.4 Replace the operator presence pedal sensor............................. 117 5.20.5 Replace the rubber stoppers .................................................... 118 5.20.6 Replace the wiring harness ...................................................... 118 5.20.7 Remove the foot lowering pedal................................................ 121 5.20.8 Bleed the lifting platform cylinder .............................................. 122 5.20.9 Guidance rollers ...................................................................... 123 5.20.10 Adjust the lifting platform sideways ........................................... 124 5.20.11 Adjust the lifting platform machine-way ..................................... 125 6 Electrical operation ...................................................................................... 126 6.1 Overview ............................................................................................. 126

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6.2 6.3 6.4 6.5 6.6

Power source ....................................................................................... 126 Safety circuit (emergency stop button).................................................... 126 Key switch............................................................................................ 126 Traction ............................................................................................... 127 AC motor operation............................................................................... 127

7 Batteries....................................................................................................... 128 7.1 General information ............................................................................. 128 7.1.1 Safety with lead-acid batteries .................................................. 129 7.2 Battery maintenance ............................................................................. 129 7.2.1 Daily maintenance................................................................... 129 7.2.2 Weekly maintenance ............................................................... 130 7.2.3 Annual maintenance................................................................ 130 7.2.4 General maintenance .............................................................. 130 7.2.5 Storage .................................................................................. 130 7.2.6 Malfunctions ........................................................................... 131 7.2.7 How to clean batteries ............................................................. 131 7.2.7.1 How to clean vehicle traction batteries ..................... 131 7.2.7.2 How to avoid damage to the plastic parts of batteries 132 7.3 7.4 7.5 7.6 7.7

Requirements for the battery charging areas........................................... 132 Charge the battery ................................................................................ 133 7.4.1 When the battery is charged..................................................... 135 Measure the specific gravity of the battery .............................................. 136 Acquire a new battery ........................................................................... 136 Replace the battery............................................................................... 136 7.7.1 How to replace the battery........................................................ 137

8 Electric system maintenance ....................................................................... 139 8.1 Control panel........................................................................................ 139 8.1.1 Emergency stop button for standard models .............................. 139 8.1.2 Key switch .............................................................................. 139 8.1.3 Walk beside drive buttons (optional).......................................... 140 8.2 Electric panel ....................................................................................... 140 8.2.1 Discharge the controllers ......................................................... 141 8.2.2 Traction controller.................................................................... 142 8.2.3 Traction controller connector .................................................... 143 8.2.3.1 CNA external connector.......................................... 144 8.2.3.2 Description of the power connections....................... 147 8.2.4

Steering controller ................................................................... 147 8.2.4.1 CNA external connector.......................................... 148 8.2.4.2

8.2.5

8.2.5.2 8.2.5.3

8.3

Description of the power connectors ........................ 149

Contactors and relays .............................................................. 149 8.2.5.1 Contactor functionality check................................... 149 Remove the controllers ........................................... 150 Remove the contactors ........................................... 151

8.2.6 Fuses ..................................................................................... 153 8.2.7 Replace the truck connector ..................................................... 153 Motor compartment............................................................................... 155 8.3.1 Magnetic brake ....................................................................... 156 8.3.1.1 The air gap of the magnetic brake............................ 156 8.3.1.2 Coil resistance measurement .................................. 156 8.3.2

Copyright © 2018 by MCFE. All rights reserved.

Traction motor......................................................................... 156

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8.3.2.1 8.3.3

8.4

8.5 8.6

Temperature sensor check ...................................... 156

Pump motor ............................................................................ 157 8.3.3.1 Solenoid valve ....................................................... 158

8.3.4 Steering motor ........................................................................ 160 Sensors ............................................................................................... 161 8.4.1 Pressure sensor ...................................................................... 162 8.4.2 Steering reference sensor ........................................................ 163 8.4.3 Steering speed sensors ........................................................... 164 8.4.4 Forks lift upper limit sensor....................................................... 164 8.4.4.1 Adjust the forks lift upper limit sensor ....................... 165 8.4.5

Speed sensor.......................................................................... 166 8.4.5.1 Replace the HALL sensor ....................................... 166

8.4.6 8.4.7 8.4.8

Operator platform sensor ......................................................... 167 Mast operating speed reduction sensor ..................................... 167 Lifting platform sensors............................................................ 168 8.4.8.1 Lifting platform lift stop sensor ................................. 168 8.4.8.2 8.4.8.3

Lifting platform lower speed reduction sensor ........... 169 Lifting platform lift speed reduction sensor................ 170

8.4.8.4

Operator presence sensor of the lifting platform ........ 170

Lifting platform foot lowering pedal ......................................................... 171 8.5.1 Lifting platform pedal functionality check ................................... 171 Horn .................................................................................................... 172 8.6.1 Diode test with a multimeter ..................................................... 172

9 Electric system adjustments and measurements ......................................... 173 9.1 Overview ............................................................................................. 173 9.2 Adjust the electrical steering .................................................................. 173 9.2.1 Assembly of the reference sensors ........................................... 173 9.2.2 Steering teaching .................................................................... 173 9.3 Insulation resistance test ....................................................................... 174 9.3.1 Test voltage ............................................................................ 174 9.3.2 Insulation tester check ............................................................. 174 9.3.3 Measure the insulation resistance............................................. 174 9.3.3.1 Insulation resistance of the truck.............................. 175 9.3.3.2

Insulation resistance of the battery........................... 175

10 Hydraulic operation...................................................................................... 177 10.1 Overview ............................................................................................. 177 10.2 Hydraulic symbols ................................................................................ 181 10.3 Hydraulic oil recommendations .............................................................. 182 10.4 Maintenance points of the hydraulic system ............................................ 183 10.5 Hydraulic aggregate (standard models) .................................................. 183 10.6 Hydraulic aggregate (lifting platform models) .......................................... 184 10.7 Hydraulic aggregate (1.2t mast model) ................................................... 185 10.7.1 Disassemble the hydraulic aggregate........................................ 185 10.7.2 Disassemble the hydraulic oil tank ............................................ 186 10.8 Replace the hydraulic cylinder ............................................................... 187 10.9 Hydraulic system with the lifting platform ................................................ 189 10.10 Hydraulic system with the simplex mast.................................................. 191 11 TruckTool Diagnostics ................................................................................. 192 11.1 Overview ............................................................................................. 192

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11.2 Location of the service socket................................................................ 193 11.2.1 Connect TruckTool to the service socket.................................... 193 12 Parameter descriptions ................................................................................ 194 13 Alarm codes ................................................................................................. 195 14 Service data ................................................................................................. 196 14.1 Special tightening torques ..................................................................... 196 14.2 Tightening torques for standard bolts...................................................... 196 14.3 Troubleshooting.................................................................................... 197 14.3.1 Standard display messages ..................................................... 198 14.3.2 Troubleshooting case examples ............................................... 198 14.3.3 Traction .................................................................................. 198 14.3.4 Brakes.................................................................................... 199 14.3.5 Hydraulics............................................................................... 199 14.3.6 Steering.................................................................................. 199 14.3.7 Charging................................................................................. 200 14.4 Lubrication ........................................................................................... 200 14.4.1 Hydraulic oil ............................................................................ 200 14.4.2 Transmission oil ...................................................................... 200 14.5 Special tools......................................................................................... 200 15 Options ........................................................................................................ 202 16 Technical specifications............................................................................... 205 16.1 Dimensions .......................................................................................... 205 16.2 Technical data ...................................................................................... 207 APPENDIX A: Stickers ...................................................................................... 210 APPENDIX B: Truck display languages............................................................. 214 APPENDIX C: Maintenance check list ............................................................... 215 Index ................................................................................................................. 218

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Service Manual

1

Foreword This service manual is a guide for servicing lift trucks.

The long productive life of your lift truck depends on regular and proper servicing, consistent with the instructions provided in this service manual.

Before you start to test, repair or rebuild a lift truck, read the respective sections of this manual carefully and make sure that you know all of the components.

The descriptions, illustrations and specifications contained in this manual are for lift trucks with serial numbers in effect at the time of printing.

The manufacturer reserves the right to change specifications or designs without notice and without incurring obligations. For your convenience, the instructions are grouped by systems as an easy reference.

Unauthorized copying and lending of this material is strictly prohibited.

READ THE MANUAL Read this manual before you operate or do maintenance on the truck. After reading this manual, store it in a safe, dry place for later use.

A truck can cause serious accidents unless you are sufficiently familiar with its operation and unless you know its operating and maintenance instructions.

To get more copies of this manual, contact your dealer.

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2

How to read this manual 2.1

Safety-related signs

These are the safety-related signs used in this document.

DANGER DANGER indicates a hazard with a high level of risk which, if not avoided, will result in serious injury or death.

WARNING WARNING indicates a hazard with a medium level of risk which, if not avoided, could result in serious injury or death, or damage to the machine.

CAUTION CAUTION indicates a hazard with a low level of risk which, if not avoided, could result in minor or moderate injury, or damage to the machine.

NOTE: Notes are used to indicate important information and useful tips.

2.2

Symbols and abbreviations

Hazard symbols These symbols indicate a hazardous situation or action. Symbols are used to warn of situations, which can cause environmental damage and personal injury.

General warning sign

Explosion and fire hazard

Battery hazard

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Corrosive hazard

Electrical hazard

Prohibited action symbols These symbols are used in warnings and notifications to indicate an action that should not be taken. The prohibited action symbols are shown below.

No smoking

Limited or restricted access

General symbol for prohibited action

Do not touch

Mandatory action symbols These symbols are used in warnings and notifications to indicate an action that must be taken. The mandatory action symbols are shown below.

Wear eye protection

General symbol for mandatory action

Read the manual or instructions

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First aid

Batteries marked with this sign must be recycled

Pb

2.3

Other symbols and abbreviations

Symbols or abbreviation

Description

OP

Option

COM

Common terminal

NC

Normally closed terminal

NO

Normally open terminal

R1/4

Taper pipe thread (external) 1/4 inch (formerly PT1/4)

RC1/8

Taper pipe thread (external) 1/8 inch (formerly PT1/8)

G1/4A

Straight pipe thread (external) 1/4 inch (formerly PF1/4–A)

Rp1/8

Straight pipe thread (external) 1/8 inch (formerly PS1/8)

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2.4

Units

SI units are used in this manual.

The following table shows the conversion of SI units to customary units.

Item

SI unit

Metric unit

Yard-pound unit

Force

1N

0.102 kgf

0.225 lbf

Pressure

1 MPa

10.1972 kgf/cm2

145.038 psi

Torque

1 Nm

0.102 kgf m

0.7376 lbf ft

Length

1 mm, 1 m

-

0.039 inch, 3.281 feet

Weight

1 kg

-

2.205 lb

Temperature

1 °C

-

°F=1.8 ˟ °C+32

Volume

1L

-

0.264 US.gal.

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3

Safety instructions 3.1

General safety instructions WARNING

The correct and safe maintenance of these lift trucks as recommended by the manufacturer is given in this document. Read this manual before you do any maintenance on these trucks. Incorrect performance of maintenance operations is dangerous and can cause injury or death.

After making this product available for the market, the manufacturer cannot be held responsible for modifications made by the customer or user and the consequences thereof, which may alter the conformity of the product with the CE marking.

Do not make changes or repairs that can make the structure of the truck weaker or put safety at risk.

READ THE MANUAL Do not operate the truck unless you have read and understood the instructions in the operation manual. Incorrect truck operation is dangerous and can result in injury or death.

MANDATORY ACTION Knowledge of the system and/or its components is important before you remove or disassemble the components.

The next sections make a list of some basic precautions that you must always obey.

3.1.1

Safety requirements for industrial trucks

The truck meets the essential requirements of Machinery Directive 2006/42/EC and EMC Directive 2014/30/EU. The truck is designed and constructed according to European safety standards EN ISO 3691-1, EN 16307-1, EN 11751 and EN 12895. The most important regulations and guidelines are given in these instructions.

As regulations for the end-user may vary from country to country, familiarize yourself with the regulations and standards valid in your country.

For further information on trucks and/or training, contact the sales organization.

3.1.2

Repairs and structural modifications

WARNING After making this product available for the market, the manufacturer cannot be held responsible for modifications made by the end user and the consequences thereof, which can alter the conformity of the product with the CE marking.

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To keep the EC Declaration Of Conformity issued by the original truck manufacturer, no modifications or alterations to a powered industrial truck, which could affect, for example, capacity, stability or safety requirements of the truck, must be made without the prior written approval of the original truck manufacturer, its authorized representative, or a successor thereof. This includes the changes affecting, for example, braking, steering, visibility and the addition of removable attachments. When the manufacturer or his successor approves a modification or alteration, the manufacturer or his successor must also make and approve the appropriate changes to the capacity plate, decals, tags and operation and maintenance manuals.

If the end user arranges a modification or alteration without the prior written approval of the original truck manufacturer, its authorized representative, or a successor, the end user must:

•

arrange for the modification or alteration to be designed, tested and implemented by an engineer(s) expert in industrial trucks and their safety

•

maintain a permanent record of the risk assessment, design, test(s) and implementation of the modification or alteration

•

approve and make appropriate changes to the capacity plate(s), decals, tags and operation and maintenance manuals

•

put a permanent and readily visible label to the truck stating how the truck has been modified or altered, together with the date of the modification or alteration and the name and address of the organization that accomplished those tasks, and

•

where appropriate, create a new EC Declaration Of Conformity and sign it.

3.1.3

Service area safety

• • •

Keep the servicing area clean. Oil, grease, and water make the floor slippery.

• •

The truck must always be supported on jacks, if someone works under it.

•

Lower the forks or other implements to the ground before performing any work on the truck. If this cannot be done, make sure the forks or other implements are blocked correctly to make sure that they do not fall unexpectedly.

•

Use steps and grab handles (if applicable) when you mount or dismount a truck. Clean mud or debris from the steps, walkways or work platforms before use. Always face the truck when you use steps, ladders and walkways. When it is not possible to use the designed access system, use ladders, scaffolds, or work platforms to perform safe repair operations.

•

To avoid back injury, use a hoist when you lift components that weigh 23 kg (51 lb) or more. Make sure that all chains, hooks, slings, etc., are in good condition and of the correct capacity. Make sure that all hooks are positioned correctly. Lifting eyes are not to be side-loaded during a lifting operation.

•

Make sure that all protective devices including guards and shields are properly installed and functioning correctly before you start a repair. If a guard or shield must be removed to perform the repair work, be even more careful than usually.

•

Always support the mast and carriage to keep the carriage or attachments raised when you perform maintenance or repair work that requires the mast to be in the lifted position.

If possible, make all repairs with the truck parked on a level, hard surface.

Before you start to do repairs on the truck, hang a Do not Operate sign in the operator compartment.

Do not work on any truck that is supported only by lift jacks or a hoist. Always use jack stands or other supports to support the truck before doing any disassembly.

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3.1.4

Personal safety

DANGER Do not lift or transport anyone on the forks or a load pallet that is on the forks. There is a risk of falling, danger to life!

Do not let anyone, under any circumstances, walk or stand under the forks.

Do not place any part of your body between the mast structures or any moving parts of the truck.

•

Remove all rings, watches and other pieces of metal jewellery before you start to do work on the truck. If a metal object becomes into touch with an electrically conductive part, it can cause a short circuit or a serious burn.

•

Always, wear protective glasses and protective shoes when you work around trucks. In particular, wear protective glasses when you use a hammer or sledge on any part of the truck or its attachments. Use welding gloves, hood/ goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose fitting or torn clothing.

3.1.5

Work safety

•

Set the power of the truck to OFF and disconnect the battery connector before you open the cover of the motor compartment or the electrical system.

•

Release all pressure in the air, oil or water systems before you disconnect or remove lines, fittings or related items. Release the residual pressure when you remove a pressurized device.

•

If it is necessary to work at height during maintenance work, make sure that you use applicable access equipment and follow the safety instructions of the equipment manufacturer.

• •

With sit-on trucks, remove the seat when you do servicing to the truck.

• •

Do not use your hands to find for oil leaks.

•

Only use clean oil in the hydraulic system. Always fill the oil through the oil filter.

•

Do not mix different lubricants. It is possible that different brands of lubricants are not be compatible with each other. Only use lubricants recommended by the manufacturer.

•

Repairs that need welding must be done only with the applicable reference information and by personnel trained in welding procedures. Determine the type of metal and select the correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of the parent metal.

•

When you weld, always disconnect the battery and electronic devices.

Remove all paint from a 10 cm radius from the welding point to avoid creating toxic gases during welding.

• •

Use the correct lifting procedures when you remove components.

•

Be careful when you remove filler caps, breathers and plugs on the truck. Put a cloth around the cap or plug to make sure that you do not become sprayed

Before you operate, lubricate or repair the truck, read all warning plates and stickers on the truck.

To prevent burns, be careful of the hot sections and hot fluids in lines, tubes and compartments, also when the truck is idle or OFF.

Be careful when you remove cover plates. Gradually, remove the last 2 bolts or nuts at the opposite ends of the cover or device. Before you remove the last 2 bolts or nuts, turn the cover loose to release springs or other pressures.

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or splashed by liquids under pressure. Be aware that the liquids spray and splash more easily immediately after you have stopped the truck, because the fluids are very hot.

•

Only use well-maintained tools. Also, make sure that you use the tools in a correct way.

•

Reinstall all fasteners with the same part number. If a replacement is necessary, do not use a fastener of lesser quality.

•

Do not cause damage to the wiring during the removal process. Do not use damaged wiring. When you install the wiring back, make sure the wiring does not touch sharp corners or hot parts. Put all wiring away from the oil pipe.

•

Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or hit high pressure lines or install ones that are bent or damaged. Examine all lines, tubes and hoses carefully. Pin hole (very small) leaks can cause a high velocity oil stream that cannot be seen near the hose. This oil can go through the skin and cause personal injury. Use a cardboard or paper to find pin hole leaks.

•

Tighten connections to the correct tightening torque. Make sure that all heat shields, clamps and guards are installed correctly to prevent excessive heat, vibration or rubbing against other parts during operation. Protective shields against oil sprays onto hot exhaust components in the event of a line, tube or seal failure must be installed correctly.

•

Do not operate the truck, if a rotating part is damaged or touches another part during operation. All high speed rotating components that are damaged or altered must be examined for balance before you use them again.

3.1.6

Operating temperature

The ambient operating temperature range of the truck is +5...+25°C. The truck can be operated at a temperature of 0...+45°C for short periods. The recommended humidity is 30...95% (noncondensing).

CAUTION Do not move a damp truck into a freezer storage! Let the truck dry before you do! If you move a damp truck into a freezer storage, there is a risk of malfunction because of ice accumulation!

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4

General information 4.1

Intended use

Low Level Order Picker - This truck is a 4-wheel ride-on electric pallet truck with a multifunctional control panel for driving, steering and load handling. It is designed for transporting collected goods on level surfaces indoors. Goods can be collected onto pallets or roll containers from the first order picking level. If the truck is equipped with a second order picking level option, the second order picking level can be reached by standing on the lifting platform or on the steps in the front and back of the operator compartment. It is also suitable for transport pallets in similar operating conditions. The maximum capacity with load centre distance is indicated on the truck's capacity plate.

4.2

Identification plates on the truck CAUTION

Make sure that all the plates and stickers on the truck are legible and securely attached.

4

5

8 4 1

6 2 3

7

Figure 1: Plates and stickers of the truck overview 1.

2.

3.

4.

Type plate Capacity plate Battery type plate General warning sticker

5.

6.

7.

8.

Do not step warning sticker Lifting hook sticker Hydraulic oil tank filling cap sticker Quick Guide sticker

Figure 1: Plates and stickers of the truck overview shows the plates and stickers of the truck and their locations. For more information on the plates and stickers of the truck, see APPENDIX A: Stickers.

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The type and capacity plates of the truck include:

• • • • • • • • • • •

CE mark Manufacturer name and address Truck designation Truck model Serial number Year of manufacture Battery minimum and maximum mass (kg) Battery terminal voltage (V) Nominal power (kW) Rated capacity (kg) with load centre distance (mm) Unladen mass of the truck in working order without battery (kg)

NOTE: If a plate or sticker is damaged, replace it with a new identical sticker.

When you send an order for a sticker, include the serial number of the truck in your order.

4.3

Overview of the truck 1

2 4

3 Figure 2: Overview of the truck 1. Safety devices 2. Battery compartment

3. Operator compartment 4. Load handling device

See detailed descriptions in the following sections.

4.3.1

Operating position

To operate the truck in the riding mode, step on the operator’s platform and keep your hands on the steering wheel. When you operate the truck, keep your body within the outlines of the truck. Adjust the steering wheel to make your operating position ergonomic.

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4.3.2

Operating direction

Figure 3: Forward driving direction

• •

To go forward, operate the truck to the direction of the steering wheel.

To go backward, operate the truck in the direction of the forks.

4.3.3

Operating devices

2 1

3 4

Figure 4: Operating devices 1. Control panel 2. Multifunctional steering wheel

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3. Optional controls in the backrest 4. Operator’s platform

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4.3.4

Control panel

3 1

4 2

Figure 5: Control panel overview 1. Emergency stop button 2. Key switch/start switch

3. Standard display 4. Keypad for standard display (optional)

Table 1: Control functionalities Control

Functionality description

Emergency stop button

Push the emergency stop button to disconnect the power supply of the truck. Turn the button clockwise to release it. Use the emergency stop button only in case of emergency.

Note that the truck stops abruptly!

Do not use the emergency stop button as a key switch/start switch!

Key switch/start switch

The truck is equipped with a removable key switch: Turn the key switch clockwise to switch on the electrical system of the truck.

After use, turn the key switch counterclockwise to switch off the electrical system of the truck. Remove the key when you leave the truck unattended.

Alternatively, the truck can be equipped with a PIN-code system.

This system includes a keypad and a non-removable start switch which replaces the key switch. Turn the start switch clockwise to switch on the electrical system of the truck. The PIN query appears on the display. Enter the PIN-code with the keypad. After use, turn the start switch counterclockwise to switch off the electrical system of the truck.

The key switch/start switch positions are: • 0 = Power off (power can be still connected to certain electronic devices) • I = Power on, economy mode (ECO) • I = Power on, professional mode (PRO) For more information on the operation modes, see Section 4.3.7 Operation modes.

Standard display

For information about the display, see Section 4.3.8.1 Standard display.

Keypad for standard display (optional)

Use these buttons to enter the PIN code. For information about the PIN-code system, see Section 4.3.8.2 Keypad for standard display (optional).

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4.3.5

Side control panel

3 2 1

Figure 6: Side control panel 1. Emergency stop button 2. Walk beside drive button, forward/ backward

4.3.6

3. Buttons for lift/lower

Emergency stop button

The emergency stop button is in the side control panel.

Push the emergency stop button to disconnect the power supply of the truck.

To release the button, turn the button clockwise.

Use the emergency stop button in these conditions:

•

If there is a short circuit or some other electrical malfunction (for example, if the pump motor does not stop running)

•

If there is an accident

4.3.7

Operation modes

3 2 1

Figure 7: Operation modes 1. Power off 2. Power on, economy mode

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3. Power on, professional mode

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The truck can be operated in two operation modes.

•

Economy mode (ECO).This is an easy truck operation mode for occasional truck operators, for training and for long truck operation periods. In the economy mode, the truck does not immediately respond to sudden actions of the truck operator and so the truck movements are smoother. In this mode, the truck operation is more economic than in the professional mode.

•

Professional mode (PRO). This is a professional truck operation mode for experienced truck operators. In the professional mode, the truck responds to the actions of the truck operator quicker than in the economy mode. In this mode, the experienced truck operators can operate the truck more intensively.

Use the key switch/start switch to select the operation mode, see Figure 7: Operation modes.

4.3.8

Truck display

2

1

Figure 8: Truck display 1. Standard display

4.3.8.1

2. Color display (optional)

Standard display

4 1 5 2 3 Figure 9: Standard display 1. Level of battery charge 2. Battery icon 3. Operational hours, system messages and fault codes

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4. Tool icon 5. Alarm indicator

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The standard display shows the following information:

1 Level of battery charge The battery discharge indicator shows the battery charge level.

Ten black bars indicates full battery.

Figure 10: Full battery When the battery charge level drops down to two bars, the remaining bars and the battery icon together with alarm indicator start blinking to indicate low battery charge level, see Figure 11: Two last bars, battery icon and alarm indicator blinking. The battery should be charged soon.

NOTE: When the battery charge level drops down to two bars, the operating speed is limited.

Figure 11: Two last bars, battery icon and alarm indicator blinking When the battery charge level drops down to one bar, the remaining bar and the battery icon together with alarm indicator are shown blinking in the indicator. The battery is almost empty and it must be charged immediately.

Figure 12: The last bar, battery icon and alarm indicator blinking

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2 Battery icon Steady battery icon indicates that the battery charge level is sufficient. Blinking battery icon indicates that the battery should be charged soon. To charge the battery, see Section 7.4 Charge the battery.

3 Operational messages, system messages and fault codes Operational hours Truck's operating hours are displayed in the bottom of the display.

Figure 13: Truck’s operating hours

System messages System messages are displayed in the bottom of the display.

•

ECO = Economy mode selected

Figure 14: System messages

Fault codes Fault codes are displayed in the bottom of the display.

The code is a numeric value which can present info, warning or alarm.

How to solve fault situations, see Section 14.3 Troubleshooting.

In the code:

• • •

The first digit(s) indicate the source of the fault (08xxxx).

The letter in the middle indicates the type of fault (xxAxxx).

The rest of the digits provide the actual fault code (xxx223).

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Figure 15: Fault code and blinking alarm indicator

4 Tool icon The tool icon indicates a fault. How to solve fault situations, see Section 14.3 Troubleshooting.

5 Alarm indicator The red light indicates an alarm. If the indicator starts blinking, stop using the truck immediately and contact service.

Figure 16: Fault code and blinking alarm indicator

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4.3.8.2

Keypad for standard display (optional)

1 2 3 4 6 5 Figure 17: Keypad buttons 1. Exit / Esc 2. Enter 3. PIN-code 1

4. PIN-code 2 5. PIN-code 3 6. PIN-code 4

Acquire the PIN code from the site supervision. Use the keypad to enter the code.

4.3.8.2.1

Activate the truck with a PIN code (optional)

To activate the truck with the PIN code.

1. Turn the start switch to ECO or PRO position.

2. The truck is waiting for the PIN code, the standard display shows "PIn".

3. Enter the 4 digits operator code with the keypad browse buttons, the display shows "oooo".

4. Press [Enter] to activate the truck, or press [Esc] to remove all digits and return to step 2.

5. If the code is correct, the display turns off the digits one by one then shows "SLOt #" (#=1,2,3).

If the code is incorrect, the display blinks "888888" then returns to step 2.

6. The truck is activated, the display shows the operational hours.

4.3.8.2.2

Program a new PIN code

Default codes:

• • • •

slot 1 (PRO mode), default code "1432" slot 2 (ECO mode), default code "1234" slot 3 (Fireman mode), default code "1111" slot 4 (Management mode), default code "432123"

To program a new PIN code: 1. Turn the start switch to ECO or PRO position.

2. The truck is waiting for the PIN code, the standard display shows "PIn".

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3. Enter the 6 digits management code with the keypad browse buttons, the display shows "oooooo".

4. Press [Enter] to activate the teach mode, or press [Esc] to remove all digits and return to step 2.

5. If the code is correct, the display turns off the digits one by one then shows "SLOt 4".

If the code is incorrect, the display blinks "888888" then returns to step 2.

The teach mode is activated, the display shows "tEACh".

Press [Enter] to continue to the next step, or press [Esc] to return to step 2.

The display shows "SLOt 8".

Enter the slot number 1-4.

Press [Enter] to set the slot number, or press [Esc] to cancel the selection and return to step 6.

11. Enter the PIN code: 6.

7.

8.

9.

10.

• •

4 digits for slots 1-3, the display shows "8888".

6 digits for slot 4, the display shows "888888".

NOTE: One slot can include several PIN codes.

12. Press [Enter] to set the code, or press [Esc] to delete digits one by one.

13. If the code is correct, the display turns off the digits one by one and then returns to step 6.

If the code is incorrect, the display blinks "888888" then return to step 6.

14. Press [Esc] to return to step 2.

15. Turn the start switch to OFF. 16. Pin codes can be reset to factory settings by TruckTool.

4.3.8.3

Color display (optional)

KM/H

PRO

1

2

Figure 18: Color display overview 1. Truck display

2. Display control buttons

NOTE: After you have set the power of the truck to ON, but before you start to operate the truck, wait until the main view is shown on the truck display.

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4.3.8.3.1

Display control buttons

5

1

4

2

6

3

Figure 19: Display control buttons 1. Browse up / PIN code 1 button 2. Browse right / PIN code 2 button 3. Browse down / PIN code 3 button

4.3.8.4

4. Browse left / PIN code 4 button 5. Exit / Esc button 6. Enter button

Hierarchy of the truck display menus 1

4

PIN

2

3

SERVICE

12345H

Hydraulic functions disabled

KM/H

ECO: easy performance mode for occasional usage. Reduces power consumption. PRO: efficient performance mode for professional operators.

Type

PS12DF

Serial number

123456

Hours

76h

Next maintenance in

0h

Next annual inspection

-

Traction Controller

SW HW SW HW

Display EPS

SW HW

Hours Last reset

LOP18C0M24 1.42 NA14DIS 1.08.03 8G7800CE401e LOP18EPS22 0.21 0F2795

76h 37h Hours

BDI

Count

0. 10A8100 1. 8A205 2. 25W203 3. 8A205

Code

76h 76h 76h 76h

77 50 67 68

1 1 2 1

4. 25A224 5. 8A154

76h 76h

79 79

2 1

6. 9A250 7. 10A8100

76h 76h

79 79

1 1

Figure 20: Hierarchy of the truck display menus

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4.3.8.5

Main view of the truck display

4 1 KM/H

2 5

3 Figure 21: Main view of the truck display 1. Battery discharge indicator 2. Truck display icons 3. Parking brake indicator

4. Center information area 5. Message area

In normal operating situations, the main view of the truck display shows the battery discharge indicator and the center information area with speed and direction.

NOTE: The display images in this manual have English messages as examples.

The display language can be changed via TruckTool. Contact the service personnel. See APPENDIX B: Truck display languages for available display languages.

4.3.8.6

Truck display icons

When the truck display shows a message, icons are shown on the truck display.

The icons vary according to the message type. The different icons are shown in the following table.

Table 2: Truck display icons Icon

Description Alarm message icon (red)

Warning message icon (yellow)

Informational message icon (blue)

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Icon

Description Maintenance warning icon (yellow)

Temperature warning icon (yellow)

Economy mode icon (ECO)

Professional mode icon (PRO)

PRO

4.3.8.7

Battery discharge indicator

The battery discharge indicator shows the battery charge level.

Ten green bars indicates full battery.

When the battery charge level drops down to two bars, the color of the remaining bars changes to yellow. Also, an exclamation mark icon on a yellow background is shown in the bottom left-hand corner of the truck display to indicate low battery charge level, see Figure 22: Battery charge level low. When the battery discharge indicator turns to yellow, you must charge the battery as soon as possible.

NOTE: When the battery discharge indicator turns to yellow, the operating speed is limited.

KM/H

Battery voltage low Recharge battery Figure 22: Battery charge level low When the battery charge level drops down to one bar, the color of the remaining bar changes to red. Also, an exclamation mark icon on a red background is shown in the bottom left-hand corner of the truck display, see Figure 22: Battery charge level low. When the battery discharge indicator turns to red, the battery is

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almost empty and it must be charged immediately.

NOTE: When the battery discharge indicator turns to red, the hydraulic functions are disabled and only limited traction speed is allowed.

KM/H

Battery voltage critical Recharge battery Figure 23: Battery charge level almost empty

4.3.8.8

Parking brake indicator

The parking brake indicator is shown in the bottom left-hand corner of the truck display. The parking brake engages automatically, when the truck is stopped.

KM/H

Figure 24: Parking brake indicator overview

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4.3.8.9

Center information area

2

1 KM/H

2

Figure 25: Center information area overview 1. Speed indicator

2. Driving direction indicator

In a normal operating situation, the center information area shows the speed indicator. In addition, the driving direction of the truck is indicated with 2 arrows moving around the center information area. They always point to the direction where truck moves or will move. If no driving direction is set, the arrows are blinking. When the driving direction is set, the selected direction is indicated with a solid blue colored arrow and the other arrow turns gray.

4.3.8.10

Message area

Important information about the use of the truck is shown at the bottom of the display.

Informational message An informational message gives instructions to the truck operator in cases in which the truck does not work in the expected way. In case of an informational message, the color of the stripes in the main view changes to blue and an information icon with blue background is shown in the bottom left-hand corner of the truck display. The informational message is displayed in the bottom of the display. See Figure 26: Main view with an informational message.

KM/H

Accelerator lever must be released Figure 26: Main view with an informational message

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Warning message In case of a warning message, the color of the stripes in the main view changes to yellow and an icon with yellow background is shown in the bottom left-hand corner of the truck display. The icon changes according to the type of the warning message, see the list of the icons in . The warning message is displayed in the bottom of the display. See Figure 27: Main view with a warning message.

KM/H

High temperature Lighten traction use Figure 27: Main view with a warning message

Alarm message In case of an alarm message, the color of the stripes in the main view and the background of the center information area change to red and an exclamation mark icon with a red background is shown in the bottom left-hand corner of the truck display. In the center information area, the appropriate error code replaces the speed.

The alarm message is displayed in the bottom of the display.

See Figure 28: Main view with an alarm message.

08A223

Internal alarm Call Service Figure 28: Main view with an alarm message In the alarm code:

• • •

The first digit(s) indicate the source of the error (08xxxx).

The letter in the middle indicates that this is an alarm (xxAxxx).

The rest of the digits provide the actual error code (xxx223).

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Fatal error or communication error If the truck display detects a fatal error (for example, the memory is corrupted), a fatal error message is shown to the operator. See Figure 29: Fatal error. In case of a fatal error, contact the service personnel.

Figure 29: Fatal error In case of a communication problem with the vehicle controller, a communication error message is shown to the operator.

See Figure 30: Communication error. In case of a communication error, contact the service personnel.

Figure 30: Communication error

PIN query (optional) The truck can be configured to a PIN query mode. The PIN query mode requires the operator to provide a PIN code before the truck can be operated. Acquire the PIN code from the site supervision.

The PIN code consists of 5 digits and it can contain digits from 1 to 4. The PIN code is entered to the system with the Browse/PIN code buttons, see Section 4.3.8.3.1 Display control buttons.

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1 4

PIN

2

3

Figure 31: PIN query view Use the TruckTool PIN code wizard to program new PIN codes.

Sleep mode If the truck is configured to use the sleep mode when idle, the truck display also includes the sleep mode view.

In the sleep mode, the truck display shows the battery charge level and the operating hours. See Figure 32: Sleep mode with the battery charge level and the operating hours.

12345H Figure 32: Sleep mode with the battery charge level and the operating hours

Service mode Use the TruckTool to completely disable the truck, or to disable only the hydraulics for service purposes.

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SERVICE Hydraulic functions disabled Figure 33: Service mode

4.3.8.11

Selection view

Selection view The selection view enables the operator to access instructions, view basic information about the status of the truck and adjust certain settings.

To go to the selection view, push the Enter button in the main view of the truck display.

To return to the main view, push the Esc button.

1

2

3

Figure 34: Selection view 1. Instructions 2. Truck information

3. Brightness setting

The selection view shows three icons: instructions, truck information and brightness setting.

To move the selection from one icon to another, use the Browse left/right buttons. To confirm your selection, push the Enter button. To return to the main view, push the Esc button.

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Instructions view

ECO: easy performance mode for occasional usage. Reduces power consumption. PRO: efficient performance mode for professional operators.

Figure 35: Instructions view The instructions view provides instructions for the truck operator. Browse through the pages with the Browse left/right buttons.

Truck information view Type

PS12DF

Serial number

123456

Hours

76h

Next maintenance in

0h

Next annual inspection

-

Traction Controller

SW HW SW HW

Display EPS

SW HW

LOP18C0M24 1.42 NA14DIS 1.08.03 8G7800CE401e LOP18EPS22 0.21 0F2795

76h 37h

Hours Last reset Code

Hours

BDI

Count

10A8100 8A205 25W203 8A205

76h 76h 76h 76h

77 50 67 68

1 1 2 1

4. 25A224

76h

79

2

5. 8A154

76h

79

1

6. 9A250

76h

79

1

7. 10A8100

76h

79

1

0.

1.

2.

3.

Figure 36: Truck information view (pages 1-3) The truck information view provides information about the truck, such as software and hardware versions, usage and service data and an error log.

Browse through the pages with the Browse left/right buttons.

The service data page shows the number of hours until the next maintenance. If the maintenance time has already passed, a minus sign is shown before the number of the hours to indicate how many hours have passed from the maintenance time.

The error log shows the last 10 errors that have occurred in the operation of the

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truck. Use the Browse up/down buttons to scroll the error log. The most recent error is shown on top of the list. The error code count increases if the same error occurs in the system several times consecutively. When a new error occurs, a new line is added to the list.

Brightness setting view

Figure 37: Brightness setting view In the brightness setting view, the operator can adjust the brightness of the truck display. Adjust the brightness using the Browse left/right buttons. Push the Enter button to save the adjustment. Push the Esc button to discard the changes and leave the brightness setting view.

4.3.9

Operator presence sensing platform

The truck has an operator presence sensing platform. To operate the truck, you must stand on the platform with your both feet. There are two types of platforms available: a fixed platform and a lifting platform. The lifting platform makes picking items on the second racking level easy.

Figure 38: Fixed platform and lifting platform

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4.3.10

Backrest

2

1

Figure 39: Backrest 1. Seat/backrest (option)

4.3.10.1

2. Optional controls in the backrest

Seat/backrest (option)

Figure 40: Seat/backrest The truck has an adjustable seat/backrest option.

The folding seat can be used as a seat or as a backrest which makes operating the truck more ergonomic.

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4.3.10.2

Optional controls in the backrest

3 2 1

Figure 41: Optional controls in the backrest 1. Emergency stop button 2. Push buttons for moving the truck forward and backward

3. Push buttons for lifting and lowering the forks

Control description

Functionality

Emergency stop button

Push the emergency stop button to disconnect the power supply of the truck. Turn the button clockwise to release it.

Use the emergency stop button only in case of emergency.

Note that the truck stops abruptly! Do not use the emergency stop button as a key switch/start switch!

Push buttons for moving the truck forward and backward

Push the buttons to move the truck forward and backward.

Release the button to stop the truck.

WARNING! Beware of a moving truck. Crushing hazard!

Push buttons for lifting and lowering the forks

Push the buttons to lift and lower the forks. Release the button to stop the forks.

WARNING! Beware of moving forks. Crushing hazard!

4.3.11

Load handling device

4.3.11.1

Standard forks

The truck can be ordered with standard forks of 900-3600 mm in length.

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Figure 42: Standard forks

4.3.11.2

Simplex mast unit

A truck that has a simplex mast unit can be used to lift and handle pallets up to 1,200 kg load with the maximum lifting height of 850 or 1200 mm. The adjustable lifting height makes the order picking ergonomic.

Figure 43: Truck with simplex mast unit

4.3.12

Second level order picking (optional)

The truck can be obtained with 2 different options for second level order picking:

• •

Climbing rails and steps Lifting platform

WARNING Observe extreme caution when collecting items from the second order picking level! Falling hazard!

Do not climb on top of the battery cover or racking! Falling hazard!

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4.3.12.1

Climbing rails and steps

Figure 44: Climbing rails and steps The second order picking level can be reached by standing on the steps in the front and back of the operator compartment.

To ascend the steps, use three-point support as follows: 1. Take a grip of the climbing rail and the frame of the truck.

2. Raise your foot onto the back step.

3. Exert yourself up and place your foot onto the front step.

4.3.12.2

Lifting platform

Figure 45: Lifting platform The second order picking level can be reached by standing on the lifting platform.

The maximum lifting height is 1000 mm above the ground level.

Pick up an item from the second order picking level 1. Stand on the lifting platform.

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2. Pull the right lever to lift the platform.

3. Release the lever to stop the lifting.

4. Pickup the item from the racking.

Bring the item down Lowering the platform: 1. Push the right lever to lower the platform.

2. Release the lever to stop the lowering.

3. Place the item onto the pallet that is on the forks.

Lowering the platform in trucks with the platform foot lowering pedal (option): 1. Double-click the pedal with your foot and hold it down to lower the platform.

2. Release the pedal to stop the lowering.

3. Place the item onto the pallet that is on the forks.

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5

Mechanical maintenance 5.1

Lifting points

Lift or jack up the truck and put rigid stands or other supports below it.

Apply wheel chocks to the load wheels to make sure that the truck does not move.

5.2

Jack points CAUTION

When you lift the truck up, the lifting carriage rises to the height of 115 mm before the remaining truck frame.

Figure 46: Jack points indicates the correct jack points for lifting the truck up for maintenance.

Figure 46: Jack points

5.3

Hoist points CAUTION

When you lift the truck up, the lifting carriage rises to the height of 115mm before the remaining truck frame.

Figure 47: Hoist points indicates the correct hoist points for hoisting the truck up for maintenance. Make sure that the capacity of the lifting device is sufficient.

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Figure 47: Hoist points 1. Insert 2 eye bolts M16 thread with nuts in the front hoist holes.

5.4

2. Insert 2 eye bolts M16 thread in the backrest hoist holes.

3. Attach the lifting slings to all eye bolts.

Transportation

When you transport the truck, it is important that you attach it safely to make sure that it does not move. Also, you must put supports to the traction wheel.

Figure 48: How to attach the truck for transportation shows an example on how to attach the truck safely for transportation.

Figure 48: How to attach the truck for transportation

5.5

Order spare parts

When you send an order for spare parts, always speak to your maintenance center. Only use original spare parts. To make sure that you get the correct parts, include in your order the information below:

• •

Truck type Serial number of the truck

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• • •

Order number of the part Name of the part Number of parts ordered

5.6

Truck covers WARNING

Do not operate the truck without the covers in position.

CAUTION Before you open the front cover of the truck, set the power of the truck OFF and disconnect the battery connector.

3 1

4 2

Figure 49: Truck covers overview 1. Battery cover 2. Front cover

5.6.1

3. Load backrest 4. Back cover

Remove the front cover

WARNING Do not operate the truck without the front cover in position.

1. Open the battery cover.

2. Remove the screws that attach the front cover to the truck.

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3. Remove the front cover by lifting it slightly and then pulling it out.

2

1

3

5.6.2

Open the battery cover

1. Lift the steering wheel completely up.

2. Pull the battery cover locking lever to open battery locking.

3. Open the battery cover.

NOTE: When you close the battery cover, make sure that the battery lock goes back to the locking position.

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5.6.3

Remove the load backrest

1. Remove the screws that attach the load backrest to the truck.

2. Remove the load backrest.

2

1

5.6.4

Remove the back cover

1. Remove the screws that attach the back cover to the truck.

2. Remove the screws that attach the back cover to the back support.

3. Remove the back cover.

5.7

Drive unit

The drive unit is made of the steering motor, the traction motor and the transmission gear.

You can do maintenance work easier, if you remove the drive unit.

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Figure 50: Overview of the drive unit

5.7.1 1.

2.

3.

4.

Remove the drive unit

Remove the front cover. See Section 5.6.1 Remove the front cover.

Put a support below the truck frame.

Remove the screws of the plate on top of the motor compartment.

Remove the plate.

5. Disconnect the cables.

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6. Remove the 5 bolts.

7. Remove the drive unit.

To install the drive unit, repeat the steps in a reversed order.

5.7.1.1

Remove the steering motor of the drive unit

1. Remove the 4 rounded cone nuts from the steering motor base.

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2. Lift up the steering motor from the drive unit.

To install the steering motor, repeat the steps in a reversed order.

5.7.1.2

Remove the traction motor and transmission gear from the drive unit

1. Remove the 6 bolts.

2. Pull out the traction motor and transmission gear from below.

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To install the traction gear and transmission motor, repeat the steps in reversed order.

5.7.1.3

Remove the traction motor from transmission gear

1. Remove the 9 bolts to disconnect the traction motor and transmission gear from each other.

2. Pull them apart.

5.7.1.4

Assemble the traction motor and transmission gear connection

CAUTION If the motor is connected incorrectly to the transmission, the tooth flanks at the drive pinion and the helical gear can be damaged, which can cause louder noise later on.

1. Clean the motor shaft and the drive pinion carefully. The taper connection must be free from grease and oil.

2. Install the shaft seal and the ball bearings.

3. Install the shaft bushing.

4. Install the circlip of the motor shaft.

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5. Put the motor carefully into the transmission top section.

6. Turn the motor until the bolt holes of the motor and the transmission top section are aligned correctly.

7. Attach the motor and the transmission top section with the 8 cap screws and the locking pieces. The correct tightening torque of the screws is 23 Nm.

5.7.1.5

Remove the transmission gear

If you want to remove the transmission gear and traction motor without removing the whole drive unit, do the following.

CAUTION Put a support below the truck frame so that the truck does not fall when you remove the transmission gear.

1. Attach lifting slings on the truck frame using the lifting hooks.

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2. Put a support below the truck frame.

3. Disconnect all the electric cables from the drive unit.

4. Remove the bolts that attach the traction motor to the motor bed.

5. Lift the truck up until the traction motor and transmission gear come off.

NOTE: Make sure that you use applicable lifting devices and obey the safety instructions given by the lifting device manufacturer.

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6. To remove the traction motor from transmission gear, see Section 5.7.1.3 Remove the traction motor from transmission gear.

To install the transmission gear, repeat the steps in a reversed order.

5.7.2

Remove the magnetic brake

1. Remove the screws that attach the magnetic brake to the traction motor.

2. Remove the magnetic brake.

For more information on the magnetic brake, see Section 8.3.1 Magnetic brake.

5.8

Transmission gear

Figure 51: Transmission gear overview It is not necessary to change the transmission oil during the lifetime of the truck.

During maintenance, make sure that the transmission gear does not leak.

There is an oil filling hole on the side of the transmission. Add the transmission oil in the filling hole.

Transmission oil

SAE 80W/90, API GL-4

Total transmission oil quantity

1,0 l

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CAUTION Transmission oil is dangerous waste that must be discarded accordingly.

1

2

Figure 52: Transmission gear oil filling holes 1. Filling hole for new oil

5.9

2. Draining hole for old oil

Slewing bearing

Figure 53: Slewing bearing overview It is not necessary to replace the slewing bearing lubricant during the lifetime of the truck.

During maintenance:

• •

Make sure that the bearing turns easily when the traction wheel is lifted up.

Make sure that the mounting bolts of the drive unit are tightened correctly.

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Figure 54: Greasing nipples of the slewing bearing

5.10

Pump motor

The pump motor is located in the motor compartment. For more information, see Section 8.3.3 Pump motor.

5.10.1

Remove the pump motor (standard models)

1. Remove the battery.

2. Disconnect pump motor cables.

3. Disconnect the hose from the pump.

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4. Open the hydraulic connector.

5. Loosen the two bolts. You can use the keyhole to help with the removal.

6. Remove the pump.

5.10.2

Remove the pump motor (Lifting platform models)

1. Remove the battery.

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2. Disconnect pump motor cables.

3. Open the hydraulic connectors.

4. Disconnect the hose from the pump.

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5. Loosen the two bolts and lift the motor up.

5.11

Truck wheels

This truck has four wheels: a traction wheel, a castor wheel and two sets of load wheels.

For more information, see Section 5.12 Traction wheel, Section 5.14 Castor wheel and Section 5.13 Load wheels.

3

2

1 Figure 55: Wheels overview 1. Traction wheel 2. Castor wheel

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5.12

Traction wheel CAUTION

Before you install the traction wheel, make sure that the wheel shaft, the face of the rim mounting, the wheel nuts and wheel shaft bolts are clean, free from grease and not damaged.

To maintain the traction and braking performance, examine the wear of the traction wheel regularly and replace the worn-out traction wheel immediately.

NOTE: To get an access to the traction wheel, lift the truck up (see the correct lifting points in Section 5.1 Lifting points) and turn the transmission gear so that there is enough space for you to remove the wheel.

Figure 56: Traction wheel overview Examine the wear of the traction wheel:

• •

The diameter of a new traction wheel is 250 mm.

When the diameter of the traction wheel is 230 mm, replace the traction wheel.

5.12.1

Remove the traction wheel

1. Remove the front cover. See Section 5.6.1 Remove the front cover.

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2. Remove the 3 cone nuts that hold the cover plate to get easy access to the wheel.

3. Turn the wheel so that the bolts are in the middle.

4. Remove the bolts.

5. Pull out the wheel.

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6. When you have the new wheel in place, it is easier to tighten the bolts from the inside. It is however possible to tighten the bolts also from the outside.

Examine the condition of the wheel shaft bolts. Replace the bolts, if necessary.

For instructions, see Section 5.12.3 Replace the wheel shaft bolts.

5.12.2

Assemble the traction wheel

NOTE: The correct tightening torque for the rounded cone nuts of the traction wheel is 80 Nm. 1. Align the hole pattern of the rim with the wheel shaft bolts.

2. Install the traction wheel.

3. Install the 5 rounded cone nuts and tighten them. The correct tightening torque for the nuts is 80 Nm.

80 Nm

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5.12.3

Replace the wheel shaft bolts

Figure 57: Wheel shaft bolts overview NOTE: The correct tightening torque for the wheel shaft bolts is 27 Nm. If the wheel shaft bolts of the traction wheel are damaged, replace them.

1. Use for example a rod or a crowbar to lock the wheel shaft in position.

2. Remove the damaged wheel shaft bolt.

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3. Wet the new wheel shaft bolt with Loctite 243.

4. Install the new wheel shaft bolt.

5. Tighten the new wheel shaft bolt.

NOTE: The correct tightening torque is 27 Nm.

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Load wheels

76-85mm

5.13

Figure 58: Load wheels overview Examine the wear of the load wheels:

• •

The diameter of the new load wheel is 85 mm.

When the diameter of the load wheel is 76 mm, replace the load wheel.

NOTE: To access the load wheels, lift up the forks until the load wheels are off the floor. Put a support under the forks!

5.13.1

Disassemble the load wheel

1. Remove the bolt that holds the load wheel in the bracket.

2. Remove the load wheel from the bracket.

3. Examine the condition of the slide bearing. Replace the part, if necessary.

4. Examine the condition of the bracket shafts. Replace the part, if necessary.

5.13.2

Assemble the load wheel

1. Put the load wheel into the bracket.

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2. Push the bolt through the bracket and the load wheel. Be careful not to cause damage to the bolt threads.

3. Tighten the bolt that holds the load wheel in the bracket.

4. Make sure that the load wheel turns correctly.

5.14

Castor wheel

Figure 59: Castor wheel overview Examine the wear of the castor wheel:

• •

The diameter of a new castor wheel is 150 mm.

When the diameter of the castor wheel is 145 mm, adjust the castor wheel.

5.14.1

Adjust the castor wheel

The castor wheel’s height needs to be adjusted according to the wear of the traction wheel to straighten the truck vertically.

1. Remove the front cover. See Section 5.6.1 Remove the front cover.

2. Use a 46 mm wrench to hold the bottom of the castor wheel shaft in place.

3. Use another 22 mm wrench to loosen the nut above the castor wheel shaft.

3 2

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5.14.2

Remove the castor wheel

NOTE: You must remove the hydraulic power pack before you can change the castor wheel. Only in the standard model it is possible to change the castor wheel without removing the hydraulic power pack.

1. Remove the front cover. See Section 5.6.1 Remove the front cover.

2. Put a support below the truck frame.

3. Remove the four bolts.

4. Pull out the wheel.

5.14.3

Disassemble the castor wheel

1. Open the nut that holds the castor wheel shaft bolt in the bracket.

2. Remove the shaft that holds the castor wheel in the bracket.

3. Remove the bearing.

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4. Remove the castor wheel from the bracket.

5.14.4

Assemble the castor wheel

1. Install the sleeves into the new castor wheel.

2. Put the castor wheel into the bracket.

3. Push the bolt through the bracket and the castor wheel. Be careful not to damage the bolt threads.

4. Install and tighten the nut to the bolt.

5. Make sure that the castor wheel turns properly.

5.15

Lifting system and fork carriage 2

5

3

4

1

4

6

5

7

Figure 60: Lifting system and fork carriage overview 1.

2.

3.

4.

Chassis shaft Link Fork carriage shaft Side bearing

5. Locking pin 6. Push rod shaft 7. Push rod shaft

If you remove the chassis shaft and the side bearing, then you can remove the whole lifting system under the fork.

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The lifting cylinder lifts the fork carriage, while the push rod mechanism helps to lift the fork tips. For stable lifting, it is important that there is not too much play in the linkage mechanism.

5.15.1

Disassemble the linkage mechanism

1. Remove the back cover. See Section 5.6.4 Remove the back cover.

2. Remove the lifting cylinder.

3. Put supports under the truck frame.

4. On the wheel fork side, remove the locking pin from the load wheel fork shaft.

5. Remove the load wheel fork shaft from the link.

6. Open the screw from the chassis shaft.

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7. Install a bolt (size M8) onto the threads at the end of the chassis shaft and use a slide pull hammer to pull the chassis shaft out.

8. Open the screw from the fork carriage shaft.

9. Remove the fork carriage shaft.

10. Remove the shafts.

11. Remove the slide bearings from the link.

12. Remove the locking pin from the push rod shaft.

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13. Remove the push rod shaft.

14. Remove the slide bearings from the wheel fork.

To assemble the linkage mechanism, do the steps again in reversed order.

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5.16

Steering wheel 1

3

2

Figure 61: Steering wheel overview 1. Steering wheel 2. Color display (optional)

5.16.1

3. Gas spring

Remove the steering wheel

CAUTION Before you remove the steering wheel, set the power of the truck to OFF and disconnect the battery connector. Record the points of the harness connections before you remove the steering wheel.

When you disconnect the connector, hold the connector housing and plug and then unlock the connector. If you hold the case you can cause damage to the inside card. If you hold the cable you can break the wire.

1. Open the battery cover. See Section 5.6.2 Open the battery cover.

2. Remove the front cover. See Section 5.6.1 Remove the front cover.

3. Disconnect the cables under the control panel.

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4. Remove the control panel.

5. Remove the plastic parts.

6. Remove the screws of the steering wheel.

7. Remove the steering wheel.

To assemble the steering wheel, do the steps in a reversed order.

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5.16.2

Replace the gas spring of the steering wheel

1 2

Figure 62: Gas spring of the steering wheel overview 1. Gas spring

2. Shaft

1. Remove the front cover. See Section 5.6.1 Remove the front cover.

2. Disconnect the cables under the control panel.

3. Remove the control panel.

4. Release the steering-wheel adjustment lever spring.

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5. Remove the 2 bolts.

6. Remove the bolt and nuts from the gas spring.

7. Bend the steering wheel slightly.

8. Remove the gas spring.

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5.16.2.1

Install a new gas spring

1. Adjust the new gas spring. Measure the length of the gas spring to be the same as in the old gas spring when it is open.

2. Put the gas spring to its correct position.

3. Install the screws on top of the gas spring.

4. Install a long hexagonal screw to the bottom of the gas spring.

5. Install the bolt and nuts to the gas spring.

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NOTE: After you have installed the gas spring, make sure that the locking mechanism of the gas spring functions correctly.

• •

Push the steering-wheel adjustment lever to release the gas spring.

Release the steering-wheel adjustment-button to lock the gas spring.

5.17

Color display

The color display is available only as factory installed option.

5.17.1

Change the color display

5.17.1.1

Remove the color display

CAUTION Before you remove the color display, set the power of the truck to OFF and disconnect the battery connector. Record the points of the harness connections before you remove the color display.

When you disconnect the connector, hold the connector housing and plug and then unlock the connector. If you hold the case you can cause damage to the inside card. If you hold the cable you can break the wire.

1. Push gently the 4 plastic clips with a flat-headed screwdriver.

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2. Remove the display.

3. Disconnect the display connector.

5.17.1.2

Install the color display

1. Make sure that the cables are neatly tied inside the plastic cover.

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2. Insert the display into the cover.

3. Slide the display into its position above the steering wheel.

4. Attach the plastic part under the display with screws.

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5.18

Simplex mast unit CAUTION

You must be approved to work on mechanical and hydraulic systems before you can service the mast units.

10

5

6

7

4

2

1

8 3 9 Figure 63: Simplex mast unit detailed construction 1.

2.

3.

4.

5.

Mast unit Lifting carriage Lifting cylinder Chain Chain anchor

5.18.1

6. Chain wheel 7. Chain yoke 8. Main roller 9. Load wheel 10.Level rod

Maintenance of the mast unit

This section gives instructions on the regular maintenance operations for mast units. Regular maintenance makes sure that the truck and its mast units stay in good condition and safe for the truck operators.

5.18.1.1

Daily maintenance

• • •

Make sure that there are no oil leaks in the mast unit.

• •

Make sure that all the fastenings of the mast chains are not damaged.

Examine all the wheels for damages or outer wear.

Set the current to on position and lift and lower the forks to do a test of the operation of the lifting hydraulics.

Make sure that the forks are not damaged. For instructions, see Section 5.18.5 Inspect the forks.

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5.18.1.2

Monthly maintenance

•

Make sure that all the screws, nuts and pipe / hose connections are correctly tightened.

•

Examine the tension of the mast chains. All chain pairs must have equal tension to ensure proper load distribution and mast operation. For instructions on how to examine the mast chain tension and adjust the chains, see Section 5.18.6.1 Inspect the mast chains and Section 5.18.6.5 Adjust the mast chains.

•

Put grease on all areas that are not painted in the mast channels.

5.18.1.3

Annual maintenance (1000 h)

•

Clean and lubricate the mast chains, if necessary. See the recommended lubricants and fluids in Section 5.18.2 Lubricant recommendations.

Note: Do not remove or contaminate the lubrication applied in the factory. Do not wash, sand blast, etch, steam clean or paint the chains.

•

Examine the chains for elongation. For instructions, see Section 5.18.6.1 Inspect the mast chains.

• •

Examine all the cylinder fastenings.

Examine the cylinders for damages, nicks, marring or scratches.

5.18.2

Lubricant recommendations

5.18.2.1

Mast chains

For the best chain life, use graphite or molybdenum type lubricants (for example, sprays), which dry up and leave the graphite or molybdenum on the chain.

CAUTION Make sure that there is no dust or sand on the chains when you lubricate them. If you use oil or grease to lubricate the chains in dusty or sandy operating conditions, dirt particles can attach to the chains, which can cause rapid wear from abrasion.

5.18.2.2

Mast channels

For the lubrication of the mast channels, use lubrication grease NLGI No. 2 that contains molybdenum disulphide.

5.18.3

Remove the mast unit

CAUTION Before you remove the mast unit from the truck, lower the mast unit and support the truck frame so that the load wheels are slightly lifted from the ground.

Before you disconnect a hydraulic pipe or hose, make sure that all pressure is released from the hydraulic system.

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1. Put a support below the truck frame.

2. Remove the back cover. See Section 5.6.4 Remove the back cover 3. Remove the 2 bolts from the truck frame.

4. Remove the floor. See Section 5.19.1 Remove the operator sensing platform floor.

5. Remove the 2 bolts from the bottom of the truck frame.

6. Move the mast approximately 50-100 mm from the truck.

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7. Remove the hydraulic connector that connects the mast unit to the hydraulic aggregate.

8. Connect the hydraulic plugs on both sides to prevent oil leakage.

9. There are no lifting hooks on the mast. Attach a lifting device to the mast and tighten the lifting ropes.

NOTE: Make sure that you use applicable lifting devices and obey the safety instructions given by the lifting device manufacturer.

10. Use lifting slings to remove the mast unit.

To install the mast unit, do the steps in a reversed order.

5.18.4

Disassemble the mast unit

WARNING When you disassemble the mast unit, mark down the direction of the different hydraulic connectors, the correct fastening points, direction of the rollers and the correct positioning of the hydraulic oil hoses and pipes.

When you assemble the mast unit, make sure that all the hydraulic connections, fastening points, roller directions and hose and pipe positions are the same as before you disassembled the mast unit.

Prepare a drip pan to collect the remaining oil in the pipes and hoses before you disconnect each pipe. Make sure that no dust or dirt goes into the opening of the pipe and valve connections.

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5.18.4.1

Remove the lifting carriage

You can remove the lifting carriage when the mast unit is in place. However, it is recommended to first remove the mast unit before you remove the lifting carriage.

1. Remove the mast unit. See Section 5.18.3 Remove the mast unit.

2. Remove the padded top plate.

3. Remove the 2 nuts from the bottom chain anchor.

4. Remove the bottom chain anchor from the mounting hole and let the chain hang freely.

5. Do the same to the other chain anchor and chain.

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6. Attach lifting slings to the lifting carriage and lift it out of the grooves.

NOTE: If you want to remove the chains from the machine, see Section 5.18.6.6 Disassemble the chains.

To attach the lifting carriage to the truck, do the steps in reversed order.

NOTE: Make sure that you use applicable lifting devices and obey the safety instructions given by the device manufacturer. The lifting carriage tilts forward when the rollers exit the grooves.

5.18.4.2

Remove the main rollers of the lifting carriage

1. Remove the lifting carriage from the mast unit. See Section 5.18.4.1 Remove the lifting carriage.

2. Remove the circlips from the main rollers of the lifting carriage.

3. Remove the main rollers from the lifting carriage.

To assemble the main rollers of the lifting carriage, do the steps in reversed order.

5.18.4.3

Remove the mast cylinder

You can remove the mast cylinder when the mast unit is connected to the truck. It is recommended to remove the mast unit before working on the mast cylinder.

1. Remove the mast unit. See Section 5.18.3 Remove the mast unit.

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2. Remove the lifting carriage. See Section 5.18.4.1 Remove the lifting carriage.

3. Remove the 2 nuts from the top chain anchor.

4. Remove the top chain anchor from the mounting hole and remove the chain.

5. Repeat steps 3-5 to the second chain.

6. Remove 2 bolts.

7. Lift the mast cylinder up and remove it.

To assemble the mast cylinder, do the steps in reversed order.

5.18.4.4

Disassemble the chain yoke

You can disassemble the chain yoke without removing the mast unit, but you have to remove more parts than what is described here.

1. Remove the mast cylinder. See Section 5.18.4.3 Remove the mast cylinder.

2. Remove the pin that attaches the chain yoke to the lifting cylinder.

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3. Remove the chain yoke from the lifting cylinder.

4. Remove the circlips.

5. Remove the rollers.

To assemble the chain yoke, do the steps in reversed order.

5.18.5

Inspect the forks

Examine the forks carefully after each 300 hours of operation (or more frequently in severe or extreme environments).

CAUTION Do all inspection, repair, or replacement work of forks by pair. Often, both forks are damaged.

The fork inspection must be done carefully by approved personnel only.

5.18.5.1

Welded forks

Examine the forks for any cracks. Pay special attention to the heel section, the mounting brackets and all welded areas.

If there are any cracks in the forks, remove the lifting carriage from service.

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2

1

Figure 64: Examine the forks for cracks 1. Heel section

5.18.6

2. Guidewheel shaft

Mast chains

WARNING Do not increase the length of the mast chains.

Do not decrease the length of worn mast chains, but always replace worn chains with new ones.

7 2 6 3 1

4 5

Figure 65: Mast chains overview 1.

2.

3.

4.

Chains Locking pin Tightening nut Locking nut

5.18.6.1

5. Chain anchor 6. Chain wheels 7. Chain yoke

Inspect the mast chains

Examine and lubricate the chain masts after each 300 hours of operation (or more frequently in severe or extreme environments). Do these checks for the

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chains:

Elongation To measure the elongation of the chains, you need a slide gauge and a chain gauge.

Measure the mast chain from the section that moves over the chain wheel as that part of the chain flexes the most. In case the chain is long, measure it at two different points.

500 mm Figure 66: Measure the elongation in the chain with a chain gauge

5.18.6.2

Measure the elongation of the mast chains

1. Lift a load of approximately 300 kg up.

2. Use a slide gauge to measure the distance between two chain pins in millimeters.

3. Find the correct measurement value in the chain gauge.

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6 24

15.875

14

9.525

18

12

9

12.7 19.05 25.4

Chain pitch

Number of pitch

38.1

4. Record the value below the measurement value. You need the recorded value when you count the number of pins in step 5.

5. Set the slot of the chain gauge on one of the chain pins.

9.525

12.7 19.05 25.4

24

18

12

9

6

Number of pitch

Number of pitch

38.1

Chain pitch

Chain pitch

7

14

5

31.75

15.875

44.45

6. Count the same number of chain pins as you recorded in step 3. Begin counting at the first chain pin after the chain gauge. This gives you the length of the chain section under inspection.

7. Examine if the last chain pin you counted is approximately at the vertical line of the chain gauge. If the chain is approximately at that line the length of the chain is right.

38.1

6 9

38.1

Chain pitch

12

12.7 19.05 25.4

Number of pitch

12.7 19.05 25.4

9.525

18

18

24

12

9

6

5

44.45

Number of pitch

15.875

Chain pitch

Number of pitch

24

7

31.75

9.525

14

15.875

Chain pitch

14

2

% 3 worn chain

% worn chain

2

3

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8. Make sure that the elongation is not more than 2%. If the elongation is more than 2%, you must replace the chain.

2

% 3 worn chain

2

3 % worn chain

You can also measure the elongation without a chain gauge.

When a chain with the original length of 330.2 mm has elongated to the length of 336.8 mm replace the chain (the elongation is approximately 2%).

330.2-336.8 mm

Figure 67: Measure the elongation in the chain without a chain gauge

5.18.6.3

Maintenance of the mast chains

Edge wear To examine the chains for link plate edge wear, move your finger back and forth over the chain edge.

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Figure 68: Chains edge-wear check The wear of a link plate edge must not be more than 5%.

Turning or protruding pins A heavily loaded chain operated without sufficient lubrication can cause unusual friction between the pins and the link plates. In extreme cases, the torque can surpass the press fit force between the pins and the outside plates, which can lead to pin rotation. When a chain is operated in such a condition, a pin or a series of pins can start to twist out of the chain, which can cause a failure.

Figure 69: Protruding and turning chain pins Examine the chain pin heads to make sure that all the flats are correctly aligned.

Replace chains with rotated or displaced heads or unusual protrusion immediately. Do not try to weld or drive the pin(s) back into the chain. The wear patterns on the pin heads or the sides of the link plates indicate misalignment.

Such wearing damages the chain and increases frictional loading and must always be corrected.

Cracked side plates Examine all the chains periodically for cracked plates.

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Figure 70: Cracked side plates Examine the chains carefully from all sides. If you find a cracked plate in the chain, find the cause of the crack to make sure that the condition does not occur again. If there is a cracked plate in a chain, you must replace the chain.

Fatigue cracking Fatigue cracks are a result of repeated cyclic loading exceeding the endurance limit of the chain.

Fatigue cracks almost always start at the pin hole of the link plate (the point of the highest stress) and are perpendicular to the chain pitch line. In their early stages, fatigue cracks are microscopic. Unlike with elongation, there is no noticeable yielding or stretching of the material.

Stress-corrosion cracking Stress corrosion is an environmentally assisted failure, caused by corrosive agents and static stress. In the chain, the press fit pin causes static stress on the pin hole. No cycle motion is required, and the plates can crack even during idle periods. In addition, the reaction of several chemical agents (such as battery acid fluids) with hardened steel can release hydrogen, which attacks and weakens the grain structure of the steel.

The outside link plates of the chain, which are heavily press fitted to the pins, are particularly susceptible to stress-corrosion cracking. Like other cracks, stresscorrosion cracks also initiate at the highest stress point (pin hole), but tend to extend in an arch-like pattern between the holes of the plate. A link plate often has more than one crack.

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Figure 71: Link plate with stress-corrosion cracks Do not try to electroplate a leaf chain or its components. The plating process releases hydrogen that causes hydrogen embrittlement cracks, which look almost the same as stress-corrosion cracks.

If a plated chain is necessary, contact the manufacturer. Plated chains are assembled from modified, individually plated components, which can decrease the rating of the chain.

Corrosion fatigue Corrosion fatigue is caused by the combined action of an aggressive environment and cyclic stress (unlike in stress-corrosion cracking where static stress alone can be a cause).

Corrosion fatigue cracks look like normal fatigue cracks. Frequently corrosion fatigue cracks and normal fatigue cracks are the same. Corrosion fatigue cracks usually start at the pin hole and move perpendicularly to the chain pitch line.

Ultimate strength failure This type of failure is caused by loads that are far heavier than the maximum load of the mast.

Figure 72: Ultimate strength failure

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Tight joints All the joints in a leaf chain must flex freely. Tight joints resist flexing and increase internal friction, thus increasing the chain tension required to fit a given load. Increased tension accelerates wearing and causes more fatigue problems.

Figure 73: Tight joints

5.18.6.4

Inspect the tension of the mast chains

Examine the tension of the mast chains every week. All chain pairs must have equal tension to ensure proper load distribution and mast operation.

To determine if chain pairs have equal tension: 1. Extend the unloaded mast unit to put the chains under tension.

2. Push the center of the chains in the chain pair.

Both the chains must have equal give. If the chains do not give in equally, adjust the chains as instructed in Section 5.18.6.5 Adjust the mast chains.

5.18.6.5

Adjust the mast chains

To adjust the tension of the mast chains, tighten or loosen the nuts of the chain anchors.

5.18.6.6

Disassemble the chains

1. Remove the 2 nuts from the top chain anchor.

2. Remove the top chain anchor from the mounting hole.

3. Remove the locking pin from the top chain anchor.

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4. Remove the top chain anchor from the chain.

5.

6.

7.

8.

Remove the 2 nuts from the bottom chain anchor.

Remove the bottom chain anchor from the mounting hole.

Remove the locking pin from the bottom chain anchor.

Remove the bottom chain anchor from the chain.

5.18.6.7

Replace the mast chains

When you replace the mast chains, make sure that the new chains are of the correct length.

1. Remove the mast chains. Mark down the correct fastening points of the chains. For instructions on how to remove the mast chains, see the mast chain related steps in Section 5.18.2.2 Mast channels and Section 5.18.4 Disassemble the mast unit.

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2. Attach chain anchor(s) to one end of the new chain(s).

3. Move the free end of the chain onto the chain wheel.

4. Install the top chain anchor to the mounting hole.

5. Install but do not tighten the 2 nuts to the top chain anchor.

6. Install the locking pin to the top chain anchor.

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7. Attach the chain anchor to the other end of the chain.

8. Install the bottom chain anchor to the mounting hole.

9. Install but do not tighten the 2 nuts to the chain anchor.

10. Install the locking pin to the chain anchor.

11. Adjust the chain tension. See Section 5.18.6.5 Adjust the mast chains.

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5.18.7

Lifting cylinder

3

2

6 1 7

5 4 Figure 74: Lifting cylinder overview 1.

2.

3.

4.

Lifting cylinder Chains Chain yoke Hydraulic pipe/hose

5.18.7.1

5. Hydraulic connector 6. Sealing housing 7. Bleed screw

Replace the lifting cylinder

WARNING During the removal of the lifting cylinder, mark down the direction of the different hydraulic connectors, the correct fastening points and the correct positioning of the hydraulic oil hoses and pipes.

During the installation of the new lifting cylinder, make sure that all the hydraulic connections, fastening points and hose and pipe positions are the same as before you disassembled the cylinder.

During the installation of the new lifting cylinder, make sure that the hose break valve is in the correct position. The hose break valve is a safety valve at the bottom of the lifting cylinder. It controls the oil flow so that the fork does not move down too quickly, if the piping between the lifting cylinder and lowering valve is broken or if the flow of return oil from the lifting cylinder becomes excessive because of an incorrectly adjusted proportional valve or a fault of another component.

1. Remove the lifting cylinder. For instructions, see the related steps in Section 5.18.4 Disassemble the mast unit.

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2. Remove the cap from the new lifting cylinder.

3. Make sure that the hose break valve is in the correct position.

4. Attach but do not tighten the connector to the bottom of the lifting cylinder.

Make sure that the connector points to the correct direction.

5. Install the new lifting cylinder. Make sure that the hydraulic connector points to the correct direction.

6. Install the 2 screws that hold the lifting cylinder in position. Make sure that the cylinder is in the correct position.

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7. Install the chain yoke to the top of the lifting cylinder.

8. Apply protective wax to the chain yoke.

9. Attach and tighten the hydraulic pipes/hoses.

10. Tighten all hydraulic connections.

11. Install the lifting cylinder chain. For instructions, see steps 3-11 in Section 5.18.6.7 Replace the mast chains.

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5.18.7.2

Sealing housing of the lifting cylinder

If you notice an oil leakage, first make sure that the lifting cylinder piston is not damaged.

Examine the external surface of the piston on the full length passing the housing (with the cylinder fully out) for scratches.

If there are scratches on the piston surface, replace the cylinder.

If the piston surface is not damaged, replace the seals. The recommended solution is to replace the whole sealing housing (includes factory-assembled seals). When you replace the whole sealing housing, the installation is simpler and you do not cause damage to the gaskets when you do the installation. If it is necessary only to replace the seals, you can also make an order for the gasket kit for each cylinder.

5.18.7.3

Disassemble the lifting cylinder

To disassemble the lifting cylinder, follow the instructions below. To assemble the lifting cylinder, repeat the steps in the opposite order.

1. Remove the lifting cylinder. For instructions, see the related steps in Section 5.18.4 Disassemble the mast unit.

2. Install the lifting cylinder onto a work bench.

3. Use the special hook tool (see Section 14.5 Special tools) to open the sealing housing.

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5.18.7.4

Bleed the mast cylinder

Figure 76: Bleed screw of the mast cylinder After you replace the lifting cylinder seals or sealing housings, bleed out the air from the lifting cylinder. Air in the hydraulic system, lifting cylinders, valves or the piping can cause shimmy and unusual noises together with the jerky movement of the mast unit and forks.

1. Lift the forks to the up position.

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2. Examine the hydraulic oil level in the tank. The min. and max. levels are shown as lines on the side of the hydraulic oil tank.

MAX MIN

3. Lower the forks.

4. Lift the mast unit until the lifting carriage is lifted by one meter.

5. Loosen the bleed screw and let the air bleed out.

6. When air bubbles stop to come out, tighten the bleed screw.

7. Do steps 4, 5 and 6 again until only hydraulic oil flows out from the connection.

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8. Fill up the hydraulic oil tank to the same level as in step 2.

9. If the truck has a lifting platform, bleed out the air from the side cylinder. For instructions, see Section 5.20.8 Bleed the lifting platform cylinder.

10. Measure the air of the lifting cylinder again after you have bled the air out of the side cylinders.

5.19

Operator presence sensing platform

1

2

Figure 77: Operator presence sensing platform overview 1. Operator platform

2. Operator platform sensor

When you do maintenance to the operator presence sensing platform:

•

Examine the condition of the operator platform sensor the following way.

1. Examine the mechanics of the sensor.

2. Examine the function of the sensor with TruckTool.

3. Measure the wiring using the circuit diagram.

4. If the problem is not solved, then change the sensor. See Section 5.19.2 Replace the operator platform sensor.

•

Examine the condition of the rubber stoppers and replace them, if necessary, see Section 5.19.3 Replace the rubber stoppers.

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5.19.1

Remove the operator sensing platform floor

To remove the operator sensing platform floor: 1. Remove the screws.

2. Remove the floor plate with the rubber mat attached to it.

5.19.2

Replace the operator platform sensor

To replace the operator platform sensor: 1. Remove the back cover, see Section 5.6.4 Remove the back cover.

2. Remove the floor plate, see Section 5.19.1 Remove the operator sensing platform floor.

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3. Remove the operator platform sensor from the mounting plate.

4. Install the new operator platform sensor to the mounting plate.

NOTE: Loosen the screws of the mounting plate so that you can adjust the sensor later.

5. Install the wiring.

NOTE: Make sure that the wires do not touch moving parts.

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6. Adjust the operator presence sensor.

2-4

mm

NOTE: Make sure that the sensor senses the counterpart in the middle of the movement range.

7. Tighten the screws.

8. Install the floor plate and the attached rubber mat.

9. Install the back cover.

5.19.3

Replace the rubber stoppers

To replace the rubber stoppers: 1. Remove the floor plate.

2. Examine the rubber stoppers on the rear part of the truck frame floor.

Replace the rubber stoppers, if necessary.

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3. Examine the rubber stoppers on the front part of the truck frame floor.

Replace the rubber stoppers, if necessary.

4. Examine the floor springs. Replace them, if necessary.

5. Install the floor plate.

NOTE: Tighten the screws of the floor plate by hand.

5.20

Lifting platform

5.20.1

Remove the lifting platform

CAUTION Before you do maintenance work below the lifting platform, support the lifting platform below with jacks.

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1. Remove the top cover.

2. Remove the locking screws.

3. Remove the back cover, see Section 5.6.4 Remove the back cover.

4. Attach a lifting device the lifting platform.

NOTE: Make sure that you use applicable lifting devices and obey the safety instructions of the lifting device manufacturer.

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5. Lift the lifting platform until you have safe access to the cable cover before the lifting platform.

6. Remove the cable cover.

7. Remove the wires and cables.

8. Remove the bolts that attach the wiring harness to the truck and detach also the wiring harness upper end. When you lift the lifting platform, guide the wiring harness. You can also attach the wiring harness to the platform with a cable tie.

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9. Lift the lifting platform out from the truck frame.

NOTE: The lifting platform tilts forward when the rollers exit the grooves.

5.20.2

Remove the floor of the lifting platform

NOTE: Before you remove the floor, make sure that the lifting platform is in the lowest position.

1. Remove the screws.

2. Remove the metal plate with the rubber mat attached to it.

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3. Remove the rubber mounts, if necessary.

5.20.3

Remove the battery of a lifting platform truck

1. Lift up the lever.

2. Turn the steering wheel assembly.

3. Open the battery cover. See Section 5.6.2 Open the battery cover.

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5.20.4

Replace the operator presence pedal sensor

1

2

Figure 78: Operator presence pedal sensor overview 1. Lifting platform

2. Operator presence pedal sensor

CAUTION Before you do maintenance work below the lifting platform, support the lifting platform below with jacks.

1. Lift the lifting platform up and put supports below it.

2. Remove the 2 screws from the mounting plate.

3. Remove the sensor from the mounting plate.

4. Install the new sensor to the mounting plate.

5. Install the wiring.

NOTE: Make sure that the wires do not touch moving parts.

6. Install the sensor with the mounting plate to the truck.

NOTE: Let the screws of the mounting plate stay loose so that you adjust the sensor.

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7. Adjust the sensor.

NOTE: Make sure that the sensor senses the counterpart in the middle of the movement range.

8. Lower the lifting platform.

5.20.5

Replace the rubber stoppers

NOTE: Before you do maintenance work below the lifting platform, support the lifting platform below with jacks.

To replace the rubber stoppers: 1. Lift the lifting platform to the up position and put supports below it.

2. Examine the rubber stoppers on the rear part of the truck frame floor.

Replace the rubber stoppers, if necessary.

3. Examine the rubber stoppers on the front part of the truck frame floor.

Replace the rubber stoppers, if necessary.

5.20.6

Replace the wiring harness

CAUTION Before you do maintenance work below the lifting platform, support the lifting platform below with jacks.

1. Lift the lifting platform to the up position and support it.

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2. Remove the harness cover plate.

3. Disconnect the steering wheel and instrumental panel connectors.

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4. Disconnect the connector of the floor pedal sensor.

5. Remove the nuts from both brackets of the flexible cable duct.

6. Disconnect the lifting platform connector.

7. Remove the cable duct with cable.

8. Remove the cable from the duct.

9. Install the new cable.

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To install the new wiring harness, do the steps in reversed order.

5.20.7

Remove the foot lowering pedal

NOTE: Before you do maintenance work below the lifting platform, support the lifting platform below with jacks.

1. Lift the lifting platform to the up position.

2. Below the lifting platform, remove the screws that attach the pedal to the lifting platform.

3. Remove the wiring harness.

4. Remove the XS54/ connector.

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5. Remove the foot lowering pedal.

5.20.8

Bleed the lifting platform cylinder

This procedure is not for standard truck models.

1. Make sure that there is oil in the hydraulic oil tank.

2. Lift the forks and the lifting platform to the up position.

3. Loosen the bleed screw and let the air bleed out.

4. When no more air bubbles come out, tighten the bleed screw.

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5. Lower the forks and the lifting platform to the down position.

6. Fill up the hydraulic oil tank to the correct level. The min. and max. levels are shown as lines on the side of the hydraulic oil tank.

MAX MIN

5.20.9

Guidance rollers

Figure 79: Guidance rollers overview

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5.20.10

Adjust the lifting platform sideways

To adjust the lifting platform sideways, do the following.

There are 2 adjustment screws on the upper part and 2 adjustment screws on the lower part. The screws of the upper part are visible and can be adjusted without disassembling the lifting platform.

1. Remove the lifting platform. See Section 5.20.1 Remove the lifting platform.

2. Loosen the locking nut.

3. Turn the adjustment screw to make sure the lifting platform is centered.

4. Repeat the adjustment for all 4 screws, if required.

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5. When the lifting platform is centered, tighten the locking nut.

5.20.11

Adjust the lifting platform machine-way

To adjust the lifting platform to the driving direction (machine-way) do the following.

1. It is easier to adjust the lifting platform, if you remove the lifting platform. See Section 5.20.1 Remove the lifting platform.

2. Adjust the lifting platform gap with pushing the adjustment knobs.

3. Place as many shim plates between the knob and the frame as required.

xx

xx

4. Make sure the lifting platform is centered.

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6

Electrical operation 6.1

Overview

This chapter gives the electrical operating principles of the lift truck. The standard model and its electrical schematic diagram are used as an example.

CAUTION Always use the correct schematic diagram for the specific model you are servicing. The latest schematic diagrams are available from the Web site of the manufacturer.

To do troubleshooting to a particular component, find the component on the applicable page of the schematic diagram and examine the circuitry associated with it. Keep the schematic diagram at hand for reference while you read the explanation. Make sure that you have the correct schematic diagram with regard to the truck model and its age.

6.2

Power source

This truck product family uses 24 V lead acid batteries that have 12 cells and supply a nominal voltage of 24 volts. The batteries have the maximum capacity of 625 Ah, depending on the truck model. The batteries reside in a separate compartment and are connected to the system through the X1 battery connector. In the electrical schematic diagram, the battery is presented as G1.

6.3

Safety circuit (emergency stop button)

When the emergency stop button (S2) is in its normal closed position, B+ continues to flow to the key switch (S1). B + also flows to the coil of the main contactor K2. The operator can shut down the system power at any time by pushing the emergency stop button. When the button is pushed, the connection opens and removes B+ from the coil of the main contactor K2.

6.4

Key switch

The key switch S1 controls the electrical power supply to the entire system with the help of the main contactor K2. The coil controlling the main contactor K2 contacts is presented on page 3.

The key switch is activated by turning it to the ON position (ECO/PRO). When the key switch S1 closes, B+ flows to the coil of the main contactor K2, the negative is connected to the battery via the controller pin 12 of the connector XA1 and the contactor K2 closes the contacts. Positive electrical power is supplied to the system through the main fuse 9F1.

The fuse 9F1 is rated at 425 A. In the electrical schematic diagram, the location of the main fuses is illustrated on page 1. After the main fuse, the B+ supply is fed to the traction controller. From the traction controller it continues to the pump motor. The pump motor negative is controlled by the pump controller. In the schematic diagram, the M2 contacts are presented on page 2.

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The traction controller controls the traction motor. In the schematic diagram, the M1 contacts are presented on page 2. The main voltage is supplied to the terminal B+ on the traction controller.

6.5

Traction

The traction controller controls the movement of the truck. Before the truck can be operated, the battery must be connected, the key switch must be closed and the system must have passed the self-test procedure.

When the power of the truck is set to ON and the truck in the standby mode, it can be operated by turning the accelerator at the steering wheel forward or backward. In the electrical schematic diagram, the accelerator is presented on page 5. Acceleration and travel speed varies according to the movement of the accelerator.

6.6

AC motor operation

In the induction motor (= asynchronous motor), the stator is powered with alternating current and designed to create a rotating magnetic field, which rotates in time with the AC oscillations. In the induction motor, the rotor rotates at a slower speed than the stator field and thus the magnetic field through the rotor is changing (rotating). The rotor has windings in the form of closed wire loops. The rotating magnetic flux induces currents in the rotor windings as in a transformer. These currents in turn create magnetic fields in the rotor that interact with the stator field. Due to Lenz's law, the direction of the created magnetic field is such as to oppose the change in current through the windings.

The cause of induced current in the rotor is the rotating stator magnetic field, so to oppose it, this rotor starts to rotate in the direction of the rotating stator magnetic field to make the relative speed between the rotor and the rotating stator magnetic field zero.

For these currents to be induced, the speed of the physical rotor must be lower than that of the stator's rotating magnetic field, or the magnetic field would not be moving relative to the rotor conductors and no currents would be induced. As the speed of the rotor drops below synchronous speed, the rotation rate of the magnetic field in the rotor increases, inducing more current in the windings and creating more torque. The ratio between the rotation rate of the magnetic field as seen by the rotor (slip speed) and the rotation rate of the stator's rotating field is called "slip". Under load, the speed drops and the slip increases enough to create sufficient torque to turn the load. For this reason, induction motors are sometimes referred to as asynchronous motors. An induction motor can be used as an induction generator, or it can be unrolled to form the linear induction motor, which can directly generate linear motion.

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7

Batteries 7.1

General information WARNING

Always keep the battery of the truck clean and dry to prevent tracking currents.

Obey the instructions of the battery manufacturer when you clean the battery.

Any liquid in the battery tray must be extracted and disposed of in the prescribed manner. After cleaning, repair all damages to the insulation of the tray to prevent tray corrosion and to make sure that the insulation value complies with the standard EN 62485-3 .

If the battery is taken out of service for a longer period, make sure that the battery is fully charged and store it in a dry, frost-free room. The storage time should be taken into account when considering the lifetime of the battery.

In case of any malfunctions on the battery or in the charger, contact the battery manufacturer immediately.

MANDATORY ACTION When you use motive batteries and chargers, always make sure that you follow the current standards, laws, rules and regulations in force in the country of use.

For batteries according to the ATEX directive 94/9 EC, the instructions for maintaining the appropriate protection class during operation must be complied with (see the relevant certificate).

WARNING Batteries marked with this sign must be recycled.

Batteries that are not marked with this sign are not returned for the recycling process and must be disposed of as hazardous waste.

WARNING

Pb

Batteries marked with this sign must be recycled.

Batteries that are not marked with this sign are not returned for the recycling process and must be disposed of as hazardous waste.

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7.1.1

Safety with lead-acid batteries Read the operating instructions of the battery and keep them near the battery.

Only skilled personnel can do work on batteries.

Use protective glasses and clothes when you work on batteries.

Pay attention to the accident prevention rules as well as the standards EN 62485-3 and EN 50110-1.

No smoking!

Do not expose batteries to naked flames, glowing embers or sparks, because it can cause the battery to explode.

Acid splashes in the eyes or on the skin must be washed immediately with water.

In case of an accident, consult a doctor immediately!

Clothing contaminated by acid must be washed with water.

Risk of explosion and fire, avoid short circuits!

Metal parts of the battery are always live. Do not place tools or other metal objects on the battery!

Electrolyte is highly corrosive.

Batteries and cells are heavy.

Ensure secure installation. Use only suitable handling equipment, for example lifting gear in accordance with the standard VDI 3616.

Dangerous electrical voltage!

Pay attention to the hazards that can be caused by batteries.

7.2

Battery maintenance

These maintenance instructions applies only to open lead-acid batteries.

Consult the battery supplier for instructions for other types of batteries.

7.2.1

Daily maintenance

Charge the battery after every discharge.

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For batteries with electrolyte circulation, measure the electrolyte level towards the end of the charging and, if necessary, top it up to the specified level with deionized water according to the instructions of the manufacturer. The electrolyte level must not fall below the anti-surge baffle, the top of the separator or the electrolyte minimum level mark.

For batteries with filling level sensors, look at the illuminated display daily. If the display is green, the level is OK. If the display shows a blinking red color, the filling level is too low.

For batteries with float indicator in the water filling plug, make sure that the white indicator is on the height of the window.

For batteries with standard vent plugs, open the plug and visually inspect the electrolyte If water level is low, top it up with demineralized water after the end of the charge.

NOTE: For instructions on how to do maintenance on Tensor or XCF batteries, see the instructions of the batteries.

7.2.2

Weekly maintenance

After recharging, examine the battery visually for signs of dirt or mechanical damages to the components of the battery. Pay special attention to the battery charging connectors and cables. In special cases when charging with an IU characteristic curve, also an equalizing charge must be carried out.

7.2.3

Annual maintenance

The insulation resistance of the truck and the battery are measured in accordance with the standard EN 1175-1 at least once per year. The insulation resistance of the disconnected, filled and charged traction battery mounted on the truck must be at least 50 Ω multiplied by the nominal voltage of the truck system between the live parts and the frame of the truck.

For batteries fitted with an electrolyte circulation system, examine the filter of the air pump and clean or replace it, if necessary. It is possible that the filter must be replaced earlier than expected if there are no leaks in the air pipes, but for some reason the defect signal of the air mixing system on the charger or on the battery (on the DC air pump or remote signal) is illuminated.

During annual maintenance, also test the correct operation of the air pump.

7.2.4

General maintenance

Keep the battery clean and dry to prevent tracking currents. Do the cleaning of the battery according to the ZVEI code of practice, see Section 7.2.7 How to clean batteries.

If there is liquid in the battery tray, remove it and obey an approved procedure to discard it. Repair damage to the insulation of the tray after you have cleaned the tray. In this way, you can make sure that the insulation value is in accordance with EN 62485-3 and that you do not cause corrosion to the tray. If you must remove cells, contact the battery manufacturer.

7.2.5

Storage

If you remove a battery from service for a long period of time, make sure that:

• •

The battery is fully charged The storage is dry and frost-free

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To make sure that the battery is always prepared for operation, you can select one of these charging procedures:

• •

Do the equalizing charge monthly Do float charging at a charging voltage of 2.23 V × the number of cells.

Count the storage time, when you think about the life of the battery.

7.2.6

Malfunctions

If you find malfunctions in the battery or in the charger, contact the battery manufacturer immediately.

7.2.7

How to clean batteries

The instructions that follow are in accordance with the ZVEI code of practice.

It is important that you keep the battery clean. A clean battery:

• • • •

can prevent accidents. is less likely to become damaged. is less likely to become damaged by corrosion or tracking currents. has a long life and operating time.

Dust on batteries can cause tracking currents that can lead to self-discharge of the battery. If there is a flow of higher tracking currents, electrical sparking can occur and there is a risk of explosion of the charging gas.

General instructions for battery maintenance

•

Use protective eyewear and protective clothing.

Make sure that the surface resistance of your safety clothes, boots and gloves is ≤ 108Ω to prevent a build-up of static electricity.

•

Do not use dry cleaning cloths to clean the battery.

7.2.7.1

How to clean vehicle traction batteries

1. Before you clean the battery, remove the battery from the vehicle.

2. Make sure that you collect the rinsing water that contains electrolyte and discard it in a correct procedure.

When you discard used electrolyte water or rinsing water, refer to the instructions for health and safety at work, accident prevention and how to discard water and waste.

3. Do not remove or open the cell plugs. See the instructions of the manufacturer.

4. Clean the plastic parts of the battery, especially the cell containers, with a cleaning cloth and clean water. Do not use cleaning agents.

You can also clean a vehicle traction battery with high pressure cleaning equipment. See the instructions of the high pressure cleaning equipment.

5. After you have cleaned the battery, dry the battery with compressed air or damp antistatic cleaning cloth (cotton, for example). You can also use other applicable methods to dry the battery.

6. If there is liquid in the battery tray, remove it by suction and obey an approved procedure to discard it. For details, see EN 62485-3 and the ZVEI information leaflet Safety measures for the handling of electrolyte for leadacid batteries.

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7.2.7.2

How to avoid damage to the plastic parts of batteries

1. Make sure that you do not cause damage to the plastic parts of batteries, such as lids, the insulation of the intercell connectors and other connectors.

2. Before you clean the battery, tighten the intercell connectors down or push them in tightly.

3. Make sure that the connectors are in their correct position and closed.

4. Do not use cleaning agents.

5. The maximum permitted temperature setting for the high pressure cleaning equipment is 140 ºC. Make sure that the temperature is no more than 60 ºC measured at 30 cm behind the jet nozzle.

6. Make sure that the distance between the jet nozzle of the high pressure cleaning equipment and the battery is no less than 30 cm.

7. Make sure that the maximum working pressure is no more than 50 bar.

8. Clean large surface areas of the battery at a time to avoid heating the battery too much.

9. Do not leave the jet on one spot for a longer period of time than 3 seconds.

10. After you have cleaned the battery, dry the battery with compressed air or damp antistatic cleaning cloth (cotton, for example). You can also use other applicable methods to dry the battery.

11. Do not use air heaters with an open flame or with glow wires.

12. Make sure that the surface temperature of the battery is no more than 60 ºC. 13. If there is liquid in the battery tray, remove it by suction and obey an approved procedure to discard it. For details, see EN 62485-3 and the ZVEI information leaflet Safety measures for the handling of electrolyte for leadacid batteries.

7.3

Requirements for the battery charging areas

The battery charging areas must be in compliance with the standard EN 624853:2014.

•

The battery charging area must be clearly defined by marking it permanently on the floor.

•

The battery charging area must be adequately spaced from materials that can constitute a hazard, such as inflammable or explosive goods.

•

Except during essential maintenance or repair, the battery charging area must not be subjected to any sources of ignition, such as sparks or sources of high temperature.

•

It is important to prevent electrostatic discharges when working with batteries: make sure not to wear clothes and footwear that can build up electrostatic charge. Absorbent cloth for battery cleaning must be antistatic and used moistened only with water without cleaning agents.

•

When the battery is being charged or serviced, there must be a space 0.8 m wide on the sides of the truck that require access.

•

When charging batteries on or off the truck the ventilation requirements of EN 62485-3:2014 clause 6 must be met. The required air flow must preferably be ensured by natural ventilation, otherwise by forced artificial ventilation.

•

The charger must be installed so that it does not get damaged if the truck moves.

•

The battery charging area must not be vulnerable to falling objects, drip water or liquids that can leak from fractured pipes.

•

The battery charging area must contain appropriate warning signs: –

Obey the instructions

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– – – – – –

• •

Battery hazard Dangerous voltage Highly corrosive electrolyte Use protective clothes and goggles Prohibition of naked flame Explosion hazard

The battery charging area must contain fire extinguishing equipment.

The disassembly and disposal of batteries must be done according to the prevailing local regulation and by qualified personnel only.

7.4

Charge the battery

3

1

2

Figure 80: Charge the battery overview 1. Battery connector 2. Charger

3. Truck connector

CAUTION Make sure that the charger is the appropriate model (correct battery type and voltage) and that the battery has sufficient ventilation.

See the charger manual for detailed charging instructions.

1. Park the truck in the battery charging area.

2. Set the power of the truck to the OFF position. Make sure that the charger is set to the OFF position.

I

O

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3. Open the battery cover. For instructions, see Section 5.6.2 Open the battery cover.

4. Disconnect the battery connector from the truck connector.

5. Connect the battery connector to the charger connector.

6. Set the charger to the ON position.

I

O

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7.4.1

When the battery is charged

1. Set the charger to the OFF position

I

O 2. Disconnect the battery connector from the charger. Hold the connectors. Do not pull the cables.

3. Examine the battery. See the maintenance instructions of the battery manufacturer.

4. Connect the battery connector to the truck connector. Make sure that the battery cables stay fully safe in the frame of the truck.

5. Close the battery cover. Make sure that the battery lock goes back to the locking position.

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7.5

Measure the specific gravity of the battery

Measure the specific gravity of the battery water according to the instructions of the battery manufacturer. The specific gravity of a fully charged battery is 1.28 to 1.30 at +30 °C. The gravity is:

• • • •

1.24 when the battery is 3/4 charged.

1.20 when the battery is 1/2 charged.

1.16 when the battery is 1/4 charged.

1.15 when the battery is empty. Charge the battery immediately.

7.6

Acquire a new battery

When you acquire a battery for the truck, take the following sections of standard EN 1175-1+A1 into consideration:

•

5.1 Traction batteries (includes the requirements for the protective cover of the battery case, ventilation and interior surface treatment)

•

7.4 Minimum markings (includes the requirements for the truck battery plate).

The battery plate should give at least the following information:

• • • • • •

Manufacturer Type Serial number Nominal voltage Capacity (Ah / 5h) Service weight.

7.7

Replace the battery

NOTE: To replace the battery, you must have the battery replacement device.

CAUTION Always obey the instructions of the manufacturer when you replace the battery.

When you replace the battery, use a battery with equivalent dimensions and weight to maintain the stability and the braking properties of the truck. The minimum weight of the battery is given on the identification plate of the truck.

When you install a battery, use the applicable tools to move, connect and attach the battery correctly. Do not keep tools or other metal objects on top of uncovered batteries.

Make sure that the capacity of the used lifting device is sufficient. When you use a lifting device to lift the battery, put a non-conductive plate on top of the battery to prevent the risk of a short circuit. This is not necessary, if the lifting device has sufficient insulation and is equipped with a distributor, or if the pole shoes and cell combinations are fully protected.

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7.7.1

How to replace the battery

1. Park the truck on the battery changing area.

2. Open the battery cover. For instructions, see Section 5.6.2 Open the battery cover.

3. Disconnect the battery connector from the truck connector.

4. Lift the locking lever.

5. Open the battery lock.

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6. Remove the battery.

7. Insert the new battery.

8. Close the battery lock.

9. Close the locking lever.

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8

Electric system maintenance 8.1

Control panel

8.1.1

Emergency stop button for standard models

Type

Complete emergency stop

Contact rating

24 Vdc / 2 A

Electrical wiring

Quick connect terminals 2.8 x 0.8 mm

Switching output

1 x NC

Functionality check of the emergency stop button: 1. Measure at the resistance area to make sure that the contacts in the emergency stop button are not stuck together.

2. Release the emergency stop button.

The contacts are closed between pins 21-22 and 31-32 and the resistance is ~0 Ω. The contacts are open between pins 13-14 and 43-44 and the resistance is ~∞Ω.

3. Push the emergency stop button down.

The resistance values are reversed: The contacts are open between pins 2122 and 31-32 and the resistance is ~∞ Ω. The contacts are closed between pins 13-14 and 43-44 and the resistance is ~0 Ω.

4. If the contacts are stuck together or broken, replace the contact block of the emergency stop button.

8.1.2

Key switch

3 2 1

Figure 81: Key switch 1. Power off 2. Power on, economy mode

3. Power on, standard mode

As an alternative to the start button, you can have the key switch installed to your truck. In a truck that has the key switch, the PIN query is not necessary.

The key switch sets the electrical system of the truck ON and OFF. When the key switch is set to OFF, the electrical system of the truck is OFF. Note that

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when the key switch is set to OFF, power can still be connected to some electronic devices.

Type

Key switch

Contact rating

24 Vdc / 5 A

Electrical wiring

Plug-in connector 6 poles

Switching output

2 x NO

Functionality check of the key switch: 1. Measure at the resistance area to make sure that the contacts in the key switch are not stuck together.

2. Turn the key switch to power off.

The resistance is ~0 Ω between the pins 6-1 and 4-5.

3. Turn the key switch clockwise once (ECO mode).

The resistance is ~0 Ω between the pins 6-1, 4-5, 6-4, 6-3, 1-4 and 1-3.

4. Turn the key switch clockwise to the second time (PRO mode).

The resistance is ~0 Ω between the pins 6-1, 4-5, 6-5, 6-2, 1-5 and 1-2.

5. If the contacts are stuck together or broken, replace the key switch contact block.

8.1.3

Walk beside drive buttons (optional)

Type

Rocker switch

Contact rating

24 V / 5 A

Electrical wiring

Quick connect terminals 6.3 x 0.8 mm

Switching output

2 x NO

Functionality check of the walk beside drive buttons: 1.

2.

3.

4.

Examine the functionality of the switch with TruckTool.

Measure the wiring using the circuit diagram.

Measure the switch.

Measure at the resistance area to make sure that the contacts in the walk beside drive button are not stuck together.

5. Set the button in the neutral position.

The resistance is ~∞ Ω between pins 1-2 and 2-3.

6. Actuate the button.

The resistance is ~0 Ω between pins 1-2 and 2-3 depending on the actuation direction.

7. If the contacts are stuck together or broken, replace the walk beside drive button.

8.2

Electric panel WARNING

Before you examine the controller, disconnect the battery connector.

Do not operate the truck without the controller cover in position.

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CAUTION Before you examine and replace fuses, turn the key switch to the OFF position and disconnect the battery connector.

2 7 3 6 1 4

9 8

10 5 Figure 82: Electric panel overview 1. Fuse box 1F1-8F1 2. Traction and pump controller A1 3. Electric power steering controller EPS A3 4. Option contactor K1 5. Steering motor fuse 10F1

8.2.1

6. Service connector X56 7. Truck connector X1 8. Controller fan M6 9. Main contactor K2 10.Traction and pump motor fuse 9F1

Discharge the controllers

CAUTION Before you start to do maintenance on the controllers, you must discharge them. Also, if you continue the maintenance work of the controllers after you have switched the power of the truck ON and OFF, you must discharge the controllers again. There is a risk of electric shock!

NOTE: It is not necessary to discharge each controller separately. If you discharge one controller, the other controllers are discharged at the same time.

To discharge the controllers: 1.

2.

3.

4.

Switch the power of the truck OFF. Disconnect the battery connector.

Connect the red cable of the bleeder resistor to the B+ pole.

Connect the black cable of the bleeder resistor to the B- pole.

Keep the bleeder resistor connected for at least 5 seconds.

5. Disconnect the cables of the bleeder resistor.

6. Measure the voltage between the terminals with a multimeter.

The value must be less than 5 V.

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Figure 83: Positive and negative poles of the controller voltage feed

8.2.2

Traction controller

The COMBI AC0 inverter has been developed to do all the electric functions that are usually present in walkie and rider pallet trucks, stackers and low level order pickers.

The controller can do these functions:

• • • • •

Controller for AC 700W to 2,5 kW AC motors Pump controller for series wounded DC motors up to 5 KW Drivers for ON/OFF electrovalves and for proportional valves CAN bus interface ESD protection on CAN BUS inputs CANL and CANH

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8.2.3

Traction controller connector

CAUTION Before any inspection or repair work, turn the key switch to the OFF position, disconnect the battery connector, discharge all controllers and record the places of the harness connections before disassembly.

When you disconnect the connector, hold the connector housing and plug and unlock the connector. If you hold the case you can cause damage to the inside card. If you hold the cable you can break the wire.

CAUTION If the high-power cable terminals of the battery-operated vehicle are not tightened correctly, the increased contact resistance causes excessive heat generation, and can even cause a fire. To prevent accidents and equipment problems, examine the torque of the high-power cable terminals regularly.

CAUTION Do not pull the cables to examine connections or during adjustment. If the cable terminal sections are moved, tighten the connections again.

Figure 84: Traction controller connector The traction controller uses 1 connector:

•

CNA 35 poles connector

Contacts 0.5-1.5 mm2 for CNA connector

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8.2.3.1

CNA external connector

Table 3: Traction controller connector (standard models) Connection

Description

A1 DI0 (XA1/1) (STEER WHEEL STOP SWITCH X17/6)

Steering wheel stop switch input, connected to +Batt.

A2 PEB (XA1/2) (POSITIVE OF THE MAGNETIC BRAKE XY31/2)

Positive of the electromechanical brake coil.

A3 PAUX (XA1/3) (VALVE COILS SUPPLY)

Positive supply for electrovalve coils. This input has to be supplied with positive taken after main contactor.

A4 NEB (XA1/4) (NEGATIVE OF THE MAGNETIC BRAKE XY31/2)

Electromagnetic brake coil driver output; PWM controlled, 2.5A maximum continuous current (driving to -Batt).

A5 NENC (XA1/5) (NEGATIVE OF THE TRACTION SPEED SENSOR XM1/4)

Negative of the encoder.

A6 D12 (XA1/6) (PEDESTRIAN FWD X15/2)

Pedestrian FWD switch input, connected to +Batt.

A7 DI6 (XA1/7) (MULTIPURPOSE 1 INPUT X20/9)

Multipurpose input 1, connected to +Batt.

A8 EV5 (XA1/8) (NOT USED)

Output of the on/off electrovalve.

A9 EV1 (XA1/9) (PEDESTRIAN LIFT X15/5)

Pedestrian LIFT switch input, connected to -Batt.

A10 +KEY (XA1/10) (KEY SWITCH S1/4)

Input of the key switch signal.

A11 EV2 (XA1/11) (PEDESTRIAN LOWER X15/6)

Pedestrian LOWER switch input, connected to -Batt.

A12 NMC (XA1/12) (MAIN CONTACTOR K2/ A2)

Main contactor coil driver output; PWM controlled, 2.5A maximum continuous current (driving to -Batt).

A13 ENC B (XA1/13) (CHANNEL B OF THE TRACTION SPEED SENSOR XM1/2)

Traction motor encoder channel B.

A14 ENC A (XA1/14) (CHANNEL A OF THE TRACTION SPEED SENSOR XM1/3)

Traction motor encoder channel A.

A15 CPOTTR (XA1/15) (MULTIPURPOSE 2 INPUT X10/2)

Multipurpose input 2, connected to +12V.

A16 DI10 (XA1/16) (FLOOR SENSOR XS19/ 4)

Input of the floor sensor signal, connected to +Batt.

A17 DI8 (XA1/17) (PEDESTRIAN BWD X15/ 3)

Pedestrian BWD switch input, connected to +Batt.

A18 DI11 (XA1/18) (PRESSURE SENSOR XB42/2)

Input of the PRESSURE SENSOR signal.

A19 DI5 (XA1/19) (BATTERY LOCK XS50/4)

Input of the BATTERY LOCK sensor signal, connected to +Batt.

A20 DI1 (XA1/20) (ECO/PRO S1/2)

Input of the ECO / PRO -mode signal, connected to +Batt.

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Connection

Description

A21 DI12 (XA1/21) (PIN CODE INPUT1 XB5/ 2)

Input 1 of the PIN-code keyboard, connected to +Batt.

A22 THMOT (XA1/22) (TRACTION MOTOR TEMPERATURE XM1.1/1)

Input of the traction motor thermal sensor.

A23 EVP2 (XA1/23) (NOT USED)

Output of the on/off electrovalve.

A24 LOWER EVP1 (XA1/24) (LOWER VALVE COIL DRIVER XY1/A2)

Output of the second proportional electrovalve driver, (driving to -Batt).

A25 PENC (XA1/25) (TRACTION MOTOR SPEED SENSOR POSITIVE XM1/1)

Traction motor encoder positive supply +12V.

A26 HORN OUT (XA1/26) (DRIVE ALARM XH7.1/2)

MULTIPURPOSE OUTPUT 3 driver, (driving to -Batt).

A27 CANL (XA1/27) (CAN BUS LOW)

Low level CAN-BUS voltage I/O.

A28 CANH (XA1/28) (CAN BUS HIGH)

High level CAN-BUS voltage I/O.

A29 DI9 (XA1/29) (PIN CODE INPUT2 XB5/ 2)

Input 2 of the PIN-code keyboard, connected to +Batt.

A30 CPOTL/NPOT (XA1/30) (MULTIPURPOSE INPUT 3 X10/10)

Multipurpose input 3, connected to +Batt.

A31 DI4 (XA1/31) (EMS STATUS S2/12)

Input of the EMERGENCY SWITCH, connected to +Batt.

A32 DI3 (XA1/32) (NOT USED)

Input of the DI3.

A33 EV3 (XA1/33) (CONTROLLER FAN X6/ 2)

MULTIPURPOSE OUTPUT 2 driver, (driving to -Batt).

A34 EV4 (XA1/34) (FORWARD LIGHT X51/2)

MULTIPURPOSE OUTPUT 1 driver, (driving to -Batt).

A35 DI7 (XA1/35) (PIN CODE INPUT3 XB5/ 4)

Input 3 of the PIN-code keyboard, connected to +Batt.

Table 4: Traction controller connector (lifting platform models) Connection

Description

A1 DI0 (XA1/1) (STEER WHEEL STOP SWITCH X17/6)

Steering wheel stop switch input, connected to +Batt.

A2 PEB (XA1/2) (POSITIVE OF THE MAGNETIC BRAKE XY31/2)

Positive of the electromechanical brake coil.

A3 PAUX (XA1/3) (VALVE COILS SUPPLY)

Positive supply for electrovalve coils. This input has to be supplied with positive taken after main contactor.

A4 NEB (XA1/4) (NEGATIVE OF THE MAGNETIC BRAKE XY31/2)

Electromagnetic brake coil driver output; PWM controlled, 2.5A maximum continuous current (driving to -Batt).

A5 NENC (XA1/5) (NEGATIVE OF THE TRACTION SPEED SENSOR XM1/4)

Negative of the encoder.

A6 D12 (XA1/6) (PEDESTRIAN FWD X15/2)

Pedestrian FWD switch input, connected to +Batt.

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Connection

Description

A7 DI6 (XA1/7) (PLATFORM LIFT SPEED REDUCTION SENSOR XS53/4)

Multipurpose input 4, connected to +Batt.

A8 EV5 (XA1/8) (FORKS LOCK VALVE XY3/ A2)

Output of the on/off forks lower valve, (driving to -Batt).

A9 EV1 (XA1/9) (PEDESTRIAN LIFT X15/5)

Pedestrian LIFT switch input, connected to -Batt.

A10 +KEY (XA1/10) (KEY SWITCH S1/4)

Input of the key switch signal.

A11 EV2 (XA1/11) (PEDESTRIAN LOWER X15/6)

Pedestrian LOWER switch input, connected to -Batt.

A12 NMC (XA1/12) (MAIN CONTACTOR K2/ A2)

Main contactor coil driver output; PWM controlled, 2.5A maximum continuous current (driving to -Batt).

A13 ENC B (XA1/13) (CHANNEL B OF THE TRACTION SPEED SENSOR XM1/2)

Traction motor encoder channel B.

A14 ENC A (XA1/14) (CHANNEL A OF THE TRACTION SPEED SENSOR XM1/3)

Traction motor encoder channel A.

A15 CPOTTR (XA1/15) (MULTIPURPOSE 1 INPUT X11/9)

Input of the lift limit sensor (option), connected to +12V.

A16 DI10 (XA1/16) (FLOOR SENSOR XS19/ 4)

Input of the floor sensor signal, connected to +Batt.

A17 DI8 (XA1/17) (PEDESTRIAN BWD X15/ 3)

Pedestrian BWD switch input, connected to +Batt.

A18 DI11 (XA1/18) (PRESSURE SENSOR XB42/2)

Input of the PRESSURE SENSOR signal.

A19 DI5 (XA1/19) (MAN LIFT LIMIT SENSOR XS51/4)

Input of the MAN LIFT LIMIT sensor signal, connected to +Batt.

A20 DI1 (XA1/20) (ECO/PRO S1/2)

Input of the ECO / PRO -mode signal, connected to +Batt.

A21 DI12 (XA1/21) (PIN CODE INPUT1 XB5/ 2)

Input 1 of the PIN-code keyboard, connected to +Batt.

A22 THMOT (XA1/22) (TRACTION MOTOR TEMPERATURE XM1.1/1)

Input of the traction motor thermal sensor.

A23 EVP2 (XA1/23) (FORWARD LIGHT X51/ 2)

MULTIPURPOSE OUTPUT 1 driver, (driving to -Batt).

A24 LOWER EVP1 (XA1/24) (LOWER VALVE COIL DRIVER XY1/A2)

Output of the second proportional electrovalve driver , (driving to -Batt).

A25 PENC (XA1/25) (TRACTION MOTOR SPEED SENSOR POSITIVE XM1/1)

Traction motor encoder positive supply +12V.

A26 HORN OUT (XA1/26) (DRIVE ALARM XH7/2)

MULTIPURPOSE OUTPUT 3 driver, (driving to -Batt).

A27 CANL (XA1/27) (CAN BUS LOW)

Low level CAN-BUS voltage I/O.

A28 CANH (XA1/28) (CAN BUS HIGH)

High level CAN-BUS voltage I/O.

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Connection

Description

A29 DI9 (XA1/29) (PIN CODE INPUT2 XB5/ 2)

Input 2 of the PIN-code keyboard, connected to +Batt.

A30 CPOTL/NPOT (XA1/30) (PLATFORM LOWER SPEED REDUCTION XS52/4)

Multipurpose input 3, connected to +Batt.

A31 DI4 (XA1/31) (EMS STATUS S2/12)

Input of the EMERGENCY SWITCH, connected to +Batt.

A32 DI3 (XA1/32) (FORKS LOWER STOP XS56/4)

MULTIPURPOSE INPUT 5, connected to +Batt.

A33 EV3 (XA1/33) (CONTROLLER FAN X6/ 2)

MULTIPURPOSE OUTPUT 2 driver, (driving to -Batt).

A34 EV4 (XA1/34) (PLATFORM LOCK VALVE 2Y2/A2)

Output of the on/off electrovalve, (driving to -Batt).

A35 DI7 (XA1/35) (PIN CODE INPUT3 XB5/ 4)

Input 3 of the PIN-code keyboard, connected to +Batt.

8.2.3.2

Description of the power connections

Connection

Description

-B

Negative of the battery.

+B

Positive of the battery.

-P

Negative of the pump motor.

U; V; W

Connection bars of the three motor phases.

NOTE: The correct torque for the traction controller terminal bolts is 7 Nm (±1.4 Nm).

8.2.4

Steering controller

This truck has the EPS AC0 controller, which performs steering functions that are usually present in walkie and rider pallet trucks, stackers and low level order pickers.

The controller can do these functions:

• • • •

Steering controller for AC asynchronous 3-phase motors Digital Control using two microprocessors CAN bus interface Both microprocessors CAN bus connected

The steering controller uses 1 connector:

•

CNA 23 poles connector

Contact 0.5-1.5 mm2 for CNA connector.

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8.2.4.1

CNA external connector

Table 5: Steering controller connector (all models) Connection

Description

A1 CPOC1 (XA3/1) (NOT USED)

Input of the twin pot sensor channel A

A2 CPOC2 (XA3/2) (NOT USED)

Input of the twin pot sensor channel B

A3 CHA (XA3/3) (1st SPEED SENSOR CHANNEL A XM3/2)

Input of the 1st steering speed sensor channel A

A4 CHB (XA3/4) (1st SPEED SENSOR CHANNEL B XM3/3)

Input of the 1st steering speed sensor channel B

A5 GND (XA3/5) (1st STEERING SPEED SENSOR NEGATIVE XM3/4)

Negative of the 1st steering speed sensor

A6 PTHM (XA3/6) (STEERING MOTOR TEMPERATURE XM3.1/2)

Input of the steering motor thermal sensor

A7 GND (XA3/7) (THERMAL SENSOR NEGATIVE XM3.1/)

Ground for the steering motor thermal sensor

A8 GND (XA3/8) (2nd SPEED SENSOR NEGATIVE XM4/4)

Negative of the 2nd steering speed sensor

A9 PCOIL (XA3/9) (NOT USED)

Positive supply for external coil. Max 1.3A

A10 NCOIL (XA3/10) (NOT USED)

Ground for the external coil

A11 SW2 (XA3/11) (STEER FEEDBACK SENSOR B S32/4)

Input of the steering feeback sensor B signal

A12 SW1 (XA3/12) (STEER FEEDBACK SENSOR A S31/4)

Input of the steering feeback sensor A signal

A13 GND (XA3/13) (SERVICE CONNECTOR GND X56/3)

Ground for the service connector

A14 VCC2 (XA3/14) (2nd SPEED SENSOR SUPPLY XM1/3)

Positive supply for 2nd steering speed sensor, +13.5V

A15 KEY-IN (XA3/15) (KEY SIGNAL S1/4)

Input of the KEY-switch signal

A16 VCC1 (XA3/16) (1st SPEED SENSOR SUPPLY XM4/1)

Positive supply for 1st steering speed sensor, +13.5V

A17 CHB2 (XA3/17) (2nd SPEED SENSOR CHANNEL B XM4/2)

Input of the 2nd steering speed sensor channel B

A18 +5V_1 (XA3/18) (NOT USED)

1st positive supply of the twin pot sensor, +5V

A19 GND (XA3/19) (NOT USED)

Ground 1 for the of the twin pot sensor

A20 CHA2 (XA3/20) (2nd SPEED SENSOR CHANNEL A XM4/3)

Input of the 2nd steering speed sensor channel A

A21 +5V_2 (XA3/21) (NOT USED)

2nd positive supply for twin pot sensor, +5V

A22 CANL1 (XA3/22) (CAN BUS LOW)

Low level CAN-BUS voltage I/O

A23 CANH1 (XA3/23) (CAN BU HIGH)

High level CAN-BUS voltage I/O

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8.2.4.2

Description of the power connectors

Connection

Description

-B

Negative of the battery

+B

Positive of the battery

U; V; W

Connection bars of the three motor phases; follow this sequence and the indication on the motor.

NOTE: The correct torque for the traction controller terminal bolts is 2.5-3 Nm.

8.2.5

Contactors and relays

Type

Option contactor K1

Coil type

24 Vdc coil of the continuous duty

Electrical wiring

Coil: quick connect terminals 6.3 × 0.8 mm Power contacts: M6 ring terminals

Contact rating

Resistive load: 80 A @ 60 Vdc max Overload: 120 A @ 48 Vdc / UL 508

Switching output

NO

Type

Main contactor K2

Coil type

24 Vdc coil of the continuous duty

Electrical wiring

Coil: quick connect terminals 6.3 × 0.8 mm Power contacts: M8 ring terminals

Contact rating

Resistive load: 200 A @ 60 Vdc max Overload: UL 300 A

Switching output

NO

A contactor is an electrically-controlled switch used for switching a power circuit, similar to a relay, but with higher current ratings. A contactor is controlled by a circuit, with a much lower power level than the switched circuit.

8.2.5.1

Contactor functionality check

1. Measure the resistance between the coil A1 – A2 terminals.

The resistance must be ~55 Ω.If the resistance is ~0 Ω or ~∞ Ω, replace the contactor.

2. Measure the resistance between the main switching contacts 1-2.

The resistance value must be ~∞ Ω.If the value does not match the above, replace the contactor.

3. Supply +24 Vdc between the A1 (+) and A2 (-) terminals.

4. Measure between the main contacts 1 – 2 that the contacts are closed.

If the contacts are not closed, they are stuck together. In that case, replace the contactor.

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8.2.5.2

Remove the controllers

There are two types of controllers: steering controller and drive controller.

The maximum torques for cable bolts are:

• •

Steering cable bolts 3 Nm Drive cable bolts 15 Nm

1. Disconnect the controller cables.

2. Remove the screws and pull out the controller.

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8.2.5.3

Remove the contactors

2

1

Figure 85: Contactors overview 1. Contactor K1

2. Contactor K2

1. Remove the front cover. See Section 5.6.1 Remove the front cover.

2. Disconnect coil wires and power cables from the contactor.

3. Remove the screws and pull out contactor K1.

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4. Disconnect coil wires and power cables from the contactor.

5. Remove the screws and pull out contactor K2.

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8.2.6

Fuses

1 2 3 4 5 9

6

10

7 8

Figure 86: Fuses #

Description

Identifier

Rating

1

Start circuit fuse

1F1

5A

2

Controller fan and options fuse

2F1

10A

3

Sensors fuse

3F1

2A

4

Display and steering wheel fuse

4F1

2A

5

Auxiliary device fuse

5F1

10A

6

Auxiliary device fuse

6F1

10A

7

+12 Vdc output fuse

7F1

20A

8

Spare

8F1

10A

9

Traction and pump motor fuse

9F1

425A

10

Steering motor fuse

10F1

50A

NOTE: The correct torque for the fuse terminals is 4.5 Nm (±1 Nm).

8.2.7

Replace the truck connector

1. Disconnect the battery.

2. Open the battery cover. For instructions, see Section 5.6.2 Open the battery cover.

3. Remove the front cover. For instructions, see Section 5.6.1 Remove the front cover.

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4. Disconnect the truck connector cables from the electric panel.

5. Remove the bolts of the truck connector.

6. Remove the truck connector with cables.

Install the new truck connector in reverse order.

When you connect the battery, make sure that point B+ is connected to B+ and so on.

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8.3

Motor compartment CAUTION

Before you open the motor compartment covers, set the power of the truck to OFF position and disconnect the battery connector.

Before any inspection or repair work, discharge the controllers. Record the positions of cables and harness connections before disassembly.

Use the correct power cables and terminate marked cable ends to the correct terminals marked on the motor. Cables terminated at the wrong terminals can cause the motor to rotate in the opposite direction when activated.

CAUTION If the high-power cable terminals of the battery-operated vehicle are not tightened correctly, the increased contact resistance causes excessive heat generation, and can even cause a fire. To prevent accidents and equipment problems, examine the torque of the high-power cable terminals regularly.

Do not pull the cables when you examine the connections or during adjustment. If the cable terminal sections are moved, tighten the connections again.

5 1

6 8

2 3 4 7 Figure 87: Motor compartment overview 1.

2.

3.

4.

Magnetic brake Traction motor Pump motor Steering reference sensor

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5.

6.

7.

8.

Horn Cooling fan for controllers Steering motor Optional hydraulic pressure sensor

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8.3.1

Magnetic brake

Figure 88: Magnetic brake overview Applying voltage to the brake coil generates a magnetic force that acts on the friction disk. The friction disc is pulled via the air gap against the pressure of the springs. The rotor is released and the brake torque is neutralized.

8.3.1.1

The air gap of the magnetic brake

The air gap is not adjustable. It should be 0,2 mm.

8.3.1.2

Coil resistance measurement

Use a multimeter to measure the resistance of the brake coil. Measure the resistance between the brake wires. The value must be 12,6 Ω.

8.3.2

Traction motor

Type

3-phase AC

Voltage

16 V

Output power

2.6 kW

NOTE: The correct torque for the traction motor power terminals is 20 Nm ±10%.

8.3.2.1

Temperature sensor check

The temperature sensor is in the motor and it cannot be replaced. You can measure the condition of the temperature sensor with a multimeter:

•

Measure the resistance between the traction motor connector pins XM1. 1/1 and XM1. 1/2.

The value must be 1077 Ω at +20˚C. Figure 89: Resistance variation according to temperature shows how the resistance varies according to the temperature.

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PT1000 1900 1700

Resistance R(Ω)

1500

1300 1100 900 700

200

190

180

170

160

150

140

130

110

120

100

80 90

70

60

50

40

30

20

0

10

-10

-20

-30

-40

-50

-70

-60

500 Temperature °C

Figure 89: Resistance variation according to temperature

8.3.3

Pump motor

Figure 90: Pump motor overview – Lifting platform models and the standard model with mast Table 6: Pump motor – Lifting platform models and the standard model with mast Type

DC pump motor

Contact rating

24 Vdc / 2.2 kW

Electrical wiring

M8 & M8 bolt terminals

The pump motor is maintenance free. Do not attempt to repair the pump motor.

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Figure 91: Pump motor overview – Standard models The pump motor is an integral part of the hydraulic aggregate.

Table 7: Pump motor – Standard models Type

DC pump motor

Contact rating

24 Vdc / 1.2 kW

Electrical wiring

M6 & M8 bolt terminals

8.3.3.1

Solenoid valve

Figure 92: Solenoid valve (standard models)

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Figure 93: Proportional solenoid valve (models with mast)

Figure 94: Solenoid valves (lifting platform models) The solenoid valve is an electrically controlled hydraulic valve that has 2 main parts: a solenoid (coil) and a valve. The solenoid converts electrical energy into mechanical energy which, in turn, opens or closes the valve mechanically. This basic ON/OFF function is used to control the oil flow to the cylinders.

Type

Solenoid

Contact rating

24 Vdc / 22 W

Electrical wiring

Quick connect terminals 6.3 × 0.8 mm

Functionality check of the solenoid valve:

•

Measure the resistance between the solenoid terminals XY1/A1 and XY1/A2.

The value must be ~27 Ω.

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8.3.4

Steering motor

Figure 95: Steering motor overview Type

3-phase AC

Voltage

15 V

Output power

0.3 kW

Table 8: Thermal sensor measurement Connector

XM3.1/1 and XM3.1/2

Thermal sensor type

KTY 83-122

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8.4

Sensors 2

3

4

1

8

5

9

7

6

Figure 96: Sensors overview 1.

2.

3.

4.

5.

Traction motor speed sensor Battery cover lock sensor (option) Steering wheel sensor Forks lift upper limit sensor Operator platform sensor

6.

7.

8.

9.

Pressure sensor Second steering speed sensor First steering speed sensor Steering reference sensor

The truck uses the following sensors: Standard models: 1. Battery lock sensor (option) 2. Floor sensor 3. Pressure sensor (option) 4. Lift limit sensor (option in low lift models) 5. Lower stop sensor (option in mast models) 6. Steering reference sensor

Lifting platform models: 1. Battery lock sensor (option) 2. Floor sensor 3. Pressure sensor (option) 4. Lift limit sensor (option in low lift models) 5. Forks lower stop sensor (option in mast models) 6. Steering reference sensor 7. Platform lift limit sensor

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8. Platform lower speed reduction sensor 9. Platform lift speed reduction sensor 10. Platform foot lower sensor (option)

TRUCKTOOL Examine the functionality of the sensors with TruckTool.

8.4.1

Pressure sensor

Figure 97: Pressure sensor overview The pressure sensor is used to monitor the hydraulic pressure of the hydraulic system. With this sensor, the traction controller can adjust the operating speed according to the lifted load. The pressure sensor has an output signal of 0,54,5V in the range of 0-250 bar oil pressure.

Type

Pressure transmitter

Vs

9-30 Vdc

Output signal

0,5-4,5V / <15 mA

Electrical wiring

1 = L+ (supply) 2 = OUT (output signal) 3 = M (GND)

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8.4.2

Steering reference sensor

Figure 98: Steering reference sensor overview Type

Inductive proximity sensor

Size

M18 × 1 cylindrical, length 67 mm

Vs

10-65 Vdc

Switching output

NPN, NO

Electrical wiring

M12 connector

Sensing range

6 mm

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8.4.3

Steering speed sensors

2

1 3 Figure 99: Steering speed sensors overview 1. First steering speed sensor 2. Traction motor speed sensor

3. Second steering speed sensor

NOTE: Traction and steering speed sensors are not interchangeable. Traction sensor can not detect 0 Hz speed and it will cause steering malfunction.

8.4.4

Forks lift upper limit sensor

Figure 100: Forks lift upper limit sensor Type

Inductive proximity sensor

Size

Flat, 15 mm × 32 mm × 8 mm

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Vs

12-24 Vdc

Switching output

PNP, NO

Electrical wiring

Molded M8 connector, no visible colored wires.

Sensing range

2-4 mm

8.4.4.1

Adjust the forks lift upper limit sensor

1. Adjust the sensor to a distance of 4 mm from the counterpart. When the sensor senses the counterpart, a yellow light is lit.

4 mm

2. Lock the sensor in position.

3. Adjust the height of the sensor until the distance from the floor to the upper surface of the fork in the up position is at least 205 mm. Measure the height at the heel of the fork.

>205 mm

4. Test the functionality of the sensor.

NOTE: During the lift, the yellow light on the sensor is ON. When the counterpart passes the sensor, the yellow light turns OFF and the lifting of the forks stops.

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8.4.5

Speed sensor

Figure 101: Speed sensor Table 9: Speed sensor wire details PIN

Wire color

Description

1

RED

Sensor supply

2

WHT

Channel A

3

BLU

Channel B

4

BLK

Sensor GND

8.4.5.1

Replace the HALL sensor

1. Remove connector from the connector holder.

2. Remove the screw that holds the HALL sensor in place.

3. Remove the HALL sensor.

To install the HALL sensor, repeat the steps in the reverse order.

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8.4.6

Operator platform sensor

Figure 102: Operator platform sensor Type

Inductive proximity sensor

Size

Flat, 15 mm × 32 mm × 8 mm

Vs

12-24 Vdc

Switching output

PNP, NO

Electrical wiring

Molded M8 connector, no visible colored wires.

Sensing range

2-4 mm

8.4.7

Mast operating speed reduction sensor

Figure 103: Mast operating speed reduction sensor Type

Inductive proximity sensor

Size

Flat, 15 mm × 32 mm × 8 mm

Vs

12-24 Vdc

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Switching output

PNP, NO

Electrical wiring

Molded M8 connector, no visible colored wires.

Sensing range

2-4 mm

8.4.8

3

Lifting platform sensors

5

1

6

4

2 Figure 104: Lifting platform sensors 1. Lifting platform lift stop sensor 2. Lifting platform lower speed reduction sensor / Travel speed reduction sensor 3. Operator presence sensor of the lifting platform 4. Lifting platform lift speed reduction sensor 5. Lifting platform foot lower sensor 6. Mast operating speed reduction sensor

8.4.8.1

Lifting platform lift stop sensor

Figure 105: Lifting platform lift stop sensor

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Type

Inductive proximity sensor

Size

Flat, 15 mm × 32 mm × 8 mm

Vs

12-24 Vdc

Switching output

PNP, NO

Electrical wiring

Molded M8 connector, no visible colored wires.

Sensing range

2-4 mm

8.4.8.2

Lifting platform lower speed reduction sensor

Figure 106: Lifting platform lower speed reduction sensor Type

Inductive proximity sensor

Size

Flat, 15 mm × 32 mm × 8 mm

Vs

12-24 Vdc

Switching output

PNP, NO

Electrical wiring

Molded M8 connector, no visible colored wires.

Sensing range

2-4 mm

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8.4.8.3

Lifting platform lift speed reduction sensor

Figure 107: Lifting platform lift speed reduction sensor

8.4.8.4

Operator presence sensor of the lifting platform

Figure 108: Operator presence sensor of the lifting platform Type

Inductive proximity sensor

Size

Flat, 15 mm × 32 mm × 8 mm

Vs

12 - 24 Vdc

Switching output

PNP, NO

Electrical wiring

M8 connector / DC 3-wire, Vs = BRN, GND = BLU, signal output = BLK

Sensing range

2 - 4 mm

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8.5

Lifting platform foot lowering pedal

Figure 109: Lifting platform foot lowering pedal Type

Inductive proximity sensor

Size

Flat, 15 mm × 32 mm × 8 mm

Vs

12-24 Vdc

Switching output

PNP, NO

Electrical wiring

Molded M8 connector, no visible colored wires.

Sensing range

2-4 mm

8.5.1

Lifting platform pedal functionality check

1. Measure at the resistance area that the contacts inside the pedal are not stuck together.

2. Set the pedal in the neutral position.

The resistance is ~∞ Ω between terminals NO and COM. 3. Actuate the pedal.

The resistance is ~0 Ω between terminals NO and COM. 4. If the contacts are stuck together or broken, replace the pedal.

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8.6

Horn

Figure 110: Horn Type

Horn

Vs

24 Vdc

Electrical wiring

Quick connect terminals 6.3 × 0.8 mm

If the horn does not work correctly, connect the horn directly to +24V voltage source to test it.

Usually, the horn creates voltage peaks that can cause problems to other electrical devices. To prevent these voltage peaks, a diode (V5 in the circuit diagram) is installed parallel to the horn terminals.

8.6.1

Diode test with a multimeter

To make sure that the diode works correctly, do a basic diode test: 1. Remove the horn.

2. Set the multimeter to the resistance or diode range.

3. Connect the cathode terminal of the diode to the positive terminal of the multimeter and the anode to the negative or common terminal of the multimeter.

4. Set the multimeter to read the resistance or diode.

The reading must be low or 0.

5. Reverse the connections.

The reading must be high or OL. If the results do not agree with the expected values, the diode connection is damaged:

•

If the results are opposites of the expected values, the diode was assembled with incorrect polarity.

•

If the resistance values are ~0 Ω or ~∞ Ω in both directions, the diode is shorted or broken and must be replaced.

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9

Electric system adjustments and measurements 9.1

Overview

The basis for calibrations is that all parameters are correctly set according to the truck parameter list and settings. Before you start to adjust the calibration parameters, make sure that the remaining of the parameters are in order.

9.2

Adjust the electrical steering

If one or more of the electrical steering components are changed, the electrical steering must be adjusted.

9.2.1

Assembly of the reference sensors

1

2 Figure 111: Assembly of the reference sensors 1. Steering reference sensor connector

2. Steering reference sensor

The inductive reference sensors have one basic adjustment. Because of the fixed sensing range, you must obey the instructions below, to install the sensor: 1.

2.

3.

4.

5.

Turn the drive unit so that the half circle steel plate is below the sensors.

Screw the sensor as deep as possible into the motor bed.

Screw the sensor two rounds backwards.

Tighten the locking nut of the sensor.

Connect the sensor connector.

9.2.2

Steering teaching

Teach steering with TruckTool "Steered wheel (tyre) calibration wizard".

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9.3

Insulation resistance test

9.3.1

Test voltage

The insulation resistance of the truck and the traction battery are examined separately. The test voltage is greater than the nominal voltage but no more than 100 V or three times the nominal voltage: Nominal voltage

Test voltage

24 V

50 V

9.3.2

Insulation tester check

Connect the test probe to the frame of the truck (for example, to a non-painted bolt or bracket) and the other test probe to another bolt or bracket. The tester must show a zero value.

Figure 112: Insulation tester check

9.3.3

Measure the insulation resistance

The test is done with the battery disconnected from the truck. All the electrical components must be in place.

1. Release the emergency stop and set the key switch to the ON position.

2. Connect the test probe to the frame of the truck (for example, to a nonpainted bolt or bracket) and the other test probe to the positive terminal of the battery connector.

3. Read the resistance value.

4. Measure and read the negative terminal of the battery connector in the same way.

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9.3.3.1

Insulation resistance of the truck

Figure 113: Measuring the insulation resistance of the truck The insulation resistance between the live parts of all the electric components and the frame of the industrial truck with the exception of the battery is at least 1,000 Ω multiplied by the nominal voltage of the truck system.

Nominal voltage

Minimum insulation resistance

24 V

24,000 Ω

9.3.3.2

Insulation resistance of the battery

+

-

Figure 114: Measuring the insulation resistance of the battery The insulation resistance of the disconnected, filled and charged traction battery installed on the truck is at least 50 Ω multiplied by the nominal voltage of the truck system between the live parts and the frame of the truck. If the battery is fitted into more than one container, this test is done with the electricallyconnected sections (including metal battery containers).

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Nominal voltage

Minimum insulation resistance

24 V

1,200 Ω

36 V

1,800 Ω

48 V

2,400 Ω

80 V

4,000 Ω

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10

Hydraulic operation 10.1

Overview

This section presents the hydraulic operation of the truck.

CAUTION Make sure that you have the correct version of the hydraulic schematic diagram for the truck model you do maintenance to. Speak to your supplier or technical support for information on getting up to date documentation for your truck model.

The hydraulic schematic diagrams illustrate the operation of the hydraulic system.

Lift cylinder

5

Pressure transmitter (Option)

9

PT

7 4 1 1,2 kW

M 1 cc

190 bar

3 2

450 µ

6

0,75 L

8

Figure 115: Hydraulic system overview for the standard model 2.0t 1.

2.

3.

4.

5.

Pump motor Hydraulic gear pump Relief valve Check valve Lifting cylinder

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6.

7.

8.

9.

Sieve Solenoid valve Hydraulic oil tank filling hole Pressure transmitter (option)

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Lift cylinder

5 Pressure transmitter (Option)

9

PT

7 4 1 1,2 kW

M 1 cc

215 bar

3 2

450 µ

6

0,75 L

8

Figure 116: Hydraulic system overview for the standard model 2.5t 1.

2.

3.

4.

5.

Pump motor Hydraulic gear pump Relief valve Check valve Lifting cylinder

6.

7.

8.

9.

Sieve Solenoid valve Hydraulic oil tank filling hole Pressure transmitter (option)

Load handling device cylinder

Pressure transmitter (Option 1.2t & 2.0t) (Standard 2.5t)

Lift platform cylinder

PT

9 8 6

3/8¨

4

P

10

2 1

171/min

2.2kW

M

cm3/tr

7

190bar LPR 450µ 10 l

5

3

Figure 117: Hydraulic system overview for lifting platform models 1.

2.

3.

4.

5.

Pump motor Hydraulic gear pump Relief valve Check valve Sieve

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6. Solenoid valve 7. Hydraulic oil tank filling hole 8. Lifting cylinder 9. Pressure transmitter (option) 10.Proportional lower valve

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Mast cylinder

5

Pressure transmitter (Option)

PT

7

9 4 1

171/min

2.2kW

M

cm3/tr

190bar LPR 450µ

2

8 10 l

6

3

Figure 118: Hydraulic system overview for the standard model with mast 1.

2.

3.

4.

5.

Pump motor Hydraulic gear pump Relief valve Check valve Lifting cylinder

6.

7.

8.

9.

Sieve Solenoid valve Hydraulic oil tank filling hole Pressure transmitter (option)

The principle of the hydraulic operation of the truck is as follows:

Lifting 1. The electrical motor operates the hydraulic gear pump.

2. The hydraulic oil is pressurized.

3. The fluid pressure is maintained using the relief valve, which opens at a certain pressure. In such cases, the hydraulic oil is flows back to the fluid tank. The opening pressure of the relief valve is shown in the hydraulic schematic diagram.

4. The pressurized hydraulic oil flows through the check valve to the lifting cylinder.

5. The lifting cylinder piston lifts the forks.

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Figure 119: Hydraulic oil flow during lifting

Lowering 1. The solenoid valve is opened with the lowering switch.

2. The hydraulic oil flows through the 450 μ sieve back to the fluid tank.

3. As the hydraulic pressure decreases, the lifting cylinder piston retracts and the forks are lowered.

Figure 120: Hydraulic oil flow during lowering NOTE: Different truck models can have different hydraulic system configurations.

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10.2

Hydraulic symbols

Symbol

Description Pressure sensor

Lifting cylinder

Plugged measuring point

Check valve

450 μ

450 µ sieve

Solenoid valve

Pump motor and hydraulic pump

M

Adjustable relief valve

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Symbol

Description Hydraulic oil flow choker

FILLING

10.3

Hydraulic oil tank filling hole

Hydraulic oil recommendations CAUTION

Hydraulic oil is dangerous waste that must be discarded accordingly.

Normal operating conditions

ISO VG 32

Cold storage

ISO VG 15

Hot temperatures

ISO VG 46

Fill the hydraulic oil tank at maximum ¾ of the full volume. The filling hole for the hydraulic oil is shown below.

Figure 121: Filling hole for hydraulic oil

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Figure 122: Filling hole for hydraulic oil – lifting platform models

10.4

Maintenance points of the hydraulic system

During maintenance, clean the hydraulic oil suction filter in the hydraulic oil tank.

10.5

Hydraulic aggregate (standard models) 6

3 5 7 1

2

4 Figure 123: Hydraulic aggregate (standard models) 1.

2.

3.

4.

Hydraulic connector Hydraulic oil tank Solenoid valve Hydraulic oil hose

5. Pressure sensor 6. Pump motor 7. Filling hole for hydraulic oil

The hydraulic aggregate has an electric pump motor, hydraulic gear pump unit, hydraulic oil tank, suction filter, relief valve, solenoid valve, hydraulic oil hoses and connections for different hydraulic equipment.

The hydraulic aggregate is used to control the load handling device.

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10.6

Hydraulic aggregate (lifting platform models)

5

8

4

7

3

9 1

6

2

Figure 124: Hydraulic aggregate (lifting platform models) 1.

2.

3.

4.

5.

Hydraulic connector Hydraulic oil tank Proportional valve Solenoid valve for lifting platform Solenoid valve for forks

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6.

7.

8.

9.

Hydraulic oil hose Pressure sensor Pump motor Filling hole for hydraulic oil

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10.7

Hydraulic aggregate (1.2t mast model)

6 5 3

7 1 4

2

Figure 125: Hydraulic aggregate (standard model with mast) 1.

2.

3.

4.

Hydraulic connector Hydraulic oil tank Solenoid valve Hydraulic oil hose

5. Pressure sensor 6. Pump motor 7. Filling hole for hydraulic oil

The hydraulic aggregate has an electric pump motor, hydraulic gear pump unit, hydraulic oil tank, suction filter, relief valve, solenoid valve, hydraulic oil hoses and connections for different hydraulic equipment.

The hydraulic aggregate is used to control the load handling device.

10.7.1

Disassemble the hydraulic aggregate

WARNING Prepare a drip pan to collect the remaining oil in the pipes and hoses before you disconnect each pipe. Make sure that no dust or dirt goes into the opening of the pipe and valve connections.

1. Remove the hydraulic oil hose.

2. Remove the hydraulic connector.

3. Remove the bolts that attach the hydraulic aggregate to the truck frame.

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4. Remove the hydraulic aggregate.

10.7.2

Disassemble the hydraulic oil tank

To adjust the relief valve or to clean the hydraulic oil suction filter, you must disassemble the hydraulic oil tank.

1. Remove the 4 bolts that attach the hydraulic oil tank to the pump motor.

2. Remove the hydraulic oil tank.

3. Adjust the relief valve, if necessary. Note that the relief valve is factory adjusted and usually it is not necessary to adjust it again.

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4. Clean the hydraulic oil suction filter and the hydraulic oil tank.

10.8

Replace the hydraulic cylinder CAUTION

Attach caps to the cylinder connectors for protection of the threads of the connectors and to prevent oil flow out of the cylinder when it is removed.

5 1 4 3

2

1. Hydraulic cylinder 2. Hydraulic oil hose

3. Hydraulic oil hose connector

1. Lift the lifting carriage to the up position.

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2. Support the lifting carriage with a lifting device or slings.

3. Remove the back cover. If the truck has an optional ladder installed, remove it first.

4. Remove the cylinder piping.

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5. Remove the screws. Tilt the hydraulic cylinder forward and remove it.

To install the hydraulic cylinder, repeat the steps in reverse order.

10.9 2

Hydraulic system with the lifting platform 3 4

5 1 6

7 Figure 126: Hydraulic system with the lifting platform overview 1.

2.

3.

4.

Proportional valve Solenoid valve for lifting platform Solenoid valve for forks Lifting platform hydraulic cylinder

5. Lifting platform hydraulic cylinder hose 6. Lifting hydraulic cylinder hose 7. Pressure sensor

The solenoid valve is an electrically controlled hydraulic valve that has 2 main parts: a solenoid (coil) and a valve. The solenoid converts electrical energy into mechanical energy which, in turn, opens or closes the valve mechanically. This basic ON/OFF function is used to control the oil flow to the cylinders.

To lift the lifting platform, the system uses the pump motor and the solenoid valve for the lifting platform.

To lower the lifting platform, the system uses the proportional valve and the solenoid valve for the lifting platform.

To lift the forks, the system uses the pump motor and the solenoid valve for forks.

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To lower the forks, the system uses the proportional valve and the solenoid valve for forks.

Type

Proportional valve

Contact rating

24 Vdc / 35 W / ED 100%

Electrical wiring

Quick connect terminals 6.3 x 0.8 mm

Type

Solenoid

Contact rating

24 Vdc / 20 W

Electrical wiring

Quick connect terminals 6.3 x 0.8 mm

Functionality check of the solenoid valves:

•

Measure the resistance between the proportional lower valve terminals 2Y1/ A1 and 2Y1/A2 (Lift platform proportional valve).

The value must be ~17 Ω.

•

Measure the resistance between the solenoid terminals 2Y2/A1 and 2Y2/A2 or 2Y3/A1 and 2Y3/A2 (Forks or mast on/off valve).

The value must be ~19 Ω.

CAUTION Before you do maintenance on the truck you must release the pressure from the system. Lower the lifting platform and the forks to the down position. Lift the lifting platform with a lifting device and put supports below it, before you begin the maintenance.

After you have replaced a part in the solenoid valve unit, you must bleed the system and do a test lifting to make sure that there are no oil leaks. Also, make sure that there is enough oil in the hydraulic oil tank.

NOTE: Add hydraulic oil when necessary!

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10.10

Hydraulic system with the simplex mast

4 5 1 2 3 Figure 127: Hydraulic system with the simplex mast overview 1. Hydraulic cylinder 2. Hydraulic oil hose connector 3. Hydraulic oil hose

4. Proportional solenoid valve 5. Pressure sensor

The hydraulic system uses the pump motor for lifting the forks.

The hydraulic system uses the proportional lower valve for lowering the forks.

Type

Proportional valve

Contact rating

24 Vdc / 35 W / ED 100%

Electrical wiring

Quick connect terminals 6.3 x 0.8 mm

Functionality check of the solenoid valves:

•

Measure the resistance between the solenoid terminals XY2/A1 and XY2/A2 (Lift platform valve).

The value must be ~28 Ω. (~17 Ω for proportional valve).

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11

TruckTool Diagnostics 11.1

Overview

Software maintenance can be performed with a diagnostics application called TruckTool. This program runs on a laptop PC and connects to the data bus of the truck (CAN) via a special adapter.

TruckTool can be used to receive, display and modify settings, update (flash) controller firmware, reset settings to hardware defaults, review and clear alarms, perform calibrations, execute a quick truck setup and monitor digital and analog inputs and outputs.

Additional training is required to use the program.

Figure 128: TruckTool Diagnostics For more information, see https://www.trucktool-online.com/

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11.2

Location of the service socket

Figure 129: The location of the service socket for connecting TruckTool to the truck

11.2.1

Connect TruckTool to the service socket

The service socket is behind the front cover.

1. Remove the front cover. See Section 5.6.1 Remove the front cover.

2. Remove the dust cover of the service connector.

3. Connect TruckTool to the service socket.

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12

Parameter descriptions TRUCKTOOL To view or change the parameters, see the instructions of TruckTool.

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13

Alarm codes TRUCKTOOL To view the possible alarms, see the instructions of TruckTool.

NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. Before you start to do troubleshooting to the truck:

•

Make sure that all the power supplies, fuses and connections are not damaged.

•

Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins and so on.

•

Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals).

•

Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 16.8 V.

•

Make sure that the battery is fully charged. Low battery voltage can cause error messages.

•

Set the power of the truck OFF and ON again. This can clear some error messages.

• •

Look at the status of the truck display (warning/alarm/info code).

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s).

NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V.

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14

Service data 14.1

Special tightening torques

Traction wheel

80 Nm

Traction controller terminal bolts

13-14 Nm

Steering controller terminal bolts

2.5-3 Nm

14.2

Tightening torques for standard bolts 8.8

10.9

12.9

Bolt size

Pitch [mm]

Nm

kg-m

Nm

kg-m

Nm

kg-m

M4

0.70

2.8

0.3

4.1

0.4

4.8

0.5

M5

0.80

5.5

0.6

8.1

0.8

9.5

1.0

M6

1.00

9.5

1.0

14

1.4

16.5

1.7

M7

1.00

15

1.5

23

2.3

28

2.9

M8

1.25

23

2.3

34

3.5

40

4.1

1.00

24

2.4

36

3.7

43

4.4

1.50

46

4.7

68

6.9

79

8.1

1.00

52

5.3

76

7.7

89

9.1

1.25

49

5.0

72

7.3

84

8.6

1.75

79

8.1

115

11.7

135

13.8

1.25

87

8.9

125

12.7

150

15.3

1.50

83

8.5

120

12.2

145

14.8

1.75

125

12.7

185

18.9

215

21.9

1.50

135

13.8

200

20.4

235

24.0

2.00

195

19.9

280

28.6

330

33.7

1.50

205

20.9

300

30.6

360

36.7

2.50

280

28.6

390

39.8

460

46.9

1.50

310

31.6

440

44.9

520

53.0

2.00

290

29.6

420

42.8

490

50.0

2.50

390

39.8

560

57.1

650

66.3

1.50

430

43.8

620

63.2

720

73.4

2.50

530

54.0

750

76.5

880

89.7

1.50

580

59.1

820

83.6

960

97.9

M10

M12

M14

M16

M18

M20

M22

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8.8

10.9

12.9

Bolt size

Pitch [mm]

Nm

kg-m

Nm

kg-m

Nm

kg-m

M24

3.00

670

68.3

960

97.9

1,000

112.2

1.50

760

77.5

1,100

112.2

1,250

127.5

2.00

730

74.4

1,050

107.1

1,200

122.4

3.00

1,000

102.0

1,400

142.8

1,650

168.3

1.50

1,100

112.2

1,600

163.2

1,850

188.6

2.00

1,050

107.1

1,500

153.0

1,800

183.5

3.50

1,350

137.7

1,900

193.7

2,250

229.4

1.50

1,550

158.1

2,200

224.3

2,550

260.0

2.00

1,500

153.0

2,100

214.1

2,500

254.9

3.50

1,850

188.6

2,600

265.1

3,000

305.9

1.50

2,050

209.0

2,900

295.7

3,400

346.7

2.00

2,000

203.9

2,800

285.5

3,300

336.5

4.00

2,350

239.6

3,300

336.5

3,900

397.7

1.50

2,700

275.3

3,800

387.5

4,450

453.8

3.00

2,500

254.9

3,500

356.9

4,100

418.1

4.00

3,000

305.9

4,300

438.5

5,100

520.1

1.50

3,450

351.8

4,900

499.7

5,700

581.2

3.00

3,200

326.3

4,600

469.1

5,300

540.4

M27

M30

M33

M36

M39

14.3

Troubleshooting CAUTION

Only adequately trained truck operators and service personnel can carry out the daily and weekly check-ups.

Only trained service personnel can carry out other maintenance operations.

The terms of warranty prescribe the appropriate maintenance of the truck.

Use original spare parts.

When you start troubleshooting, always look at the truck display messages first.

Obey the instructions. See the examples in Section 14.3.2 Troubleshooting case examples.

Before you contact the service personnel:

•

Make sure that the battery is fully charged (low battery voltage can cause error messages)

•

Restart the truck (some error messages can be cleared after the restart)

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14.3.1

Standard display messages

Table 10: Incorrect start error codes Error code

Origin

I 01

Operator presence sensing platform

I 02

Accelerator

I 03

Lever for lifting and lowering forks

I 05

Lever for lifting and lowering forks (lifting platform, if applicable)

I 07

Push buttons for moving the truck forward and backward

I 08

Push buttons for lifting and lowering the forks

14.3.2

Troubleshooting case examples

Table 11: Error code examples Display message

Cause

Action

I 02 / Accelerator

Accelerator is active at start up.

Release to continue.

08A223 / internal alarm

There is an internal error in the control system of the truck.

Restart the truck. If this does not help, contact service.

For further troubleshooting instructions, see below.

14.3.3

Traction

Table 12: When the truck does not move

1

2

Question

Answer

Action

Does the truck display have power?

NO

1. Connect the battery.

2. Set all emergency stop switches ON. 3. Turn the key switch / start switch ON. 4. Start the truck again.

If this does not help, contact service.

YES

Examine the display for error codes.

NO

Turn the accelerator.

If the display still has no error code, start the truck again and examine the display for error codes.

If this does not help, contact service.

YES

Examine the display instructions. In case of incorrect start error, see Table 10: Incorrect start error codes.

If this does not help, start the truck again.

If this does not help, contact service.

Does the display have an error code?

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14.3.4

Brakes

Table 13: When the brakes do not work correctly

1

2

Question

Answer

Action

Is the correct operation mode selected?

NO

Select the correct operation mode (PRO/ ECO).

YES

Make sure that both accelerator levers are released and they move freely.

NO

1. Remove any obstacles that block the movement.

2. Start the truck again.

If this does not help, contact service.

YES

Start the truck again.

If this does not help, contact service.

Are both accelerator levers released and move freely?

14.3.5

Hydraulics

Table 14: When the hydraulics do not work correctly

1

2

Question

Answer

Action

Is the correct operation mode selected?

NO

Select the correct operation mode (PRO/ ECO).

YES

Make sure that the lift/lower levers are released and move freely.

NO

1. Remove any obstacles that block the movement.

2. Start the truck again.

If this does not help, contact service.

YES

Start the truck again.

If this does not help, contact service.

Are the lift/lower levers released and move freely?

14.3.6

Steering

Table 15: When the steering does not work correctly

1

2

3

Question

Answer

Action

Is the truck moving when the problem occurs?

NO

Make sure the traction wheel is not in a hole, against a wall or otherwise blocked.

YES

Move on to the next question.

NO

Examine the condition of the traction wheel and the floor.

YES

Start the truck again.

If this does not help, contact service.

NO

Replace a worn traction wheel and/or repair worn floor surface.

YES

Start the truck again.

If this does not help, contact service.

Is the steering wheel turned extremely fast when the problem occurs?

Is the condition of the traction wheel and floor OK?

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14.3.7

Charging

Table 16: When the charger does not work correctly

1

2

3

Question

Answer

Action

Is the charger display ON?

NO

Connect mains to the charger.

YES

Examine the battery connection.

NO

Connect the battery.

YES

Examine the battery water level and battery voltage.

NO

Add battery water.

If this does not help, contact service.

YES

Start the charger again.

If this does not help, contact service.

Is the battery connected?

Is the battery water level and battery voltage OK?

14.4

Lubrication

14.4.1

Hydraulic oil

Normal operating conditions

ISO VG 32

Cold storage

ISO VG 15

Hot temperatures

ISO VG 46

14.4.2

Transmission oil

SAE 80W/90, API

14.5 Figure

Copyright © 2018 by MCFE. All rights reserved.

GL-4

Special tools Description

Part #

Extraction tool for main connectors (SUPERSEAL)

622096

Extraction tool for the key switch

360402

Extraction tool for standard display connector series

360058

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Figure

Copyright © 2018 by MCFE. All rights reserved.

Description

Part #

Crimp tool for the key switch connector

360401

Crimp tool for main connectors

354737

Extraction tool for main connectors

622350

Extraction tool for main connectors

622094

Hand tool frame

622090 Die set for female pin (HDSCS)

622091

Die set for male pin (HDSCS)

622092

Complete tool (SUPERSEAL)

622095

Complete tool (AMPSEAL)

622097

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15

Options 22

2

17

12

11

14

10 9 4 18

8 7

4 6 15

16 21

1

19

3

20

5

13

Figure 130: Options overview

Safety accessories These safety accessories are available as options: #

Option

Description

1

Blue point safety light towards driving direction, forks trailing (programmable)

The blue point light consists of 4 very bright LEDs. It projects a large blue point onto the floor. This warns pedestrians and other forklift operators of approaching forklift truck. The light is automatically activated when driving in forward direction (forks trailing).

CAUTION: Blue Light Radiance - Risk Group 2. Possibly hazardous optical radiation emitted from this product. Do not stare at operating light. May be harmful to the eye.

1

Driving light towards driving direction, forks trailing (programmable)

The LED drive light is to improve visibility in a dark environment. It projects a light in the forward direction (forks trailing).

2

Warning strobe, yellow

The warning beacon flashes when the operator has activated the accelerator.

3

Drive alarm (programmable)

Smart audible driving alarm to warn pedestrians and other traffic in noisy environments of a moving truck. The sound level of the alarm adapts automatically depending of ambient noise level in the range of 82-102 dB.

4

Fire extinguisher

Hand-held 2 kg fire extinguisher mounted on the backrest at floor level.

General accessories These general accessories are available as options:

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#

Option

Description

5

Foot switch for lowering the operator’s platform

Platform lowering foot switch enables the operator to lower the platform even with load in their hands.

6

Accessory rail in front

Allows mounting of various options, like scanner holder, equipment holder and so on.

7

Picking tray

This tray is used under two conditions: After picking a heavy box it can be stored temporary, for ergonomic reasons, while the platform is lowering or whilst driving to the next close-by location. For P/PF model only. Max 50 kg.

8

Scanner holder, no picking tray

Allows storage of a hand-held scanner. Not together with Picking tray option.

8

Scanner holder for picking tray

Allows storage of a hand-held scanner. Only in combination with Picking tray option.

9

Equipment holder (RAM mountings)

One or two pieces of RAM® Mounts fixed to optional Accessory bar (BAR) provides rugged mounting solution for various equipment.

10

Wrapping roll holder

Wrapping roll pole. Length 250 mm, diameter 35 mm.

11

Second level picking rail

Front, rear or both front and rear rails for 2nd level order picking, includes foldable climbing steps.

12

Load backrest

Prevents loads from falling towards the operator.

13

Sideways battery change (left side / right side)

Battery bed with rollers for quick sideways battery change with quick battery locking. Battery change from left hand side or right-hand side (towards drive direction, forks trailing).

14

Clipboard on battery cover, A4 size

For example, for a pick list or other necessary paper document.

15

Front storage boxes

Storage boxes can be used for miscellaneous items. They can prevent from dropping of pieces of tape, rope or wrap on the warehouse floor which can cause damage to bearings and axles of load wheels.

16

Storage folder on bottom of platform

Storage folder for operator’s personal items, for example coats, caps or gloves.

17

Entry and exit rollers for crosswise pallet handling

Rollers on bottom side fork tip. For easy entry and exit of bottom boarded pallets.

18

Seat/backrest

Tiltable to seat position for back and feet rest. Adjustable in height. Offers extra comfort during short breaks and at long shuttles from or to the order picking area as seat or as a backrest.

19

Power supply Power supply USB 5 V

Converts 24 V to 12 V. USB-connector for charging for example, a mobile phone.

20

Heavy duty front rubber bumper

Offers extra protection to the front bumper of the power unit.

21

Raised front guard plate

Offers extra protection to the front cover.

22

Rear grab handle on backrest

Improves the operator’s comfort during backwards driving.

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1

2

#

Option

Description

1

Keypad for standard display

Keypad for PIN code access. Only for access, no settings possible. Key switch is replaced with a start switch. ECO and PRO mode still selectable.

2

Color display

Multifunctional interactive color display with PIN code access.

3 2 1

#

Option

Description

1

Emergency stop button

Pressing this button stops the truck.

2

Walk beside drive button in backrest, forward/ backward

When the next order picking location is too close by to step on the truck and accelerate, this button offers increased productivity, max drive speed 4 km/h.

3

Buttons for lift/lower on sides of backrest

Forks can be lifted or lowered when the operator is outside the platform in order to adjust the pallet height to their preference.

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16

Technical specifications 16.1

Dimensions

Figure 131: Side dimensions of the standard model / lifting platform model

Figure 132: Side dimensions of the standard model with mast / lifting platform model with mast

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Figure 133: Dimensions of the standard model / lifting platform model

Figure 134: Dimensions of the lifting platform model with mast

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16.2

Technical data

Table 17: Technical specifications Truck type

Standard model

Lifting platform model

Standard model

Lifting platform model

Standard model with mast

Lifting platform model with mast

Power source

Battery

Battery

Battery

Battery

Battery

Battery

Operator type

Stand-on, Fixed platform

Stand-on, Lifting platform

Stand-on, Fixed platform

Stand-on, Lifting platform

Stand-on, Simplex mast

Stand-on, Lifting platform, Simplex mast

Load capacity (kg)

2000

2000

2500

2500

1200

1200

Load center distance (mm)

600

600

600

600

600

600

Load wheel axle to fork face (forks lowered)

960

960

960

960

785

785

Wheelbase

2054

2054

2054

2054

1929

1929

Truck weight with load, with maximum battery weight

3079

3215

3579

3715

2420

2556

Truck weight without load with maximum battery weight

1079

1215

1079

1215

1220

1357

Axle loadings with nominal load & maximum battery weight, drive/load side

1082/1997

1130/2085

1178/2401

1223/2492

Axle loadings without load & with maximum battery weight, drive/load side

829/250

913/302

829/250

913/302

853/367

940/416

Tyres: PT=Power Thane, Vul=Vulkollan, drive/load side

Vul/Vul

Vul/Vul

Vul/Vul

Vul/Vul

Vul/Vul

Vul/Vul

Tyre dimensions, drive side

ø250

ø250

ø250

ø250

ø250

ø250

Tyre dimensions, load side

ø85

ø85

ø85

ø85

ø85

ø85

Castor wheel dimensions (diameter x width)

ø180x65

ø180x65

ø180x65

ø180x65

ø180x65

ø180x65

Number of wheels, load/ drive side (x=driven)

4 / 1x1

4 / 1x1

4 / 1x1

4 / 1x1

4 / 1x1

4 / 1x1

Track width (center of tyres), drive side

494

494

494

494

494

494

Characteristics

Weight

Wheels, Drive Train

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Truck type

Standard model

Lifting platform model

Standard model

Lifting platform model

Standard model with mast

Lifting platform model with mast

365

365

365

365

355

355

Height

1173

1394/2244

1173

1394/2244

1173

1394/2244

Lift height

135

135

135

135

765/1115

765/1115

Height with mast extended

-

-

-

-

1275/1625

1275/1625

Seat- or stand height

123

150

123

150

123

150

Height of support legs

-

-

-

-

80

80

Platform height, raised

-

1000

-

1000

-

1000

Fork height, fully lowered

85

85

85

85

85

85

Overall length

2421

2421

2421

2421

2471

2471

Length to fork face

1271

1271

1271

1271

1321

1321

Overall width

800

800

800

800

800

800

Fork dimensions (thickness, width, length)

60/ 175/ 900-3600

60/ 175/ 900-3600

60/ 175/ 900-3600

60/ 175/ 900-3600

56/ 186/ 950-1450

56/ 186/ 950-1450

Outside width over forks (minimum/maximum)

480/ 660

480/ 660

480/ 660

480/ 660

540/ 570

540/ 570

Ground clearance at center of wheelbase, (forks lowered)

25

25

25

25

25

25

Working aisle width (Ast) with 800 x 1200 mm pallets, load lengthwise, platform up/ down

2898

2898

2898

2898

2881

2881

Turning radius

2231

2231

2231

2231

2106

2106

Travel speed, with/without load (optional)

9,0/9,0 (9/13)

9,0/9,0 (9/13)

9,0/13,0

9,0/13,0

9,0/9,0 (9/13)

9,0/9,0 (9/13)

Lifting speed, with/without load

0,04/ 0,05

0,04/ 0,05

0,03/ 0,05

0,03/ 0,05

0,13/ 0,21

0,13/ 0,21

Lowering speed, with/ without load

0,05/ 0,03

0,05/ 0,03

0,05/ 0,03

0,05/ 0,03

0,21/ 0,15

0,21/ 0,15

Gradeability, with/without load

7/15

7/15

7/15

7/15

7/15

7/15

Service brake

Electric

Electric

Electric

Electric

Electric

Electric

Track width (center of tyres), load side Dimensions

Performance

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Truck type

Standard model

Lifting platform model

Standard model

Lifting platform model

Standard model with mast

Lifting platform model with mast

Drive motor capacity (60 min. short duty)

2,6

2,6

2,6

2,6

2,6

2,6

Lift motor output at 15% duty factor

1,2

2,2

1,2

2,2

2,2

2,2

Battery voltage/capacity at 5-hour discharge

24 / 465620

24 / 465620

24 / 465-620

24 / 465-620

24 / 465620

24 / 465620

Battery weight

366-493

366-493

366-493

366-493

366-493

366-493

Energy consumption according to EN 16796

0,37

0,37

0,4

0,4

Stepless

Stepless

Stepless

Stepless

Stepless

Stepless

Electric motors

Miscellaneous Type of drive control

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APPENDIX A: Stickers PIN? _ _ _ _ _ PRO

1 4

PIN

2

3

ECO

OFF

3

2

1

4

PRO

5

ECO

OFF

STOP

6

7

Figure 135: Quick Guide sticker

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WARNING FOR SAFETY OBSERVE THE FOLLOWING WARNINGS

1. Do not operate this truck unless you have been trained and authorized to do so. Read all warnings and instructions in operator's manual and on this truck, Operation & Maintenance Manual is supplied with this truck or available from our Forklift truck dealers.

2. Do not operate this truck until you have checked its condition, Give special attention to Tires, Rims, Horn, Lights, Battery(s), Controller, Lift and Tilt systems including Forks or attachments, chains, cable and limit switches, brakes, steering mechanisms, Fuel system, hydraulic hoses and guards.

3. Operate truck only from designated operating position. Never place any part of your body into the mast structure, between the mast and the truck, or outside the truck. Do not carry passengers.

4. Do not operate truck without overhead guard, unless conditions prevent use of a guard. Use special care if operation without overhead guard is required.

5. Do not handle loads which are higher than the load backrest or load backrest extension unless load is secured so that no part of it could Fall backward.

6. Do not handle unstable or loosely stacked loads. Use special care when handling long, high or wide loads to avoid losing the load, striking bystanders or tipping the truck.

7. Do not overload truck. Check capacity plate for load weight and load center information.

8. Start, stop, travel, steer and brake smoothly. Slow down for turns and on uneven or slippery surfaces that could cause truck to slide or overturn. Use special care when traveling without load as the risk of overturn is greater.

9. Elevate Forks or other lifting mechanism only to pick up or stack a load. Lift and lower with mast vertical or tilted slightly back- NEVER FORWARD. Watch out for obstructions, especially overhead.

I0. Operate tilting mechanism slowly and smoothly. Do not tilt forward when elevated except to pick up or deposit a load. When stacking, use only enough backward tilt to stabilize load.

11. Travel with load or lifting mechanism as low as possible and tilted back. Always look in direction of travel. Keep a clear view, and when load interferes with visibility travel with load or lifting mechanism trailing (except when climbing ramps).

12. Use special care when operating on ramps — travel slowly, and do not angle or turn. When truck is loaded, travel with load uphill, when truck is empty, travel with lifting Mechanism downhill.

13. Observe applicable traffic regulations. Yield right of way to pedestrians. Slow down and sound horn at cross aisles and wherever vision is obstructed.

14. When using Forks, space Forks as far apart as load will permit. Before lifting, be sure load is centered and Forks are completely under load.

15. Do not allow anyone to stand or pass under load or lifting mechanisms.

16. Do not lift personnel except on a securely attached specially designed Work Platform. Use extreme care when lifting personnel. Place mast in vertical position, place truck controls in neutral and apply brakes. Lift and lower smoothly. Be available to operate controls as long as personnel are on the Work Platform. Never transport personnel on Forks or Work Platform.

17. Before getting off truck, neutralize control, fully lower lifting mechanism and set parking brake.

When leaving truck unattended, also shut off power.

18. Stay inside compartment until truck comes to a complete halt.

19. Be aware of steering direction inherent to specific chassis.

20. Extend Forks/attachments only to pick-up or discharge loads.

21. Travel with reach mechanism/attachment fully retracted and Load adequately centered during travel.

620190 EN

Figure 136: General warning sticker Manufacturer Truck type Truck

Serial number

Truck weight

kg Battery minimum weight

kg Battery terminal voltage

V Nominal power

kW Nominal lifting capacity

kg Year of manufacture

MADE IN FINLAND

Figure 137: Type plate

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Service Manual

1

2 400

mm

600

mm

3

kg

0 0

0

4

0

5

6

Figure 138: Capacity plate 1. Load center distance 400 mm 2. Load center distance 600 mm 3. Maximum lifting height (mm)

4. Actual capacity (kg) at maximum lifting height 5. Lifting height (mm) for rated capacity 6. Rated capacity (kg)

145851

Figure 139: Operation warning sticker

Figure 140: Do not step warning sticker

6234600 Figure 141: Serial number sticker

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212 (222)

Service Manual

145869

INSTALL BATTERY RESTRAINT BEFORE OPERATING TRUCK.

DISCONNECT BATTERY FROM TRUCK BEFORE ATTEMPTING TO SERVICE THIS TRUCK.

W H E N C O N N E C T I N G B AT T E RY TO LIFT TRUCK, BE SURE POLARITY OF B AT T E R Y C O N N E C T O R A N D L I F T TRUCK CONNECTOR AGREE BEFORE CONNECTING BOTH HALVES. DO NOT CONNECT CHARGER TO LIFT TRUCK CONNECTOR.

Figure 142: Battery maintenance warning sticker

145834

DO NOT STEAM CLEAN THE CONTROLS.USE A LOW PRESSURE AIR HOSE TO BLOW OFF CONTROLS WHEN REQUIRED.

Figure 143: Electric panel cleanup warning sticker

U>75V NIMIKE BESKRIVNING DESCRIPTION DESIGNATION TYYPPI TYP TYPE TYPE

NIMELLISJANNITE NOM. SPANNING NOMINAL VOLTAGE. TENSION NOM.

SARJANROT/T-nro SERIENNR./T-nro SERIAL NO./T-No NO DE SERIE/No de’l

KAPASITEETTI KAPACITET CAPACITY CAPACITE

PIIRUSTUSNRO RITNINGSNR DRAWING No NO DE PLAN

KENNOMAARA CELL KVANTITET NUMBER OF CELLS NOMBRE ELTS

PAIVAYS DATUM DATE DATE

PAINO VIKT WEIGHT POIDS

COUNTRY OF ORIGIN -

ELEKTROLYYTTISISALTO ELECTROLYTE INNEHALL ELECTROLYTE CONTENT VOLUME D’ELECTROLYTE

Figure 144: Battery type plate

Figure 145: Hoist point indication sticker

369871 1

Figure 146: Hydraulic oil tank filling cap sticker

Copyright © 2018 by MCFE. All rights reserved.

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Service Manual

APPENDIX B: Truck display languages The following truck display languages are available:

• • • • • • • • • • • • • • • • • • • • • • • • •

Bulgarian – Български Croatian – Hrvatski Czech – Čeština Danish – Dansk Dutch – Nederlands English Estonian – Eesti Finnish – Suomi French – Français German – Deutsch Greek – Ελληνικά Hungarian – Magyar Italian – Italiano Latvian – Latviešu Lithuanian – Lietuvių Norwegian – Norsk Polish – Polski Portuguese – Português Romanian – Română Russian – Русский Slovak – Slovenčina Slovene – Slovenščina Spanish – Español Swedish – Svenska Turkish – Türkçe

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Service Manual

APPENDIX C: Maintenance check list CAUTION Only adequately trained truck operators and service personnel can carry out the daily and weekly check-ups.

Only trained service personnel can carry out other maintenance operations!

The terms of the warranty prescribe appropriate maintenance of the truck.

Use original spare parts.

Legend: C = check, R = Repair, Clean or Change, G = Grease Before daily use (user)

Monthly (owner)

1000 h or once a year (service)

2000 h or every second year (service)

C

C

C

C

Steering bearing

C

C

Fastening of the transmission gear

C

C

Lubrication of the drive unit bearing

G

G

C

C

Drive unit Transmission leakage check

Hydraulics Leakage check

C

C

Replace of the oil filter and breather

R

Hydraulic oil change

R

Oil level

C

C

C

Hose and cylinder

C

C

C

C

C

C

C

C

Mounting of the mast

C

C

Visual inspection of the wear level of the mast rollers and contact surface

C

C

C

C

Chain lubrication (clean and lubricate)

G

G

Chain wear measurement and replacement if over the 2% limit

C

C

C

C

Tightness of the cylinders and piston rods, possible leaks and damages

C

C

Lifting and lowering speed

C

C

Chain lubrication, clean and lubricate if needed

C

C

Operation of the hydraulics

C

Relief valves Mast (if applicable)

Chain setting, adjustment if needed

Tightness of the hydraulic connections, hoses and pipes, possible leaks and damages

Copyright © 2018 by MCFE. All rights reserved.

C

C

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Service Manual

Before daily use (user)

Monthly (owner)

1000 h or once a year (service)

2000 h or every second year (service)

Lubrication of the mast contact surfaces

C

C

Functionality of the lift sensors in the mast, possible damages

C

C

Test lift with rated load, and with a customer specific load if needed

C

C

Cracking and welding in the mast

C

C

Mounting of any attachments and load carrying components

C

C

Cracking and wear in the fork base

C

C

Cracking in the welds of the masts

C

C

Cracking in the lift bracket welds

C

C

Cracking and damage in the rollers, roller pins and welds

C

C

Cracking and welding in the fork carriage

C

C

Mounting, wear and damage of the forks and the load handling device

C

C

Fork thickness and locking

C

C

Bearings

C

C

Linkage

C

C

Fork spring

C

C

C

C

C

C

C

C

Fork carriage

Linkage

Wheels Damage and wear in the wheels Traction wheel

C

C

Traction wheel must be replaced when its diameter reaches 230 mm Load wheels

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

Battery Battery water level Clean the battery if needed Battery cable and connector

C

C

Battery cell voltage and specific gravity Battery automatic watering system Charger

C

Electrics

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Service Manual

Before daily use (user)

Monthly (owner)

Sensors (examine the functionality of all sensors)

1000 h or once a year (service)

2000 h or every second year (service)

C

C

Steering wheel functions

C

C

C

C

Horn

C

C

C

C

Braking functions

C

C

C

C

Brake air gap and disc thickness

C

C

Controller power cable torque

C

C

Cable torque of the motor

C

C

Alarm history checking/clearing

C

C

Cables and wiring

C

C

C

C

Lubrication (examine the correct lubrication points)

G

G

Examine cracking and welding in the frame

C

C

General Cleaning

C

C

Frame and the fork carriage

C

C

C

C

Gas spring of the steering wheel

C

C

C

C

Type plate

C

C

C

C

Covers

C

C

C

C

Safety functions • Brake • Battery locking • Warning stickers • Emergency stop button • Key switch

C

C

C

C

C

C

C

C

Fastening of the steering wheel Options (CSM) DC/DC converter Load backrest

C

C

C

C

Accessory rack

C

C

C

C

C

C

Examine the functionality of the options

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217 (222)

Service Manual

Index A AC motor operation....................................... 127 Adjust the mast chains ....................................98 Alarm codes ................................................. 195 Assemble the castor wheel ..............................71 Assemble the traction motor and transmission gear connection.........................54 Assemble the traction wheel ............................65

B Batteries ...................................................... 128 Acquire a new battery ................................ 136 Annual maintenance .................................. 130 Charge the battery..............................133, 135 Daily maintenance ..................................... 129 General maintenance ................................ 130 How to avoid damage to the plastic parts of batteries.................................................. 132 How to clean batteries................................ 131 How to clean vehicle traction batteries......... 131 How to replace the battery.......................... 137 Malfunctions.............................................. 131 Measure the specific gravity of the battery ... 136 Replace the battery ................................... 136 Requirements for the battery charging areas ...................................................... 132 Weekly maintenance ................................. 130 Battery maintenance Storage..................................................... 130 Bleed the mast cylinder ................................. 106

Drive unit........................................................50 Remove the drive unit ..................................51 Remove the steering motor of the drive unit ...52 Remove the traction motor and transmission gear from the drive unit...............................53 Remove the traction motor from transmission gear ..........................................................54 Remove the transmission gear .....................55

E Electric panel................................................ 140 Discharge the controllers............................ 141 Electric system adjustments and measurements ............................................ 173 Electrical operation ....................................... 126 Power source ............................................ 126 Electrical steering Adjust the electrical steering....................... 173 Emergency stop button ...................................23 Emergency stop button for standard models ... 139

F Fuses .......................................................... 153

G General information ........................................20 Identification plates of the truck.....................19 Intended use ...............................................19 Guidance rollers ........................................... 123

C Castor wheel ..................................................69 Adjust the castor wheel ................................69 Disassemble the castor wheel ......................70 Remove the castor wheel .............................70 Coil resistance measurement......................... 156 Color display ..................................................80 Install the color display.................................81 Remove the color display .............................80 Contactors and relays ................................... 149 Control panel................................................ 139 Covers Truck covers ...............................................48

D Description of the power connections ............. 147 Description of the power connectors............... 149 Diode test with a multimeter........................... 172 Disassemble the chain yoke ............................89 Disassemble the chains...................................98 Disassemble the hydraulic aggregate ............. 185 Display menus Message area .............................................34

Copyright © 2018 by MCFE. All rights reserved.

H Horn ............................................................ 172 How to operate the truck Operating direction ......................................21 How to start the truck Activate the truck with a PIN code .................28 Hydraulic aggregate Disassemble the hydraulic oil tank .............. 186 Lifting platform models ............................... 184 Standard model with mast .......................... 185 Standard models without mast.................... 183 Hydraulic cylinder Replace the hydraulic cylinder .................... 187 Hydraulic oil recommendations ...................... 182 Hydraulic operation ....................................... 177 Hydraulic symbols......................................... 181 Hydraulic system Hydraulic system with the lifting platform ..... 189 Hydraulic system with the simplex mast .......... 191

I Inspect the forks .............................................90

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Service Manual

Inspect the tension of the mast chains ..............98 Insulation resistance of the battery ................. 175 Insulation resistance of the truck .................... 175 Insulation resistance test ............................... 174 Test voltage .............................................. 174 Insulation tester check................................... 174

K Key switch.............................................126, 139

L Lifting cylinder .............................................. 102 Disassemble the lifting cylinder................... 105 Replace the lifting cylinder.......................... 102 Lifting platform.............................................. 112 Adjust the lifting platform ............................ 124 Adjust the lifting platform machine-way........ 125 Bleed the lifting platform cylinder ................ 122 Remove the floor of the lifting platform ........ 115 Remove the foot lowering pedal.................. 121 Remove the lifting platform ......................... 112 Replace the operator presence pedal sensor..................................................... 117 Replace the rubber stoppers ...................... 118 Replace the wiring harness ........................ 118 Lifting platform foot lowering pedal ................. 171 Lifting platform lift stop sensor........................ 168 Lifting platform pedal functionality check......... 171 Lifting system .................................................71 Lifting the truck Hoist points .................................................46 Jack points..................................................46 Lifting points................................................46 Linkage mechanism Disassemble the linkage mechanism ............72 Load handling device ......................................42 Simplex mast unit ........................................43 Standard forks.............................................42 Load wheels ...................................................68 Disassemble the load wheel .........................68 Lubrication ................................................... 200 Hydraulic oil .............................................. 200 Transmission oil ........................................ 200

M Magnetic brake ............................................. 156 The air gap of the magnetic brake ............... 156 Maintenance Battery maintenance.................................. 129 Daily maintenance of the mast unit................83 Maintenance check list............................... 215 Monthly maintenance of the mast unit ...........84 Maintenance of the mast chains .......................94 Maintenance of the mast unit ...........................83 Maintenance points of the hydraulic system .... 183 Mast chains .............................................. 84, 91 Inspect the mast chains ...............................91 Replace the mast chains ..............................99

Copyright © 2018 by MCFE. All rights reserved.

Mast channels ................................................84 Mast unit Disassemble the mast unit ...........................86 Remove the mast unit ..................................84 Simplex mast unit ........................................83 Measure the elongation of the mast chains .......92 Measure the insulation resistance .................. 174 Motor compartment....................................... 155

O Operating environment Operating temperature.................................18 Operator compartment Backrest .....................................................41 Color display (optional) ................................29 Control panel ..............................................22 Display control buttons.................................30 Hierarchy of the truck display menus.............30 Keypad for standard display (optional) ..........28 Operating devices .......................................21 Operation modes.........................................23 Operator presence sensing platform .............40 Optional controls in the backrest ...................42 Seat/backrest (option)..................................41 Standard display .........................................24 Truck display...............................................24 Operator presence sensing platform............... 108 Options ........................................................ 202 Overview of the truck.......................................20

P Parameter descriptions ................................. 194 Personal safety...............................................17 Program a new PIN code.................................28 Pump motor ........................................... 59, 157

R Remove the battery of a lifting platform truck... 116 Remove the contactors ................................. 151 Remove the controllers ................................. 150 Remove the lifting carriage ..............................87 Remove the load backrest ...............................50 Remove the magnetic brake ............................57 Remove the main rollers of the lifting carriage ...88 Remove the mast cylinder ...............................88 Remove the operator sensing platform floor .... 109 Remove the pump motor Lifting platform models .................................60 Standard models .........................................59 Replace the rubber stoppers.......................... 111 Replace the truck connector .......................... 153 Replace the wheel shaft bolts ..........................66

S Safety Repairs and structural modifications..............15 Safety requirements for industrial trucks ........15

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Safety with lead-acid batteries .................... 129 Safety-related signs ..................................... 11 Safety circuit (emergency stop button)............ 126 Safety instructions ..........................................15 Sealing housing of the lifting cylinder .............. 105 Second level order picking...............................43 Second level order picking (optional) Climbing rails and steps ...............................44 Lifting platform ............................................44 Sensors ....................................................... 161 Adjust the forks lift upper limit sensor .......... 165 Assembly of the reference sensors ............. 173 Forks lift upper limit sensor......................... 164 Lifting platform lift speed reduction sensor ... 170 Lifting platform lower speed reduction sensor..................................................... 169 Lifting platform sensors .............................. 168 Mast operating speed reduction sensor ....... 167 Operator platform sensor ........................... 167 Operator presence sensor of the lifting platform................................................... 170 Pressure sensor ........................................ 162 Replace the HALL sensor........................... 166 Replace the operator platform sensor.......... 109 speed sensor ............................................ 166 Steering reference sensor .......................... 163 Steering speed sensors ............................. 164 Service area safety .........................................16 Side control panel ...........................................23 Slewing bearing ..............................................58 Solenoid valve .............................................. 158 Spare parts ....................................................47 Special tightening torques ............................. 196 Special tools................................................. 200 Steering controller......................................... 147 Steering controoler CNA external connector ............................. 148 Steering motor.............................................. 160 Steering teaching.......................................... 173 Steering wheel................................................75 Install a new gas spring................................79 Remove the steering wheel ..........................75 Replace the gas spring of the steering wheel ........................................................77 Stickers........................................................ 210

Transportation.............................................47 Troubleshooting............................................ 197 Brakes do not work .................................... 199 Charger does not work............................... 200 Error messages......................................... 198 Hydraulics do not work............................... 199 Steering does not work .............................. 199 Troubleshooting case examples ................. 198 Truck does not move ................................. 198 Truck covers Open the battery cover.................................49 Remove the back cover ...............................50 Remove the front cover ................................48 Truck display Change the color display..............................80 Main view of the truck display .......................31 Selection view .............................................38 Truck display icons ......................................31 Truck display languages ................................ 214 Truck display view Battery discharge indicator ...........................32 Center information area ...............................34 Parking brake indicator ................................33 TruckTool Connect TruckTool to the service socket...... 193 Location of the service socket..................... 193 TruckTool diagnostics.................................... 192

U Units ..............................................................14

W Walk beside drive buttons.............................. 140 Welded forks ..................................................90 Wheels ..........................................................62 Work safety ....................................................17

T Technical specifications................................. 205 Dimensions............................................... 205 Technical data ........................................... 207 Temperature sensor check ............................ 156 Tightening torques for standard bolts.............. 196 Traction........................................................ 127 Traction controller ......................................... 142 Traction controller connector.......................... 143 CNA external connector ............................. 144 Traction motor .............................................. 156 Traction wheel ................................................63 Remove the traction wheel ...........................63 Transmission gear ..........................................57 Transportation and storage

Copyright © 2018 by MCFE. All rights reserved.

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Notes

Copyright © 2018 by MCFE. All rights reserved.

221 (222)

For more information on this range visit: www.catliftdealer.com www.catlifttruck.com

639785-EN A (03/2018) © 2018, MCFE. All rights reserved. CAT, CATERPILLAR, BUILT FOR IT, their respective logos, “Caterpillar Yellow”, the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

Mass production drawings IR 2017-12-11

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Pg 0 1 2 3 4 5 6 7 8 9 10

16

17

18

Title TABLE OF CONTENTS VOLTAGE SUPPLIES MOTORS EMS, KEY, SENSORS SENSORS 2 STEERING WHEEL STEERING CIRCUITS CAN-BUS HYDRAULICS, AUX DEVICES AUX. DEVICES TRAVEL FROM SIDE

19

20

Rev D D D D B B D B D D D

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23

Description Mass production drawings Mass production drawings Mass production drawings, 2nd steer Mass production drawings, X12/ remo 0-Series drawings 0-Series drawings Service connector +supply moved 0-Series drawings Mass production rev, Connectors rem Mass production drawings Mass production drawings, S13 & S14

24

25

26

27

28

29

30

Rev Date 2017-12-11 2017-12-11 2017-12-11 2017-12-11 2017-07-04 2017-07-04 2017-12-11 2017-07-04 2017-12-11 2017-12-11 2017-12-11

D

REV

DATE:

NAME:

CHANGE:

11

DATE: DESIGN. 2017-03-23 CHECK. APPROV.

NAME: JL

CIRCUIT DIAGRAM

NO12N2F(P), NO20N2(P), NO25N2(P) TABLE OF CONTENTS

0 / 10

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11

12

13

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24

25

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MAIN CONTACTOR

OPTION CONTACTOR

+24V

3-12

27

28

29

30

K1 J15 1

K2

9F1

3-14

425A

9-21

2

J12 3-14

1

2

A

B

1F1

2F1

X1/ +

2A

3L3

4L3

8-20

3-20

4-27

1L2

2L2

3L2

4L2

8-28

8-14

3-23

7-16

4

10A

5

10A

2L1

3L1

4L1

5L1

6L1

2-24

8-12

6-19

5-12

9-14

9-19

COMBI CONTROLLER

6

20A

AUX. DEVICES

10L1

3-12

X1/ -

G

7F1 7

X69/ 1

1L1

KEYSWITCH

IR 2017-12-11

3

F

6F1

D

NAME:

2A

2L3

24V

DATE:

2

E

5F1

AUX. DEVICES

G1

REV

10A

1

D

4F1

DISPLAY AND STEERING WHEEL

Mass production drawings

CHANGE:

5A

C

3F1

+12V FOR AUX. DEVICES

2

SENSORS

1

1M1

10M1

3M1

4M1

6M1

3-12

2-24

3-23

5-13

9-19

1M2

3M2

4M2

8-28

6-21

7-15

1M3

3M3

8-26

3-21

X2/

-

X69/ 2

J17 9-21

0V

DATE: DESIGN. 2017-03-23 CHECK. APPROV.

NAME: JL

CIRCUIT DIAGRAM

NO12N2F(P), NO20N2(P), NO25N2(P) VOLTAGE SUPPLIES

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10L1

10F1 50A

B+

2

A2+ M1

M3

V Max 3Nm

M2

610014

W

W Max 15Nm W V

3 V

3

W Max 3Nm

A1-

V Max 15Nm

U U Max 15Nm

U

J18

J5

SPEED SENSOR RED

PUMP MOTOR

U Max 3Nm 7-27

XM3/ 1

XA3/ 16

+13,5V

XX10 WHT

XM3/ 2

XA3/ 3

BLU

XM3/ 3

XA3/ 4

BLK

XM3/ 4

XA3/ 5

A

RED

0V

2

R32

XM3.1/ 2

XA3/ 6

XM1/ 3

XA1/ 14

BLU

XM1/ 2

XA1/ 13

BLK

XM1/ 4 XX2

B31

XM3.1/ 1

XA3/ 7

TEMP. SENSOR

XA1/ 25

WHT

1 1

XM1/ 1

+12V

XX1

B

B32

3-27

SPEED SENSOR

A

B

XA1/ 5

0V

J10 2

R31

XM1.1/ 2

4-20

XM1.1/ 1

XA1/ 22

TEMP. SENSOR

0V

-P Max 15Nm GEAR WHEEL SENSOR

XA3/ 14

WHT

XM4/ 2

XA3/ 17

BLU

XM4/ 3

XA3/ 20

BLK

XM4/ 4

XA3/ 8

+13,5V

A

B

0V

B33

626153

STEERING CONTROLLER EPS AC-0

RED

-B Max 15Nm

XM4/ 1

-B Max 3Nm

TRACTION AND PUMP CONTROLLER COMBIAC0

2017-12-11

+B Max 15Nm 1

IR

Mass production drawings, 2nd steer encoder a

+B Max 3Nm

D

REV

DATE:

NAME:

CHANGE:

1-20

A1

10M1 1-20

626154

A3

STEERING MOTOR

DATE: DESIGN. 2017-03-23 CHECK. APPROV.

PUMP MOTOR

DRIVE MOTOR

NAME: JL

CIRCUIT DIAGRAM

NO12N2F(P), NO20N2(P), NO25N2(P) MOTORS

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1L1 1-15

OPTION BATTERY COVER SENSOR

X3/ 1 X3.1/ 1

S50

Mass production drawings, X12/ removed

1

OPTION MULTIP. 3 IN

PNP

633307 4

1

3

4

3

XS55/ 1 X10/ 9

XS55/ 2

XS54/ 2

XS54/ 1

BLU

XS53/ 3

XS53/ 4

BLK

BRN

BLK

BLU

XS53/ 1

S2 EM.STOP 633472

XS50/ 3

11

XS50/ 4

XS50/ 1

BRN

X3.1/ 2 X3/ 2

12

XX3 M1

XY31/ 1

J4

KEY

6

1

KEY SWITCH 608414 3

J9

J11

10-14 PEDESTRIAN BUTTONS

2

4-19

10-21 PEDESTRIAN BUTTONS

XY31/ 2

A

IR

4-17 FLOOR MAT

J8

24V 5

J13

4-16 FLOOR MAT

S1

4

NAME:

S53

PNP

633307

OPTION MULTIP. 2 IN

X10/ 2

CHANGE:

EMS BUTTONS IN THE BACK REST PAGE 10

OPTION LIFT LIMIT SENSOR

XX6

V2

XX7

XX19

X10/ 10

X10/ 1

X20/ 9

X20/ 8

X20/ 2

X20/ 1

XX5

X20/ 10

2017-12-11

DATE:

K

D

J12

F101

XX12

K2

A2 637206

LINE CONTACTOR

KEY

PRO ECO

XA1/ 2

EMS STATUS

XA1/ 4

3L3

XA1/ 31

XA1/ 20

-

PEB

1-22

NEB

BATTERY LOCK

XX25

XX45

XX11

3M3

3L2

3M1

J18

1-22

2-25

1-22

1-22

MULTIPURPOSE 1 INPUT

MULTIPURPOSE 2 INPUT

XA1/ 30

K1

A2 637206

XA1/ 15

A1 24V

XA1/ 7

A1 24V

XA1/ 10

47uF/ 63V

+ -

XA1/ 19

+ C1

XX24

1-22 SENSORS AND DISPLAY

XA1/ 12

REV

J3 6-12 EPS

MULTIPURPOSE 3 INPUT

TRACTION AND PUMP CONTROLLER COMBIAC0

1M1 1-15

A1

DATE: DESIGN. 2017-03-23 CHECK. APPROV.

NAME: JL

CIRCUIT DIAGRAM

NO12N2F(P), NO20N2(P), NO25N2(P) EMS, KEY, SENSORS

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STOP SWITCH

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FLOOR SENSOR

J14

J4

5-16

3-23

19

20

21

22

23

24

OPTION PRESSURE SENSOR

B42

26

27

28

29

30

OPTION PIN CODE LOCK

S8

636729

L+ (+12v)

25

4

OUT A

M

3 RED

WHT

BLK

XB42/ 1

XB42/ 2

XB42/ 3

2 1

0-Series drawings

ENTER

XS19/ 1

CHANGE:

ESC

XX8

S19 633307 BN

J9

PNP

X10/ 12

3

X10/ 11

BU

XS19/ 3

4

XS19/ 4

IR 2017-07-04

BK

XB5/

1

2

3

4

B

NAME:

3-26

DATE:

X20/ 3 J13

J10

3-23

2-24

4L3 1-23

STOP SWITCH

SAFETY PEDAL

PRESSURE

PIN1

PIN2

XA1/ 35

XA1/ 29

XA1/ 21

XA1/ 18

XA1/ 16

+Key

XA1/ 1

REV

1

PIN3

TRACTION AND PUMP CONTROLLER COMBIAC0

A1

DATE: DESIGN. 2017-03-23 CHECK. APPROV.

NAME: JL

CIRCUIT DIAGRAM

NO12N2F(P), NO20N2(P), NO25N2(P) SENSORS 2

4 / 10

REV

3-7876

D

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

180° M1 STEERING COMPONENTS THROTTLE SENSOR 1

THROTTLE SENSOR 2

S312

-

0,5 ... 4,5 V

0,5 ... 4,5 V

+

-

0,5 ... 4,5 V

0,5 ... 4,5 V

S313 STOP SWITCH1

HORN

S314 STOP SWITCH2

LIFT / LOWER 1

CAN TERM

B303

120R

LIFT / LOWER 2

B304

STEERING ANGLE SENSOR 1

B307

STEERING ANGLE SENSOR 2

B308

X18/ 8

SUPPLY 0V BLUE

CANH GREEN

CANL WHITE

STOP IN YELLOW

STOP OUT ORANGE

HORN OUT VIOLET

X17/ 2

X17/ 3

X17/ 4

X17/ 5

X17/ 6

X17/ 7

4M1

J20

J21

J14

J16

X17/ 8

SUPPLY + RED

X17/ 1

FLEXIBLE STEERING CABLE

WHEEL FRAME BLACK

X18/ 7

X18/ 6

X18/ 5

X18/ 4

X18/ 3

INTERNAL PCB

X18/ 2

0-Series drawings IR

XX9

X5/1

2017-07-04 B

INTERNAL PCB

B302

X18/ 1

CHANGE: REV

DATE:

NAME:

+

B301

4L1 1-23

1-23

7-20

7-19

4-13

8-26

DATE: DESIGN. 2017-03-23 CHECK. APPROV.

TRUCKS BODY

NAME: JL

CIRCUIT DIAGRAM

NO12N2F(P), NO20N2(P), NO25N2(P) STEERING WHEEL

5 / 10

REV

3-7876

D

11

12

13

14

15

16

17

18

19

20

21

STEERING FEEDBACK SENSOR

GND FOR SERVICE CONNECTOR

SENSOR A

S31

J3

J6

3-14

7-29

NPN

Service connector +supply moved IR 2017-12-11

BN

23

BK

XX13

BU

26

3L1

3M2 1-22

28

29

30

1

BN

485304

4

BK

3

BU

Top view

XX14

1-22

27

SENSOR B

S32 NPN

3

25

STEERING FEEDBACK SENSOR

485304

4

24

S31

S32

KEY

0V

STEERING STRAIGHT SWITCH

XA3/ 11

XA3/ 12

XA3/ 13

XA3/ 15

D

NAME: DATE:

CHANGE:

1

REV

22

STEERING 90-DEG SWITCH

STEERING CONTROLLER EPS AC-0

A3

DATE: DESIGN. 2017-03-23 CHECK. APPROV.

NAME: JL

CIRCUIT DIAGRAM

NO12N2F(P), NO20N2(P), NO25N2(P) STEERING CIRCUITS

6 / 10

REV

3-7876

D

11

12

13

14

15

16

17

4M2

4L2

1-23

1-23

18

19

20

21

22

23

24

25

26

27

28

29

30

XA5.1/ 1

XA5.1/ 3 WHT

XA5.1/ 2

XA5.1/ 4 BRN

0-Series drawings IR 2017-07-04

2-16

6-15

J5

J6

B

NAME:

XX46

XX29

XX47

XX56

XX15

XX16

XX52

XX21

XX22

XX54

XX17

A6

618306 OPTION COLOR DISPLAY

J21

J20

CANL

CANH

5-14

5-13

607094

A5

DESIGN. 2017-03-23 CHECK. APPROV.

CANH

STEERING WHEEL

+13,5V

0V CANL

COMBI CONTROLLER

A3 STEERING CONTROLLER

CIRCUIT DIAGRAM

CANH

X56/ SERVICE CONNECTOR

NAME: JL

X56/ 3

CANL

X56/ 2

CANH

X56/ 9

CANL

A1

STANDARD DISPLAY

DATE:

XA3/ 23

0V

XA3/ 22

+KEY

XA5/ 1

CANH

XA1/ 28

120R

XA1/ 27

CANL

XA5/ 2

0V

XA5/ 3

+KEY

XA5/ 4

XA6/ 1

CANH

XA6/ 2

XA6/ 3

CANL

120R

X56/ 7

R2 XX44

120R

XX18

XX55

R1 XX43 XA6/ 4

REV

DATE:

CHANGE:

OPTION IF COLOR DISPLAY USED

NO12N2F(P), NO20N2(P), NO25N2(P) CAN-BUS

7 / 10

3-7876

REV

D

11

12

13

14

15

OPTION

2L1

16

17

18

OPTION

20

21

OPTION

1-21

22

23

24

25

26

27

28

OPTION

FORWARD LIGHT

2L2

1-21

19

2L3 1-21

29

30

HORN

PROGRAMMABLE FLASHING WARNING LIGHT OR WARNING SOUND

1L2 1-15

J16 5-18

14

X51/ 1 X51.1/ 1

Mass production rev, Connectors removed

CHANGE:

J2

K4

86

K11

30

NAME:

IR

DATE:

2017-12-11

30

X10/ 3 24V

87

85

XX23

24V

633809

87a

XE50/1

633809

87

85

X6/ 1

XH7.1/ 1

87a

XH7.2/ 1

RED

1

X1 FORWARD LIGHT

CONTROLLER FAN

E50

M6

H7

22

H6

V5

H1

A

A2

BLK

J2 XE50/2 (M1)

A1

K

2

X2

X6/2

XH7.1/ 2

XH7.2/ 2

A1

2Y1 A2

D

X51.1/ 2 X51/2

X10/ 4

X10/ 5

X51.1/ 3 X51/ 3

X10/ 6

X10/ 14 1M3

9-12

SPARE

1M2 1-15

XA1/ 26

SPARE

1-15

XA1/ 33

XA1/ 34

XA1/ 8

LOWER VALVE

XA1/ 23

VALVE SUPPLY

XA1/ 24

J1

XA1/ 3

REV

86

FORWARD LIGHT

FAN CONTROL

AUDIBLE ALARM

MULTIPURPOSE OUTPUT 1

MULTIPURPOSE OUTPUT 2

MULTIPURPOSE OUTPUT 3

TRACTION AND PUMP CONTROLLER COMBIAC0

A1 DATE: DESIGN. 2017-03-23 CHECK. APPROV.

NAME: JL

CIRCUIT DIAGRAM

NO12N2F(P), NO20N2(P), NO25N2(P) HYDRAULICS, AUX DEVICES

8 / 10

REV

3-7876

D

11

12

13

14

15

16

OPTION FLASHING WARNING LIGHT

17

18

23

24

25

26

27

28

29

30

OPTION AUX. DEVICES SUPPLY 12V / 24A

6L1

J15

1-27

1-29

X10/ 15

X10/ 16

X29/ 1

XX26

IR

X60/ 4

1

J1

X60/ 2

S29

1

G1

H5

18-106V

12.2V/24A

2

8-18

2

XH5/2

620706

633069

X60/ 3

X60/ 1

X29/ 2

D

2017-12-11

22

1-26

Mass production drawings

CHANGE: NAME:

21

5L1

XH5/1

DATE:

20

8-34V/5V CONVERTER USB SOCKET OUT

X10/ 13

REV

19

XX20

X10/ 7

DATE: DESIGN. 2017-03-23 CHECK. APPROV.

X10/ 8

6M1

J17

1-27

1-29

NAME: JL

CIRCUIT DIAGRAM

NO12N2F(P), NO20N2(P), NO25N2(P) AUX. DEVICES

9 / 10

REV

3-7876

D

12

13

14

15

16

17

18

REVERSING/PEDESTRIAN BUTTONS IN THE BACK REST

S15 636220

1

2 636220

3

1

22

23

24

RIGHT

2

S16

21

LIFT/LOWER BUTTONS IN THE BACK REST

LEFT

S13 636222

3

3

25

26

1

X15/

LEFT

3

2

B-

3

4

5

X20/ 6

S4

12

XS14/ 1

EM.STOP 633472

XX41

6

X20/ 7

FWD

LIFT

X3.2/ 2

XA1/ 9

BWD

X3.2/ 1

3-23 0V

XA1/ 17

J11 XA1/ 6

J8 3-23 +24V

XA1/ 11

D

X20/ 5

12

LOWER

XX40

11

1

XS14/ 3

XS14/ 2

XS13/ 1

STOP

XX39

30

RIGHT

11

LIFT

XX38

FW

1

XS13/ 2

XS16/ 3

XS16/ 1

XS16/ 2

XX37

SUPPLY

XS15/ 1

XS15/ 3

XX36

29

2

S14 636222

28

EMS BUTTONS IN THE BACK REST

LEFT

2

27

S3

X20/ 4 REV

20

EM.STOP 633472

XS15/ 2

Mass production drawings, S13 & S14: 1-3 Swap IR 2017-12-11

CHANGE: DATE:

NAME:

RIGHT

19

XS13/ 3

11

LOWER

TRACTION AND PUMP CONTROLLER COMBIAC0

A1 DATE: DESIGN. 2017-03-23 CHECK. APPROV.

NAME: JL

CIRCUIT DIAGRAM

NO12N2F(P), NO20N2(P), NO25N2(P) TRAVEL FROM SIDE

10 / 10

REV

3-7876

D

Init revision IR 2017-11-08

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

1.2 kW

M

1 cc

190bar

A

CHANGE: NAME: REV

DATE:

11

0,75L

DATE: DESIGN. 2017-11-08 CHECK. APPROV.

NAME: IR

CIRCUIT DIAGRAM

NO12N2F(P), NO20N2(P), NO25N2(P) HYDRAULIC SCHEME

1/2

REV

A

3-7717_HS

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

EP 2017-02-01

Init revision

12

3/8"

P

T

A

NAME: REV

DATE:

CHANGE:

11

17l/min

2.2kW

M 190bar LPR 450e-6

10 l

DATE: DESIGN. 2017-02-01 CHECK. APPROV.

NAME: EP

CIRCUIT DIAGRAM

NO12N2F(P), NO20N2(P), NO25N2(P) HYDRAULIC SCHEME LIFT PLATFORM

2/2

REV

A

3-7717_HS