Manitou ME315 ME316 ME318 ME320 Series 2 Repair Manual - PDF DOWNLOAD

REPAIR MANUAL MANUEL DE RÉPARATION REPARATURANLEITUNG MANUAL DE REPARACIÓN MANUALE RIPARAZIONE This document has been printed from

MANITOU BF

my e doc

Head office: 430, Rue de l’Aubinière 44150 Ancenis - FRANCE Share capital: 39,548,949 euros 857 802 508 RCS Nantes Tel: +33 (0)2 40 09 10 11 www.manitou.com

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This manual is for information purposes only. Any reproduction, copy, representation, recording, transfer, distribution, or other, in part or in whole, in any format is prohibited. The plans, designs, views, commentaries and instructions, even the document organization that are found in this document, are the intellectual property of MANITOU BF. Any violation of the aforementioned may lead to civil and criminal prosecution. The logos as well as the visual identity of the company are the property of MANITOU BF and may not be used without express and formal authorization. All rights are reserved.

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GENERAL INSTRUCTIONS AND SAFETY NOTICE GROUP 00 General characteristics and safety

1-1

AXLE ASSEMBLY - AXLE GROUP 30 Axle

2-1

BRAKE GROUP 40 Brake

3-1

MAST GROUP 60 Mast

4-1

HYDRAULIC GROUP 70 Hydraulic

5-1

ELECTRICITY GROUP 80 Electricity

6-1

- GENERAL INSTRUCTIONS AND SAFETY NOTICE - GENERAL CHARACTERISTICS AND SPECIFICATIONS - GENERAL LOCATION - GENERAL CONTROL AND ADJUSTMENT

00

GENERAL CHARACTERISTICS AND SAFETY

00 GENERAL INSTRUCTIONS AND SAFETY NOTICE

pages FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 MAINTENANCE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 RULES FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

(10/4/2013)

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00

2

GENERAL INSTRUCTIONS AND SAFETY NOTICE

FOREWORD This chapter deals with the general instructions and safety notices during inspection and maintenance work.

Other instructions and warnings are indicated in the chapters concerned.

In order to reduce accident risks, make sure to : – Follow the instructions in the truck operating and maintenance manual.  This manual should be found in all trucks.

– Please follow all safety instructions.

– Use the appropriate tools for any work to be performed.

– Use original LOC spare parts.

Any non-compliance increases the risk of accidents which may lead to grievous bodily harm and even death.

An operator who obeys the safety instructions and a well-serviced machine will ensure safe, efficient and profitable operation.

When you see this symbol:

It means: Warning! Be careful! Your safety, the safety of others or that of the lift truck is at risk.

The manufacturer cannot foresee all possible risky situations. Consequently, the safety instructions given in the safety manual are not exhaustive.

At any time, as a repairer/operator, you must consider, within reason, the possible risk to yourself, to others or to the lift truck itself when you repair, service or drive it.

Manitou cannot be held liable for the use of any lifting devices, tools or operating methods other than those specified.

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MAINTENANCE POSITION

2

1

4

3

Before any repair: 1 2 3 4

-

Place the machine on a flat surface and chock the wheels.

Turn off the engine and remove the ignition key.

Let the machine cool down.

Release all the pressure from the circuits concerned.

(10/4/2013)

3

00

GENERAL INSTRUCTIONS AND SAFETY NOTICE

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GENERAL INSTRUCTIONS AND SAFETY NOTICE

00

4

RULES FOR MAINTENANCE

Do not carry out any work on the machine unless you have the necessary training and knowledge to do so.

Make sure you have taken into consideration all the data plates on the machine and in the instruction manual.

Be careful not to burn yourself when touching hot liquids or parts when operations have to be done before the machine has had time to cool down.

1

2

ECU

Before carrying out any operation on an electrically powered component, activate the battery isolating switch.

If the truck does not have a battery isolating switch, disconnect the battery terminals then group them together.

b

Remember to disconnect the computers before carrying out any welding operations.

Machines operating in a contaminated environment (polluted or damaging to health) should be specially equipped. Moreover, local safety notices must indicate that maintenance and repair work is being carried out on such machines.

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5

00

GENERAL INSTRUCTIONS AND SAFETY NOTICE

Never stand on a part of the machine that has not been designed for that purpose.

Never wear clothes, jewelery or objects that could get caught during work and cause accidents.

Always wear protective goggles, gloves, safety shoes as well as any other protection required for the work to be carried out.

When carrying out maintenance operations near a mobile object, always make sure it is secured.

When changing, or draining oils or fuel, or any other operation with liquids, solids, or gases that are harmful to the environment, make sure the necessary precautions are taken to avoid contaminating the environment.

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GENERAL INSTRUCTIONS AND SAFETY NOTICE

00

6

When lifting or supporting a component of the machine, make sure the equipment used is suitable for at least the load for which it is subjected by the component and that it meets the national standards for lifting devices.

Using a jack, make sure it is used on a flat, uniform surface, is sturdy enough to support the load, that its lifting capacity is sufficient and that it is correctly placed and positioned under the machine.

Make sure no object or tool which could cause an accident is left in the machine.

Never check for any leaks with your hands.

max. min.

MAX

Never adjust a component to over the maximum capacity indicated by the manufacturer.

MIN 00-00-M227EN

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00 GENERAL CHARACTERISTICS AND SPECIFICATIONS

pages CHARACTERISTICS, LOADS AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 – ME315 / ME316 / ME318 / ME320 SERIES 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(11/13/2013)

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GENERAL CHARACTERISTICS AND SPECIFICATIONS

CHARACTERISTICS, LOADS AND DIMENSIONS

RUNNING CARRIAGE

WEIGHT

DESIGNATION

ME315 / ME316 / ME318 / ME320 Series 2 1.1

MANUFACTURER

1.2

MODEL TYPE

1.3

Propulsion: battery, diesel, petrol, LPG, mains

Battery

1.4

Type of operation: manual, pedestrian, standing, seated

Seated

1.5

Rated capacity/load on fork (basic capacity)

1.6

Center of gravity of load

c (mm)

500

1.8

Distance from the load bearing surface to the center of the front axle

x (mm)

355

1.9

Wheelbase

y (mm)

1250

2.1

Kerb weight of truck

kg

3050

2.2

Front axle load laden

kg

2.2.1

Rear axle load laden

2.3 2.3.1

DIMENSIONS

MANITOU ME315-48V

ME318-48V

1,6

ME320-48V

1,8

2

1358

1358

1465

3070

3090

3440

3993

4155

4305

4893

kg

557

515

585

547

Front axle load unladen

kg

1400

1565

1668

1662

Rear axle load unladen

kg

1650

1505

1422

1778

18 x 7 - 8

200/50-10

Q (t)

1,5

ME316-48V

3.1

Tire equipment: bandage (V), super-elastic (SE), pneumatic (L)

3.2

Size of front wheels

“ or mm

3.3

Size of rear wheels

“ or mm

3.5

Number of front wheels (x = drive wheel)

2x

3.5.1

Number of rear wheels (x = drive wheel)

2 twinned

SE 18 x 7 - 8

18 x 7 - 8

15 x 4,5 - 8

3.6

Front wheel gauge (middle of wheels)

b10 (mm)

902

3.7

Rear wheel gauge (middle of wheels)

b11 (mm)

175

4.1

Tilt of mast forward

α(°)

6

Tilt of mast backward

β (°)

6 1995

4.1.1 4.2

Height of mast lowered

h1 (mm)

4.3

Free lift

h2 (mm)

145

4.4

Lift height

h3 (mm)

3000

4.5

Height mast extended

h4 (mm)

3565

4.7

Height of driver protection (cab)

h6 (mm)

2020

4.8

Height of seat

h7 (mm)

930

4.12

Height of towing coupling

h10 (mm)

4.19

Total length

l1 (mm)

2862

2970

2970

3082

4.20

Length of fork at heel

l2 (mm)

1792

1900

1900

2012

4.21

Overall width

b1 (mm)

1060

1060

1060

1116

4.22

Section of fork arms

e / s (mm)

100 / 35

100 / 35

100 / 35

100 / 40

4.22.2

Length of fork arms

l (mm)

1070

Fork carriage to DIN 15173 A/B

4.24

Width of fork carriage

b3 (mm)

1000

4.31

Ground clearance of mast

m1 (mm)

100

4.32

Ground clearance at center of wheel-base

m2 (mm)

4.33

Aisle width for 1000x1200 pallet widthways

Ast (mm)

3161

3271

3271

3380

4.34

Aisle width for 800x1200 pallet lengthways

Ast (mm)

3260

3370

3370

3480

4.35

Turning radius

Wa (mm)

1440

1550

1550

1658

4.36

Inner turning radius

b13 (mm)

5.1

Speed of travel laden

km/h

12.5

12.5

Speed of travel unladen

km/h

FEM 2A

0,25

90

0 13

13 14

Rate of lift (laden)

m/s

0,29

0,28

0,27

Rate of lift (unladen)

m/s

0,44

0,44

0,43

0,4

Speed of lowering laden

m/s

0,43

0,44

0,45

0,47

Speed of lowering unladen

m/s

0,42

0,43

0,43

0,46

N

7000

7500

8000

9000

Nominal towing power unladen

N

7250

7720

8300

9300

Slope laden

%

14

13

13

11

Slope unladen

%

15

14

14

12

Acceleration time laden

s

5,2

5,2

5,3

5,7

5.9.1

Acceleration time unladen

s

4,6

4,6

4,7

4,7

5.10

Service brake

5.2 5.2.1 5.3 5.3.1 5.5 5.5.1 5.7 5.7.1 5.9

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473

4.23

5.1.1

PERFORMANCE

00

2

Nominal towing power laden

Oil-immersed multi-disc

(11/13/2013)

MISCELLANEOUS

ENGINE (11/13/2013)

6.1

Drive motor power rating

kW

2 x 4,5

6.2

Lifting motor power rating

kW

8,6

6.3

Size of battery compartment as per DIN 43 531/35/36 A,B,C, no

6.4

Battery voltage / capacity

6.6

Energy consumption according to VDI cycle

8.1

Speed control

8.2

Working hydraulic pressure for attachments

8.3

Oil flow rate for attachments

L / min

8.4

Sound level at driver's ears according to EN 12053

dB (A)

8.5

Traction controller

8.6

Hydraulic movement controller

DIN 43531 A V / Ah

48 /460

48 / 575

48 / 575

48 / 690

kWh / h

4,3

4,3

4,3

4,7

72

72

Electronic 145

Bar

65 71

3

00

GENERAL CHARACTERISTICS AND SPECIFICATIONS

72

Kollmorgen AC CURTIS DC

00-01-M227EN

GENERAL CHARACTERISTICS AND SPECIFICATIONS

00

4

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00 GENERAL LOCATION

pages LOCATION OF NAME AND IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

(11/14/2013)

00-03-M227EN

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2

GENERAL LOCATION

LOCATION OF NAME AND IDENTIFICATION PLATE Key: 1 2 3 4 5 6 -

Load chart Driver's seat plate Traction controller plate Rear axle plate Pump motor plate Traction motor plate

2

3

CAPACITE NOMINALE RATED CAPACITY NENNKAPAZITÄT CAPACIDAD NOMINAL CAPACITÀ NOMINALE

kg

CAPACITES EFFECTIVES ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT CAPACIDAD EFECTIVA CAPACITÀ EFFETTIVA

1

SUIVANT NORME EN 1726-1 ISO 1074.

1-

Jusqu'à hauteur de levée Up to height of Bis zur hubhöhe Hasta altura de elevación Sino ad altezza di sollevamento

2-

Pour hauteur maximale de For maximum height of Für maximale Höhe Para altura máxima de Per altezza massima di

MAT VERTICAL VERTICAL MAST VERTIKALER MAST MASTIL VERTICAL RAMPA VERTICALE

-

mm

-

-

-

-

-

-

1

Q : kg

mm

2

D D : mm

EQUIPEMENT ATTACHMENT ZUBEHÖR EQUIPO ATTREZZATURA

-

CAPACITES EFFECTIVES ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT CAPACIDAD EFECTIVA CAPACITÀ EFFETTIVA

1

2

n$:

5 4

6

00-03-M227EN

(11/14/2013)

Key: 7 - Mast identification 8 - Front wheel reducer plate 9 - Manufacturer's plate

7

HANGZHOU MANITOU MACHINERY EQUIPMENT CO.,LTD 398 SHIQIAO ROAD, HANGZHOU, P.R.C.

8

SERIE

MODELE

N° dans la série

Année de fabrication

9 N° de châssis

Poids sans la batterie

Poids de la batterie mini

kg Tension nominale

kg Poids de la batterie max

V

kg

Pression des pneumatiques (Bar) Avant Arrière

N°267138

(11/14/2013)

3

00

GENERAL LOCATION

00-03-M227EN

GENERAL LOCATION

00

4

00-03-M227EN

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00

00

GENERAL CONTROL AND ADJUSTMENT

pages STANDARD TIGHTENING TORQUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

(11/15/2013)

2

GENERAL CONTROL AND ADJUSTMENT

00

STANDARD TIGHTENING TORQUES

00

Standard tightening torque to be used when not otherwise indicated in the removal and refitting operations: - The following tightening torques are given for hexagon head screws without flanges and cylinder head hexagon socket screws.

- The torques are given for a friction coefficient μ = 0,20 corresponding to dry-fitted zinc-plated fasteners and for torque tools having a ± 20 % class C tightening torque accuracy (equivalent to pneumatic screwdrivers).

NF E 25-030-1 Screw / Nut connection : Tightening torque in N•m (±20%) Ø x “coarse” pitch

Grade 8.8

Grade 10.9

Ø x “fine” pitch

Grade 8.8

Grade 10.9

M3 x 0,5

1

1,5

-

-

-

M4 x 0,7

2,4

3,5

-

-

-

M5 x 0,8

4,8

7,1

-

-

-

M6 x 1

8,2

12,1

-

-

-

M8 x 1,25

20

30

M10 x 1,5

40

59

M8 x 1

22

32

M10 x 1,25

43

63

M10 x 1

46

68

M12 x 1,5

74

108

M12 x 1,75

69

102

M12 x 1,25

78

115

M14 x 2

111

163

M14 x 1,5

123

181

M16 x 2

175

256

M16 x 1,5

190

279

M18 x 2,5

240

352

M18 x 1,5

279

410

M20 x 2,5

341

501

M20 x 1,5

391

574

M22 x 2,5

470

691

M22 x 1,5

531

780

M24 x 3

588

864

M24 x 2

659

967

M27 x 3

874

1284

M27 x 2

965

1418

M30 x 3,5

1181

1735

M30 x 2

1351

1984

M33 x 3,5

1614

2371

M33 x 2

1821

2674

M36 x 4

2068

3037

-

-

-

b b

For hexagon screws with flanges: Apply an increased torque of +10%.

(Standard NF E 25-030-1)

Where washers are used, the following coefficient is to be applied (FD E 25-502) : - Smooth tapered washer (CL): +5% - Spring (or Grower) washer without jaws (W) : +10% - Conical, internal teeth (CDJ-JZC) : +15%

(11/15/2013)

GENERAL CONTROL AND ADJUSTMENT

3

00

00

t IMPORTANT t USE THE RECOMMENDED LUBRICANTS AND FUEL: - For topping up, oils may not be miscible.

- For oil changes, MANITOU oils are perfectly appropriate.

DIAGNOSTIC ANALYSIS OF OILS If a service or maintenance contract has been organized with the dealer, a diagnostic analysis of engine, transmission and axle oils may be requested depending on the rate of use. (*) RECOMMENDED FUEL SPECIFICATION Use a high-quality fuel to obtain optimum engine performance.

• Type of diesel fuel EN590 • Type of diesel fuel ASTM D975 FRONT WHEEL REDUCERS UNITS TO BE LUBRICATED

CAPACITY

FRONT WHEEL REDUCERS

0,35 Liters

RECOMMENDATION MANITOU oil Automatic transmission

PACKAGING 2l 20 l 55 l 209 l

PART NUMBER 62148 546332 546217 546195

MAST UNITS TO BE LUBRICATED

RECOMMENDATION MANITOU Lubricants Chain special (aerosol)

MAST LIFTING CHAINS

MANITOU grease BLACK multi-purpose

GREASING OF THE MAST

HYDRAULICS UNITS TO BE LUBRICATED HYDRAULIC OIL TANK ME 315 Series 2 / ME 318 Series 2 ME 318 Series 2 / ME 320 Series2

CAPACITY 25 Liters 30 Liters

RECOMMENDATION MANITOU oil Hydraulic ISO 46

PACKAGING

PART NUMBER

400 MI.

554271

400 g.

1 Kg. 5 Kg.

545996 161590 499235

PACKAGING 5l 20 l 55 l 209 l

PART NUMBER 545500 582297 546108 546109

PACKAGING 0,5 l 1l 5l 30 l

PART NUMBER 473013 473014 486363 486364

BRAKE UNITS TO BE LUBRICATED BRAKE SYSTEM

(11/15/2013)

CAPACITY 1,5 Liters

RECOMMENDATION MANITOU fluid DOT 4 brake fluid

4

GENERAL CONTROL AND ADJUSTMENT

00

00

(11/15/2013)

AXLE

- AXLE COMPONENTS LOCATION

30

- AXLE CONTROL AND ADJUSTMENT

30

AXLE COMPONENTS LOCATION

(9/10/2013)

30-03-M227EN

AXLE COMPONENTS LOCATION

30

2

Front left-hand wheel motor

Pump motor

Fro n t r i g h t hand wheel motor

Rear axle

30-03-M227EN

(9/10/2013)

pages DISASSEMBLY AND REASSEMBLY TRANSFERT BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 – SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 1. DISASSEMBLY OF THE DRIVE UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – GENERAL INSTRUCTIONS FOR THE CORRECT DISASSEMBLY AND REASSEMBLY . . . . . . . . . 11

I - DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 – 1. DISASSEMBLY OF THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 2. DISASSEMBLY OF THE HOUSING COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

II - REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 – 1. REASSEMBLY OF THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 – 2. REASSEMBLY OF THE HOUSING COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 – 3. REASSEMBLY AND ADJUSTMENT OF THE BRAKE LEVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 CONTROL AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 – 2 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 – 3 PRODUCT SAFETY AND DANGER ZONES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 – 4 GENERAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 – 4.5 STANDARD TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 – 5 PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 – 6 MOTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 – 7 ATTACHMENT OF MOTOR-TRANSMISSION UNIT TO THE VEHICLE FRAME . . . . . . . . . . . . . 35 – 8 MOUNTING OF THE DRIVE WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 – 9 CONNECTION OF THE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 – 10 REPLACEMENT OF THE DISC PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 – 11 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 – 12 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 – 13 FAILURES, POSSIBLE CAUSES AND ELIMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

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DISASSEMBLY AND REASSEMBLY TRANSFERT BOX INTRODUCTION

This documentation was issued for maintenance specialists.

Due to further technical developments of the product a repair of the existing unit may require varying processes as well as different setting and test data. Therefore we recommend you to give your axle product in the hands of masters and fitters whose practical and theoretical training is continuously updated in our after-sales services training center.

We recommend to read the entire manual before beginning of repair work, since some procedures are very complex.

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This manual is based on the technical satuts at printing date.

It was most carefully prepared to avoid mistakes.

However, we are not liable for possible errors in representation, errors in description or omission.

We reserve us the right to modification without prior notice.

The owner and user are liable for observing the safety instructions and to perform the maintenance work in accordance with the specifications.

We are not liable for fautly installation, inadequate handing, insufficient maintenance, improperly as well as incompetently performed work and the resulting consequential damages.

This is aslo applicable if no original spare parts are used.

We did not go into detail for disassembly, reassembly and repair of accessory parts.

Please observe the respective instructions and manuals of the vehicle manufacturer.

Important information with reference to technical reliability and operational safery are outlined by the following symbols :

Is applicable for instructions which have especially to be observed for execution of the work.

Is indicated for working- and operating processes which must strictly be observed to avoid a damage or destruction of the unit.

Is indicated for working- and operating processes which must strictly be observed to avoid risks for persons.

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SAFETY INSTRUCTIONS • The use as directed requires the strict observance with the manufacturer’s specifications for installation, disassembly and reassembly, initial operation and maintenance.

• Every person concerned with installation, disassembly and reassembly, initial operation and maintenance in the user plant must have read and understood the whole instructions and in particular the safety instructions.

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• Any working method which endangers the safety of the transmission is prohibited.

• Modifications and changers without the proper authority are affecting the safety of the transmission and are not allowed.

• Only original spare parts or spare parts approved are allowed to be used. It is explicity pointed out to the fact that spare parts and accessories, wich were not supplied by us are not checked and approved by us either. We do not accept any liability or admit any warranty for damages caused by the use of spare parts and accessories which are no original parts.

• The described work is only allowed to be made by autorized, trained and instructed staff.

• The proper repair of these products requires adequately trained specialists.

The repairer is responsible for the training!

• Keep away aggressive cleaners from your skin, do not drink it or inhale its vapours!

Always wear safety gloves and goggles. If by mistake cleaner was swallowed, call medical aidimmediately!

Strictly observe manufacturer instruction.

• Do not drain cleaners or transmission oil into the sewerage system or into the soil.

• Prior to start working on installed or mounted transmission, the wheels must be blocked.

• Prior to any work on the intalled transmission (e.g. oil change) or its mounted-on parts the engine must always be switched off.

• The local regulations for safety and prevention of accdients must be observed!

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GENERAL DATA

1. DISASSEMBLY OF THE DRIVE UNIT Drain oil from the transmission before disassembly of the drive unit.

Loosen and remove the wheel nuts as well as take off the drive whell. (see Fig. 1) For further work on the transmission of the drive unit see Chapter II, Section 1.

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1.1 REMOVAL OF THE DRIVE UNIT

a)

E-motor and accessories mounted to the E-motor have to be disconnected.

b)

Loosen the 7 fixing boltd (Pos. 1) on the vehicle frame and remove cautiously the drive unit. (see Fig.1)

E-motor

Drive wheel

Wheel nut

1

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1.2 REMOVAL OF THE E-MOTOR (SEE FIG. 2) Removal the three hexagon screws (1x M8x50 and 2x M8x75, Pos. 1 and 2) for E-motor.

b)

Take off cautiously the E-motor from the transmission.

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a)

Do not damage the teeth of the motor pinion and the spur gear!

Damages can cause louder running noises.

Attention In case of an inadequate removal of the E-motor from the transmission there is the danger to damage the sealing surface for the O-ring in the housing!

If only the E-motor is removed, the released transimission opening is to be sealed in order to avoid that dirt can get inside the transmission.

1.3 DISASSEMBLY OF THE INPUT PINION (SEE FIG. 3)

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a)

Hold the input pinion (Pos.2) with a suitable strap wrench (e.g. as shown in Fig. “A”) and remove the slotted nut (Pos.4) with slotted nut wrench “B”.

b)

Pull off the input pinion (Pos.2) by means of pull “C”.

a)

Take off the fitting key (Pos.3) from the motor shaft (Pos.1).

b)

Remove cautiously the O-ring (Pos.5) from the centering seat of the motor.

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1.4 AUXILIARY TOOLS FOR DISASSEMBLY OF THE INPUT PININON

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Strap wrench “A” for holding the input pinion in place

Slotted nut wrench “B” (Ident No. 618846) for removal of the stop nut.

Puller “C” (Ident-Nr. 662244) to pull off the input pinion

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AXLE CONTROL AND ADJUSTMENT SPECIAL TOOLS

Illustrations are not binding for the design!

Ident No. 618845

“H”

Sleeve To press the bearing inner ring onto the gear shaft and the planet carrier

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Ident No. 610060

“I”

Assembly drift To install radial shaft seal for the gear shaft

Ident No. 610390

“J”

Striker mandrel To install the planet gears

Ident No. 450971

“K”

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Peening mandrel To peen the planet gears

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Illustrations are not binding for the design!

Ident Nr. 4699 395 001

Puller To pull off the planet gears from the planet carrier

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“L”

Ident Nr. 4699 395 002

“M”

Press device To preassemble the wheel bolts

Ident Nr. 4699 395 003

“N”

Slotted nut wrench To loosen and to tighten the slotted nut on the gear shaft bearing

Ident Nr. 4699 295 001

“O” Measuring fixture To measure the housing dimension for bearing preaload of the gear shaft bearing

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Illustrations are not binding for the design!

Ident Nr. 4699 295 002

Measuring fixture To measure the planet carrier and gear shaft for bearing preload of the gear shaft bearing

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“P”

Ident Nr. 4699 395 004

“Q”

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Assembly dritf To install the bearing outer ring into the housing seat

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GENERAL INSTRUCTIONS FOR THE CORRECT DISASSEMBLY AND REASSEMBLY

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Cleanliness is essential for a correct work.

Transmission removed from the vehicle have to be cleaned prior to opening.

Special care and cleanliness are essential for a correct disassembly and reassembly of the unit as well as for the installation of each spare part. A fault during installation can result in an early wear and chips as well as foreign particles in the unit could cause fatal damage in the transmission.

Prior to reassembly all parts must be cleaned and inspected for wear and orther defects.

It would be a false economy to reinstall parts which are not in a perfect condition.

All parts have to be oiled carefully during reassembly. Apply a sealing compound onto housing- and cover faces, which must be tight towards the outside.

For heating of bearings ect. use heating plates, heating elements to heating furnaces.

Never heat directly with an open flame!

This avoids damage to the bearings.

If not otherwise indicated heat ball bearings, gears, flanges ect. to approx. 90 - 100°C. Parts which have been mounted in a warm condition must be subsequently installed after cooling down to ensure a perfect contact.

Lubricate both parts before shafts, bearings ect. are pressed into position.

For reassembly all of the indicated setting values, test data and tightening torques must be observed.

This units will be filled with oil after repair work.

The following description of disassembly and reassembly serves to inform both the after-sales service centers and of the vehicle manufacturer, where adequate workshop facilities and trained specialists are present.

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AXLE CONTROL AND ADJUSTMENT I - DISASSEMBLY Introduction Prior to disassembly clean transmission carefully.

A great help is a bright, spacious working place, free of dirt and chips.

The necessary working steps are described and illustrated in the correct sequence.

Part only available as assembly group will not be stripped any further.

Pleased observe strictly the instructions of the vehicle manufacturer for removing the gearbox from the vehicle.

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1. DISASSEMBLY OF THE TRANSMISSION Loosen and remove the two retaining rings (Pos.5).

Beat out the cylindrical pin (Pos.1) and remove the brake lever (Pos.2) from the cover.

Loosen the 8 cap screws M6x16 (Pos.13) and press off cautiously the cover (Pos.4) from the basic transmission.

Before loosening of the cap screws beat slightly onto the same to loosen the LOCTITEconnection!

Keep the housing cover on a clean place.

Further details on disassembly of the housing cover are indicated in Section 2.

At removal of the housing cover, the spur gear will remain connected by screws with the inner disc carrier as one unit!

Pull out the disc pack including 4x outer clutch discs and 3x inner clutch discs as well as the thrust washer from the ring gear and keep it on a clean place.

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By means of the puller “L” pull off cautiously the three planet gears from the planet carrier.

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The planet gears are pulled off with the bearing completely.

Lock the gear shaft agains torsion.

Unlock the slotted nut the gear shaft.

Loosen and remove the slotted nut for the gear shaft bearing.

Use slotted nut wrench “N”.

Expel and remove the gear shaft ( with taper roller bearing inner ring) by means of a copper mandrel and a hammer.

Pay attention that the gear shaft is not damaged at removal.

Take out the planet carrier (with taper roller bearing inner ring) from the bearing seat of the housing.

Keep the planet carrier and the gear shaft on a clean place.

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Loosen the 10 internal Torx screws M 10x35 (Pos.1) and take out the ring gear assy from the housing.

The Feyring will remain mounted to the ring gear.

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Note Dis- or reassembly of the ring gear is only required when the teeth are damaged, so that no details are indicated for ressembly.

Fastening with LOCTITE 270, as well as the tightening torque of M = 67 Nm is absolutely necessary to tighten the internal Torx screws.

On both sides the bearing outer rings for supporting the gear shaft and the planet carrier have to be removed cautiously from the houding by means of a copper mendrel and a hammer.

When the bearing outer ring in the gear side is expelled, pay attention not to damage the shim rings.

When the outer ring on the gear side is expelled, the radial shaft seal is removed together with the bearing! For reassembly a new radial shaft seal has to be used!

2. DISASSEMBLY OF THE HOUSING COVER

Put the houding cover of the transmission onto a level support.

Loosen and remove the six hexagon screws M8x35 (Pos.1).

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Remove the fixing plate (Pos.4) with the compression spring (3 pcs., Pos.3) underneath and keep te same on a clean place.

Then take off the inner disc carrier (Pos.2) with the pressure disc (Pos.5) from the spur gear.

By means of pliers remove the retaining ring 30x1,5 (Pos.6) on the bearing seat of the cover.

Press off the spur gear (with the bearing) from the bearing seat of the cover.

Use the threads M8 (6 pcs.) on the spur gear for fastening of the inner disc carrier.

By means of pliers remove the axial slide bearing from the bore seat of the cover.

Do not damage the surface of the axial slide bearing.Pay attention to the installation position of the axial slide bearing!

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AXLE CONTROL AND ADJUSTMENT II - REASSEMBLY INTRODUCTION Clean all parts with a suitable cleaning agent and remove residues of LOCTITE.

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Keep away cleaning agent from your skin, do not drink it or inhale its vapours!

Wear safety gloves and goggles! In case of the skin contact rinse immediately with a lot of water!

If by mistake the cleaning agent was swallowed, call medical aid immediately!

Observe regulations for prevention of accidents!

Check all parts for wear, damages and cracks, if required replace them.

In case of damaged running teeth, the gear set parts have to be replaced per sert.

Always replace damaged tapered roller bearings (inner- and outer ring).

Do not reuse deformed shim ring and worn thrust washers.

Touch up seal faces or smoothen with a fine file.

For reassembly the following parts should only be used as new: • • • •

Radial shaft seals, round sealing rings (O-rings) Slotted nut for gear shaft fastening Deformed or damaged shim rings Sealing rings on oil drain- and oil filler plug

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1. REASSEMBLY OF THE TRANSMISSION

1.1

PREASEMBLY OF GEAR SHAFT AND PLANET CARRIER

For pressing-in attention is to be paid that the flattened collar of the bolt shows towards the middle of the gear shaft.

Do not jam the wheel bolts at pressing-in of the same.

Fig. II- 1

Push the NILOS-ring (Pos.2) onto the gear shaft until contact and grease it with SHELL Alvania R3.

Press the taper roller bearing inner ring (Pos.3) by means of the sleeve “H” with the NILOS-ring onto the gear shuft until contact.

Fig. II-2 Only upon setting of the bearing fill up the taper roller bearing and the roller gaps with grease SHELL Alvania R3.

Illustrations are not binding for the design!

Planet carrier is to be preassembled with the taper roller bearing. (also see Chapter I, Section 1., Fig. I-7) Press the taper roller bearing inner ring (like in Fig. II-2) onto the planet carrier.

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By means of a press and the press device “M” press in the wheel bolts (Pos.1) into the gear shaft until contact.

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AXLE CONTROL AND ADJUSTMENT

1.2 INSTALL RADIAL SHAFT SEAL INTO THE HOUSING

Apply a thin layer of LOCTITE 574 onto the outer diameter of the radial shaft seal (Pos.1). By means of the assembly drift “I” install the radial shaft seal into the housing seat until contact.

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Do not damage the sealing lip of the adial shaft seal!

1.3

MEASUREMENT AND ADJUSTMENT OF BEARING PRELOAD ON THE GEAR SHAFT

Measurement of housing dimension (without bearing outer rings) Measure the housing dimension as follows: Bring fixture part with the dial gauge to position “zero”.

(Zero position on the dial gauge = 29,0mm) (O)

Measuring fixture

4699 295 001

• Insert complete fixture into the housing until contact and hand-tighten it.

• Determine the dimension and add it to dimension 29mm.

Example: Dim. A Dim. B Suma = Dim. housing

29,00 mm + 0,36 mm 29,36 mm

Measure planet carrier (with taper roller bearing)

Measure the planet carrier as follows: • Bring fixture part with the dial gauge to position “zero”.

(Zero position on the dial gauge = 7,40mm)

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Put the planet carrier (Pos.1) onto the fixture until contact.

•

Put on the fixture part (with dial gauge) and by turning motions roll in the taper roller bearings on the planet carrier.

Hand-tighten it at the same time as well as determine the dimension.

Add this dimension to 7,40 mm.

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•

19

• •

Example: Dim. A Dim. B Suma = Dim. planet carrier

7,40 mm + 0,43 mm 7,83mm

Measure gear shaft (with taper roller bearing) Measure the gear shaft as follows: •

Bring fixture part with the dial gauge to position “zero”. (Zero position on the dial gauge = 21,56mm) (P) Measuring fixture 4699 295.002

• Put the gear shaft (Pos.2) onto the fixture until contact.

• Put on the fixture part (with dial gauge) and by turning motions roll in the taper roller bearing on the gear shaft.

• Determine dimension and add it to dimension 21,56mm Example: Dim. A Dim. B Suma = Dim. gear shaft

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21,56 mm + 0,46 mm 22,02 mm

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Determination of the shim rings to be added

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The following method can be applied to determine the thickness of the shim ring. (Pos.1).

Dim. D, Dimension housing = Distance from contact plane face bearing outer ring to contact plane bearing outer ring.

Dim. E, Dimension planet carrier = Distance from plane face bearing outer ring to plane face planet carrier.

Dim. F, Dimension gear shaft = Distance from plane face bearing outer ring to plane face gear shaft.

The shim ring thickness (Pos.1) can be calculated by means of equation

Z=E+F-D Add shim ring according to thickness Z.

Example:

E= 7,83 F= 22,02 D= 29,36

measure on the planet carrier measure on the gear shaft measure on the housing

Z = 7,83 + 22,02 - 29,36 = 0,49 mm As per experience 0,1 mm will be deducted from dimension Z, so that a more favourable bearing preload adjustment is obtained for operating conditions.

Z = 0,49 - 0,1 = 0,39mm

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The shim ring thickness determined in Section 1.4 is to be combined with shim rings of a different thickness.

Put the shim ring (Pos.1) and the bearing outer ring (Pos.2) into the bearing seat.

By means of assembly drift “Q” install the bearing outer ring (Pos.2) with the shim ring (Pos.1) into the bearing seat of the housing until contact.

Install the bearing outer ring on the opposite side, as shown in Fig. II-13.

Grease the taper roller bearing inner ring and the roller gap on the preassembled wheel hub with grease SHELL Alvania R3.

Join the preassembled gear shaft (Pos.3) to the taper roller outer ring of the housing.

Lock the gear shaft against slipping and torsion.

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AXLE CONTROL AND ADJUSTMENT

Apply a thin layer of LOCTITE 270 on the internal grearing of the planet carrier (Pos.4) ans assemble it cautiously into the gear shaft teeth.

By means of a suitable drift install the planet carrier until contact.

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LOCTITTE is only to be metered into the internal gearing of the planet carrier!

Spilled LOCTITE is to be removed with a clean cloth.

Wet the thread of the slotted nut slightly with LOCTITE 270.

Put on the slotted nut, fasten it with screws and tighten it.

Tigthen the slotted nut only with the slotted nut wrench “N”, so that the wheel hub bearing is located tightly.

Slotted nut is to be tightened with a tightening torque of 535 Nm, Cat. 2.2 ZFN 148!

Hit collar of the slotted nut with a chisel (Edge of the chisel has to be a radius!) into the 2 recesses of the gear shaft Lock the slotted nut by 2-fold peening!

Rotate gear shaft several times in order to have aligned the taper rollers in the bearing rings.

No bearing play must be measurable during the check!

However, the gear shaft must be rotatable by hand.

The bearing preload is correctly adjusted, when a total earing friction torque of 1,5 ... 5,0 Nm is obtained.

Use an electronic torque spanner (Pos.5) to check the bearing friction torque.

If the bearing friction torque is beyond the requested value a new adjustment is required.

The final value has to be obtained by adding or removing of shim rings (see Fig. II-19) 30-04-M227EN

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AXLE CONTROL AND ADJUSTMENT

1.4 REASSEMBLY OF THE PLANET GEARS WITH THE PLANET CARRIER

Put the planet gear (Pos.1) straight onto the axle stub of the planet carrier, do not jam it, and press ot on whit the striker mandrel “J” until contact.

Attention!

Pay attention to the installation position of the planet gear. The radius of the inner ring must always be on the stop of the axle stub.

Repeart this procedure for the two remaining planet gears analogously. (see Fig. II-21 y la Fig. II-22) Lock the three planet gears againts axial displacement by means of peening mandrel “K”.

For this purpose expand the blind hole to such an extent that the bearing inner ring of the planet gears cannot be displaced any more. (see Fig. II-22).

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AXLE CONTROL AND ADJUSTMENT 1.5 DISC PACK ASSEMBLY OF THE TRANSMISSION

Two steps have to be oberved for disc pack assembly: Step 1 • if for wearing reasons only the disc pack (Pos.1) is replaced, the previous pressure disc (Pos.2) can be reused.

• place the clutch discs into the ring gear in the following sequence:

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-pressure disc -outer clutch disc/inner clutch disc/outer clutch disc/inner clutch disc/outer clutch disc/inner clutch disc/outer clutch disc (Fig. II-23) The sine clutch discs have to be aligned regularly depending on the undulations. (see Figures II-24 y II-25) A rapid and exact method is the alignement and the centering respectively with an inner clutch disc carrier which is not used for the assembly of the transmission.

The inner disc carrier (Pos.3) will be brought into the installation position as shown in Figure II-25.

By slight rotations and movements respectively of the inner disc carrier the position of the discs is fixed clearly now.

Following to this, the inner disc carrier is to be removed cautiously from the installation position, so that the position of the discs is not changed any more.

For assembly the direction of the sine inner clutch discs must ne observed!

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Step 2

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If several parts of the transmission (e.g.cover or pressure disc) are changed or replaced, the required thickness of the pressure disc has to be determined as follows.

Fig. II-26

The following method is used to determine the thickness of the pressure disc.

Dim. X = Determine the distance from the plane cover to plane face pressure disc.

Dim. Y = Measure thickness of the disc pack in compressed condition.

Dim. W to be calculated as follows W = X + Y Dim. V = Determine distance from plane face housing until contact of pressure disc in the ring gear.

Dim. Z to be calculated as follows: Example:

Z=V-W

X = 23,23 mm measure Y = 12,6 mm thickness of the disc pack

W = 23,23 + 12,60 = 35,83 mm V = 41,93 mm measured in the housing Z = 41,93 mm - 35,83 mm = 6,10 mm The required thickness of the pressure disc can be read in Table 1.

Dimension Z

Pressure disc C

5,58 a 6,10

4,8 mm thick

6,10 a 6,70

5,3 mm thick

6,70 a 7,22

5,8 mm thick

required pressure disc 4,80mm

Table 1

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AXLE CONTROL AND ADJUSTMENT

2. REASSEMBLY OF THE HOUSING COVER

The housing caver will in principle be reassembled in reverse order of the diassembly. (see Chapter I, Sect. 2.)

For reassembly is has to be observed as follows:

30

Place the axial slide bearing into the bore seat of the cover.

For assembly of the axial slide bearing the correct installation position has to be observed!

Put the spur gear (Pos.7, with preassembled bearing) onto the bearing seat of the cover and install it until contact.

Install the retaining ring (Pos.6) with the aid of pliers and lock the spur gear.

Put the pressure disc (Pos.5) and the inner clutch disc carrier (Pos.2) onto the the spur gear.

Place the 3 compression springs (Pos.3) into the bore hole of the inner clutch disc carrier (Pos.2) and put the fixing plate (Pos.4) with the recesses on to the compression springs.

Align fixting plate on the inner disc carrier depending on the gearing, so that the assembly of the cover is not hindered.

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30

Connect the inner clutch disc carrier with the spur gear by means of hexagon screws 6x M8x35 (Pos.1).

Put one drop each of LOCTITE 243 on the thread of the screws and tighten the same.

Tightening torque: M = 34 Nm

The sealing face of the cover has to be sealed with LOCTITE 574.

Place the cover coutiously and install it until contact by beating slighty with a plastic hammer.

By means of 8 cap screws M6x16 (Pos.3) fasten the cover to the basic transmission.

Put one drop each of LOCTITE 234 onto the threads.

Tightening torque. M = 9,6 Nm

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AXLE CONTROL AND ADJUSTMENT 3. REASSEMBLY AND ADJUSTMENT OF THE BRAKE LEVER

30

Put the brake lever (Pos.2) into the bracker (Pos.7) of the cover and pay attention to the installation position!

By means of a drift install the cylindrical pin (Pos.1) into the bracket and the brake lever at the same times.

With the two retaining rings (Pos.5) lock the cylindrical pin agrainst loosening from the bracket.

Fig. II-33 / Fig. II-34

Thus the brake lever is installed and the Adjusting dimension “A” has to be checked and set.

The adjusting dimension “A” for the brake lever is between 0,4 mm – 1,0 mm. (Fig. II-34) The adjusting dimension has to be checked with a dial gauge.

For this purpose position the feeler of the dial gauge on the brake lever in the specified measuring point range. Press the brake lever againts the cover and read the deflection on the radial gauge. (Fig.II-35 / II-36).

If the adjusting dimension should not be within the specified range, it has to be obtained and set with the pressure pin (Pos.6). (Fig. II-34) Several pressure pins can be selected. (see spare part list, pressure pin Pos. 308 on page 3) If the pressure pin is replaced the brake lever has to be removed again, as described in Chapter I, Sect. 1 Fig. I-1.

Then it is possible to pull out the pressure pin from the bore of the cover.

When installing the pressure pin do not damage the radial shaft seal.

Wet the sealing lip of the radial shaft seal (Pos.8) slighty with grease!

After installation of the brake lever, check the adjusting dimension applying the same steps as describe above.

Measuring point

Adjusting dimension for assembly

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CONTROL AND ADJUSTING

This operator’s manual describes the installation and maintenance as well as the elimination of failures for the GP 20 and GP 21 transmissions. The herein described work is only allowed to be made by specialists. It is absolutely required that design and function of the mentioned transmission types are known.

Prior to start work read this manual carefully. Carry out the single working steps as described and do not change them without permission. Observe the safety instructions. If you do not understand a procedure or cannot follow it doubtlessly, do not act on your own without permission, but consult the Technical After-Sales Service.

• insufficient maintenance • improperly and incompetently performed work and the resulting consequential damages • faulty operation We reserve further technical development of their products. It is possible that procedures can become necessary which differ from those described in the original version of this manual. In this case the customers are informed by us and the changed pages of this manual will be made available to them.

The customer is responsible to replace the changed pages and thus to keep this operator’s manual updated. The respective version is indicated on the bottom of every page for information. The current version of this manual can be requested from the Technical Service.

For the work described in this manual only original spare parts or spare parts approved are allowed to be used. If no original parts are used the optimum Keep this manual in such a way that it can always function of the transmission can be negatively be found by persons concerned with the product. affected and the warranty claim will lapse.

For an optimum maintenance and repair of the product we recommend to have made the repair We do not accept any liability for damages and and maintenance work by our service technicians. failures caused by : Maintenance and repair work made by us are also • faulty installation covered by a warranty within the applicable terms of contract.

• modifications on the transmission or the drive unit without permission • inadequate use of the transmission or the drive unit

For all publications we reserve us the right of modifications due to technical reasons in production, processing and appearance.

Transmittal of this manual, reproduction and copying – even partially –, making use and

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disclosure of its contents are forbidden without our permission. Infringements are liable for damages. All rights reserved for the grant of a patent or registration of a utility model.

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1 INTRODUCTION

30

AXLE CONTROL AND ADJUSTMENT 2 SAFETY INSTRUCTIONS 2.1 APPLIED TERMS AND WARNING SYMBOLS If the below described work is hazardous, you will be warned by means of safety instructions.

Please observe and follow these instructions.

The following terms and symbols are used: „CAUTION“ refers to possibly dangerous situations which can cause minor injuries. „ATTENTION“ refers to situations which can cause damage to the product or material.

30

This symbol refers to dangers for the environment.

This symbol refers to dangers by substances which are harmful to health.

This symbol refers to important instructions. If these are not followed by you, the transmission or add-on parts can be damaged.

This symbol is used for additional information.

3 PRODUCT SAFETY AND DANGER ZONES This product was made with utmost care and corresponds to the state of technology and the recognized safety rules. But nevertheless, this product might cause dangers which can be of • mechanical nature (transmission mechanism, drive) • thermal nature (hot transmission oil) • chemical nature (cleaning agents, adhesives).

Please read the safety instructions and the procedures of this manual carefully prior to start the work and observe all safety rules and instructions. If there is anything you do not understand or you are not sure, please consult your superior or ZF GOTHA’s After-Sales Service.

Please observe the accepted rules of industrial safety and the regulations for the prevention of accidents.

Modifications or changes on the transmission without the proper permission are not allowed and can cause hazards or damages.

3.1 IMMEDIATE ACTIONS AT CONTACT WITH CLEANING AGENTS

In case of skin contact rinse immediately with a lot of water! If swallowed, call medical aid immediately!

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4 GENERAL DATA 4.1 SAFETY INSTRUCTIONS During work on movable transmission parts in the installed transmission, these could start unexpectedly and cause injuries to you. Prior to all work on the installed transmission (e.g. oil change) or its add-on parts disconnect the power source feeding the motor.

You might get injured by aggressive cleaning agents and adhesives at contact with the skin and the eyes or when inhaled or swallowed. Always wear safety gloves and goggles working with cleaning agents and observe the manufacturer instructions.

Do not eat, drink and smoke.

You can get burned by transmission oil when the transmission was in operation before and the oil is still hot. Have the transmission cooled down prior to start work.

Cleaning agents and transmission oil can cause environmental damages, when these get into the sewerage system or the environment. Never drain cleaning agents and oil into the sewerage system or into the soil. Collect it and take care of an adequate disposal in compliance with the disposal regulations of your company.

4.2 GENERAL INSTRUCTIONS

• Pay attention to cleanliness and expert like manner for all work to be carried out. Transmissions removed from the vehicle have therefore to be cleaned prior to opening. Both utmost care and cleanliness are essential conditions for a correct disassembly and reassembly of the unit.

• Special devices and special tools are necessary besides the standard tools. Their use is unavoidable for a technically adequate assembly!

• All screws and threads in this transmission have metric dimensions. Only spanners and socket spanners with metric sizes are allowed to be used.

• For assembly work all of the indicated setting values, test data and tightening torques must be observed.

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During work on the installed or mounted transmission the vehicle might suddenly move and cause injuries to you. Block the wheels prior to start the work. The vehicle must be standing on even and not on steep ground.

32

AXLE CONTROL AND ADJUSTMENT 4.3 TORQUE LIMITS IN NM FOR SCREWS TO ZF STANDARD 148

30

Torque limits, if not especially indicated, can be taken from the following list:

Friction value: μ tot. 0.12 for screws and nuts without after-treatment, as well as phosphatized nuts.

Tightening by hand!

4.4 CONSUMABLES Suitable cold cleaners, e.g. LOCTITE. „WARNING“ Only use suitable agents which are non-toxic, non-combustible and permissible on the market. Never use benzene, solvents or other combustible agents.

Description LOCTITE No. 243 LOCTITE No. 574 LOCTITE No. 706 Transmission oil

To be used for Screw lock up to Size M10 for application onto the sealing face of the housing cover Cleaning of ground surfaces according to the Chapter: „Transmission Oil Data“

4.5 STANDARD TOOLS - Open jaw spanner/Ring spanner : 6, 8, 10, 13mm - Torque spanner Adjustable up to 200 Nm - Torx socket spanner : 15mm and 20mm - Hexagon socket spanner : 8, 13, 17mm female; 5, 6, 8, 10, 14mm male.

- Dead-blow soft-face hammer 1000 g - Impact-resistant screwdrivers - Flat-head pliers 30-04-M227EN

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4.6 SPECIAL TOOLS Description

Use

Reference Number

Illustration

For motor shaft 0 20mm 618 851 Slotted nut wrench “A”

For tightening and removal of the slotted nut

For motor shaft 0 25mm 618 846

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5 PRODUCT DESCRIPTION 5.1 COMPONENTS AND ACCESSORIES OF A HFS 507 OR GP – TRANSMISSION The transmission of the HFS 507 & GP Product Range consists essentially of the following components: Item 01 Transmission housing Item 02 Transmission cover Item 03 Wheel shaft Item 04 Model Identification Plate Item 05 Motor * Not illustrated are for instance: • Helical gear set, consisting of helical gear and drive pinion • Planetary gear stage • Oil filler and oil level plug • Brake system * optional component 5.2 TRANSMISSION IDENTIFICATION The model identification plate is fixed to the transmission housing side.

Data indicated there are as follows: • 01 Transmission Type • 02 Serial No. • 03 Total Ratio • 04 ZF Parts List No.

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AXLE CONTROL AND ADJUSTMENT 6 MOTOR INSTALLATION „ATTENTION“ The taper connection must be free from grease and oil. „ATTENTION“ At an inadequate installation of the motor to the transmission the tooth flanks at the drive pinion and the helical gear can be damaged, which will cause louder noises later!

30

„ATTENTION“ Keep away cleaning agent from your skin, do not drink it or inhale its vapours! Wear safety gloves and goggles! In case of skin contact rinse immediately with a lot of water! If by mistake the cleaning agent was swallowed, call medical aid immediately! Observe the regulations for the prevention of accidents!

• Clean the motor shaft (Item 05) and the drive pinion (Item 01) carefully e.g. with LOCTITE fast cleaner No. 706.

• Insert the curved washer (Item 04) into the slot of the motor shaft and slid on the drive pinion.

• Tighten the slotted nut with a torque spanner and the special tool „A“.

•

Observe the tightening torque of the slotted nut: M20x1 & Ø 25 Motor shaft taper: 55 Nm M14x1.5 & Ø 20 Motor shaft taper: 68 Nm

• Wet the O-Ring (Item 03) with a little bit of transmission oil or grease, insert it into the slot of the motor centering seat.

• Insert the motor cautiously into the transmission top section in vertical direction, slightly turning the wheel shaft by hand to achieve that the tooth flanks of the drive pinion are aligned with the tooth flanks of the helical gear.

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•

When the tooth flanks are aligned lower the motor until stop.

•

Turn the motor that boltholes of the motor and transmission top section are aligned adequately.

Fasten the motor and the transmission top section with the cap screws M8x50 (Item 01) and M8x75 (Item 02).

•

Tightening torque of the screws: 23 Nm

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7 ATTACHMENT OF MOTOR-TRANSMISSION UNIT TO THE VEHICLE FRAME

7.1 INSTALLATION POSITION 45 ° The motor-transmission unit can be installed within a range of 40° min. to 50° max. relative to the horizontal reference plane of the vehicle frame. „ATTENTION“ Deviations of the installation position or of the admissible tolerance require a consultation with the ZF Gotha GmbH.

The oil filler opening defines the oil quantity (e.g. overflow) to be filled in. Always unscrew the screw plug located at the lowest point to drain the transmission oil!

Check the frame surface on the vehicle for damages and roughness. The max. admissible surface roughness in the transmission mounting zone is 0.10 mm.

Fasten the drive unit with 7 hexagon screws M14 and the retaining rings to the vehicle frame. (See Figure 07) Tightening torque of the screws: 135 Nm

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The installation angle has a strong influence on the oil quantity and the transmission maintenance. One oil filler plug and oil drain plug each are located at the housing bottom side. (See Figure 07)

36

AXLE CONTROL AND ADJUSTMENT 8 MOUNTING OF THE DRIVE WHEEL This chapter is only applicable for delivery without drive wheel or for drive wheel replacement The wheel shaft is adapted to the commercially available drive wheels (Vulkollan or solid rubber). „ATTENTION“ Prior to install the drive wheel pay attention that the wheel shaft and the rim mounting face are clean, free from grease and undamaged.

Centering and fixing of the drive wheels is made as follows:

30

• for Vulkollan and solid rubber drive wheels (Item 01) over the centering collar of the wheel shaft and by means of flat collar nuts (Item 02) with spring washers (Item 03).

• The hole pattern of the rim must be adequately aligned with the wheel bolts and is then slid on the drive wheel.

• Fix the drive wheel with flat collar nuts and spring washers.

• Tightening torque of the nuts: 140 Nm

9 CONNECTION OF THE BRAKE Hydraulic or mechanical actuation of the brake is possible. For this purpose the connections of the brake hydraulics and brake cable are provided with the three mounting holes M10x1 in the brake lever.

9.1 CONNECTION OF THE BRAKE HYDRAULICS Depending on the installation position the bleeder (Item 01 in Figure 10) is to be connected to the upper tapped hole and the brake line / hydraulic line (Item 02 in Figure 10) to the lower tapped hole.

Tightening torque: 12 up to 16 Nm „ATTENTION“ Pay attention to the maximum possible bend radii when installing the hydraulic lines to ensure a quick resetting of the brake lever after braking.

9.2 CONNECTION OF THE BRAKE CABLE Screw the brake cable (Item 03 in Figure 10) into the tapped hole.

Tightening torque: 50 Nm „ATTENTION“ The installation dimensions acc. to Section A in Figure 10 have to be checked after mounting and maintained. Pay attention to the maximum possible bend radii when installing the brake cable to ensure a quick resetting of the brake lever after braking.

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„ATTENTION“ After refilling of the brake fluid bleeding of the brake system is required.

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AXLE CONTROL AND ADJUSTMENT

9.3 BRAKE SYSTEM BLEEDING When the brake fluid is filled up bleeding of the brake system is required.

Also observe the technical data in Chapter „14.4“ „ATTENTION“ Leaking brake fluid must be collected in a suitable tank. Do not drain any brake fluid into the sewerage system or into the soil.

•

• • • •

•

Remove the protection cap (Item 01) from the bleeder (Item 02) and connect a suitable hose with collecting tank.

Pressurize the brake by actuating the brake pedal and keep this position.

With an open end wrench loosen the bleeder approx. half a turn and have the air escape.

Upon tightening of the bleeder release the brake pedal.

This procedure has to be repeated until bubble-free brake fluid comes out. In the meantime the fluid level in the compensating tank is to be checked and refilled if necessary.

When brake fluid coming out is bubble-free the bleeder has to be retightened.

Tightening torque: 12 up to 16 Nm •

Remove the hose and put on the protection cap.

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AXLE CONTROL AND ADJUSTMENT 10 REPLACEMENT OF THE DISC PACK „ATTENTION“ When replacing the disc pack in a transmission, the disc pack of the transmission at the other vehicle side is to be replaced as well!

In case of non-observance there might be a strongly different braking effect between the left and the right transmission. A longer braking distance is to be expected.

The transmission must be removed from the vehicle. The motor removal is to be made in reverse order like the installation. (See Chapter 7) 10.1 DISASSEMBLY OF THE DISC PACK

30

„ATTENTION“ In vehicles without regenerative braking (motor brake) the disc pack is to be replaced every 600 hours! Otherwise a replacement is required every 3000 hours.

•

Loosen the two retaining rings (Item 01) by means of snipe nose pliers and remove them.

•

Beat out the cyl. pin (Item 02) and remove the brake lever (Item 03) with sealing ring from the cover.

•

Loosen the 8 screws M6x16 (Item 4) and press off cautiously the cover (Item 05) from the basic transmission. „ATTENTION“ Before detaching of the cap screws beat slightly onto the same to loosen the LOCTITE-connection!

•

Remove the housing cover and keep it on a clean place. „ATTENTION“ At removal of the housing cover the helical gear (Item 01) will remain connected by screws with the inner disc carrier (Item 02) as one unit! (see Figure 13)

• Pull out the disc pack - including 4x outer clutch discs and 3x inner clutch discs as well as the thrust washer - as pack from the ring gear.

• Outer and inner clutch discs are to be scrapped • Keep the thrust washer on a clean place.

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10.2 INSTALLATION OF THE DISC PACK • •

Insert the thrust washer (Item 01) Sequence to install the new disc pack (Item 02) is as follows:

Outer disc/Inner disc/Outer disc/Inner disc/Outer disc/Inner disc/outer disc

•

Sine inner discs are to be aligned equally to the undulations (see enlargement on the right) „ATTENTION“ An exact alignment of the brake discs is required for the later installation of the transmission cover!

• A quick and exact procedure is the aligning or centering with an additional inner disc carrier which is not used for the transmission installation.

• The inner disc carrier (Item 01) is brought into installation position.

• By slightly turning or moving the inner disc carrier the position of the discs is fixed clearly now.

• Following the inner disc carrier is to be removed from the installation position cautiously, so that the position of the discs is not changed.

•

Remove all LOCTITE residues from the cover sealing face carefully.

• • •

Clean additionally with emery paper.

Residues from cleaning have to be blown out.

Apply LOCTITE 574 onto the sealing face of the cover.

•

Place the cover cautiously and by beating slightly with the plastic hammer install it until contact is obtained.

Apply one drop each of LOCTITE 243 onto the threads of the eight screws M6x16 (Item 01) and insert them.

By means of the screws fasten the cover to the basic transmissions with a tightening torque of 9.6 Nm.

• •

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(Outer disc = external gearing; Inner disc = internal gearing)

40

AXLE CONTROL AND ADJUSTMENT 10.3 INSTALLATION AND SETTING OF THE BRAKE LEVER • Wet the sealing lip of the sealing ring (Item 01) with grease slightly! (See Figure 21) • Place the sealing ring into the bore. (See Figure 21) • Install the pressure pin (Item 02) into the provided bore. (See Figure 21)

30

„ATTENTION“ Do not damage the sealing ring at installation of the pressure pin.

•

•

Put the brake lever (Item 01) into the bracket (Item 02) of the cover and pay attention to the installation position!

•

At the same time the cyl. pin (Item 03) has to be mounted into the bracket and the brake lever with an assembly drift.

With the two retaining rings (Item 03) lock the cyl. pin against loosening from the bracket.

Following to this the brake lever is installed and setting dimension «A» must be checked and set.

• •

Check the setting dimension with a dial gauge.

Position the feeler of the dial gauge onto the brake lever in the specified measuring point range. (See Figure 22)

•

Press the brake lever against the cover and read the deflection on the dial gauge. (See Figure 22)

•

Should the setting dimension 0.4+0.6 mm not be within the specified range it must be adjusted by alternative pressure pins (Item 02).

Pressure pins of different lengths can be selected.

•

If the pressure pin is replaced, the brake lever has to be removed again and reinstalled. „ATTENTION“ Do not damage the sealing ring (Item 03) at installation of the pressure pin!

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11 CLEANING

„ATTENTION“ When cleaning with water jet or hot steam avoid direct contact with the motor-transmission unit. „ATTENTION“ Only use rubber-tolerant cleaning agents. Avoid cleaning agents on brake levers or in the motor. „ATTENTION“ Keep away cleaning agent from your skin, do not drink it or inhale its vapours! Wear safety gloves and goggles! In case of skin contact rinse immediately with a lot of water! If by mistake the cleaning agent was swallowed, call medical aid immediately! Observe the regulations for the prevention of accidents!

12 TECHNICAL DATA 12.1 TRANSMISSION DATA

Input power, max.

Wheel load, max. (at max. effective tire radius of 220 mm) Acceleration torque on the drive wheel, max.

Brake torque on the drive wheel, max.

Ratio Weight without oil filling and without motor, approx.

Oil quantity, approx.

KW kg Nm Nm kg Liter

4,5 2.500 1.320 1.700 22 31 0,35

12.2 BRAKE DATA

Brake pressure (transmission efficiency included) - on the piston approx.

- Operating approx.

- Nominal (max. continuous pressure) - Limit (short-time)

1 bar = 21 Nm Wheel torque 60 – 80 bar 80 bar 110 bar

Brake fluid

acc. to SAE J 1703, DOT 3 and DOT 4

Tractive effort for hand brake (transmissionefficiency included) - on the brake lever approx.

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100 N = 80 Nm Wheel torque

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It is possible to use compressed air for cleaning!

42

AXLE CONTROL AND ADJUSTMENT 13 FAILURES, POSSIBLE CAUSES AND ELIMINATION Noises Kind of noise

Loud, beating noise, speed-dependent

Possible cause

Check tooth flanks of the drive pinion and the helical gear for damage. A damaged Teeth of the helical gear stage damaged drive pinion has to be replaced; if the during motor installation helical gear is damaged the tooth flank can be filed subsequently by means of a diamond file.

30

Mechanical motor connection not OK Loud, summing noise Motor bearing defective

Wheel bearings defective Dull, grinding noise

Elimination

Motor dimensions and motor connection to be checked and retighten the drive pinion on the hub, if necessary.

Check the motor and replace it, if necessary.

Check the wheel bearings and replace, if necessary

Check the bearing preload and correct Wrong bearing preload of the wheel it, if necessary bearings Gearing of the planetary stage defective

Gear set planetary stage and wheel bearings to be checked and replaced, if necessary

Leakages – Leaks Location

Possible cause

Elimination

Breather

Excessive oil level

Housing cover

8 screws not tightened with the specified Check the tightening torque and tightening torque retighten, if necessary

Wheel shaft

Radial shaft seal damaged or worn

Check radial shaft seal and replace, if necessary

Brake lever

Sealing ring defective

Check sealing ring and replace, if necessary

Screw plugs

Check oil level, if necessary correct it

Check the tightening torque and Screws plugs not tightened with the retighten, if necessary specified tightening torque Wrong or defective sealing ring installed

Remove the screw plugs and use genuine ZF sealing rings

Motor connection

O-Ring of the motor defective

Remove the motor and replace the O-Ring

Motor

Radial shaft seal on the motor shaft worn Replace the motor, if necessary

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REAR AXLE

Steering Wheel Super Elastic Tire : 15x4,5-8

CAUTION !

After first 100h working, Customer shall retighten the five wheel-nut to this torque each side.

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Steering wheel Tighten Torque : 157 - 176 Nm

AXLE CONTROL AND ADJUSTMENT

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44

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BRAKE

- BRAKE CHARACTERISTICS AND SPECIFICATIONS - BRAKE CONTROL AND ADJUSTMENT

40

- BRAKE TROUBLESHOOTING

40

BRAKE CHARACTERISTICS AND SPECIFICATIONS

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BRAKE CHARACTERISTICS AND SPECIFICATIONS

Item

data play (mm) Height (mm)

brake pedal

master cylinder

1-3 110 - 125

Height in fully depressed position (mm)

Over 60

allowable clearance between cylinder and piston (mm)

Less than 0,15

Single-acting master cylinder Parking brake pulling force (N)

40

service brake

100 - 150 See Axle control and adjustment

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pages PARKING BRAKE LEVER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 BLEEDING THE BRAKE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 SERVICE BRAKE PEDAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 MOUNTING THE BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 ADJUSTING THE BRAKE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 EXPLODED VIEW OF BRAKE MASTER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

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BRAKE CONTROL AND ADJUSTMENT

BRAKE SYSTEM A - Parking brake: Mechanical lock. Pulling force of the order of 100 to 150 N

40

B - Service brake: wet disc submerged in oil. Axle control and adjustment.

PARKING BRAKE LEVER ASSEMBLY Tighten or slacken the steel parking brake cable.

The screw can be adjusted here by turning clockwise or anti-clockwise.

Return spring

Tightening torque: 19 to 25 Nm

Protective rubber hose sheath 40-04-M227EN

Microswitch: drive motor control ON/ OFF signal (11/15/2013)

BRAKE CONTROL AND ADJUSTMENT

3

BLEEDING THE BRAKE LINE

T : 12 to 16 Nm

Once the system has been filled with brake fluid, the air must be removed by bleeding:

•

Remove the bleeder's protective cap and connect a suitable hose to a collecting tank.

•

Depress the brake pedal and maintain this pressure.

•

Using an open-end wrench, undo the bleeder approximately half a turn and allow the air to escape.

•

Release the brake pedal as you re-tighten the bleeder.

This procedure must be repeated as long as air bubbles remain in the brake fluid. During this time, check the compensating tank fluid level and top-up as required.

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STAGES:

4

BRAKE CONTROL AND ADJUSTMENT

SERVICE BRAKE PEDAL ASSEMBLY Brake fluid: In accordance with SAE J 1703,DOT 3 and DOT 4

40

Double brake switch, one is used for the stop light, the other for the drive motor.

Greasing nipple

Return spring Extension rod (screw)

MOUNTING THE BRAKE MASTER CYLINDER

Parking brake cable

Brake pedal Main cylinder booster Sheath Rubber hose

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ADJUSTING THE BRAKE PEDAL

After fitting the brake pedal, adjust it and ensure that the pedal operates smoothly over its entire travel, without sticking, twisting or making a noise.

40

H : 110 to 125 mm

Adjust the screw of the brake pedal assembly, ensuring that the pedal travel to the mat is approximately 125 mm.

Brake master cylinder diagram

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BRAKE CONTROL AND ADJUSTMENT

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EXPLODED VIEW OF BRAKE MASTER CYLINDER

DISASSEMBLY Remove and dispose of the piston cup; install a new one.

When removing the components, chose a clean, dust-free location and set down the components in an orderly fashion for ease of reassembly.

INSPECTION: Clean all the components with brake fluid and check their condition.

Do not use other cleaning solvents to clean the components.

ASSEMBLY: To assemble the components, proceed in the reverse order to disassembly. Comply with the following instructions: • Clean all components with brake fluid.

• Apply a layer of brake fluid to the friction surfaces of the piston and the cylinder.

• Take care not to scratch the components when they are assembled.

• Place a new piston cup. Dispose of the old one.

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BRAKE TROUBLESHOOTING

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2

BRAKE TROUBLESHOOTING

MASTER CYLINDER ASSISTANCE

Problems

Probable cause

Corrective action

Insufficient or excessive braking force

Brake assist fault

Replace

Incorrect distributor adjustment

Adjust

Brake assist fault

Replace

Weak pedal return action

Brake assist fault

Replace

Problems

Probable cause

Corrective action

Brake hose fluid leak

Repair and refill

Presence of air in the brake hoses

Bleed the air out

Presence of water or oil on the linings

Clean or replace

Uneven brake disc wear

Correct or replace

Incorrect operation of the master cylinder or wheel cylinder

Correct or replace

Blocked brake hoses

Clean

No clearance

Adjust

Incorrect operation of brake linings

Adjust

Incorrect operation of master cylinder

Adjust or replace

Piston fault

Replace

Weak or broken return springs

Replace

Blocked piston return

Clean

Blocked brake hoses

Clean

Maladjusted bearings

Adjust the bearings

Dragging brake

40

Other

Insufficient braking force

Dragging brake

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MAST

- MAST CHARACTERISTICS AND SPECIFICATIONS - MAST COMPONENTS LOCATION - MAST CONTROL AND ADJUSTMENT - COMPONENT DIAGRAMS AND CROSS SECTIONS - MAST REMOVAL

- MAST TROUBLESHOOTING

60

- MAST REFIT

MAST CHARACTERISTICS AND SPECIFICATIONS

pages PRESENTATION OF MASTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 – SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – DOUBLE HIGH VISIBILITY MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

60

– DOUBLE FULL FREE LIFT MAST (INCLUDING CONTAINER MAST). . . . . . . . . . . . . . . . . . 2 – TRIPLE FULL FREE LIFT MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – DOUBLE AND TRIPLE MAST TILT ANGLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – BASIC MODEL MAST WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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MAST CHARACTERISTICS AND SPECIFICATIONS

PRESENTATION OF MASTS SUMMARY The lifting system is composed of inner and outer mast, fork arm carrier, fork arms, load bracket, chain, roller, lifting jack, and tilt cylinder, etc. Oil line system, hydraulic pressure system and it compose fork lift truck work equipment. This equipment is performing framework of load and unload. Common mast has simple mast, double mast and Triple mast class mast framework type. Fork lift truck what is made in our company is fitted with Double wide view mast, Double full free lift mast (including container mast), Triple full free lift mast, mast framework adopted is CL model juxtaposition roller type.

60

DOUBLE HIGH VISIBILITY MAST Double mast is composed of outer mast which can’t lift and inner mast which can lift. Lifting jack bottom is fixed on outer mast below cross beam, oriented with pin. Piston rod extremity is joined with upper cross beam of inner mast; cylinder body is fixed on outer mast fixation board with U-bolt. Commonly free lift range is 100 mm ~145mm, which is difference with different tonnage. Two lifting jacks are laid out back of outer mast to realize high visibility; two lifting jacks are laid outside of outer mast.

Fork arm is hung on fork arm carrier by hook. Roller, combined roller (side roller is installed middle of roller outside) and side roller (It is adopted combined roller in 1-1.8 tonnage fork lift truck) is installed on fork arm carrier. Combined roller is installed on below of inner mast.

Pressure oil from hydraulic control valve is entered into lifting jack by unidirectional speed limiting valve, forced piston and piston rod rising, thereby forced inner mast rising. At the same time one end of lifting chain on inner mast is fixed on outer mast, the other is joined with fork arm carrier. Fork arm carrier and fork arm is rising with inner mast rising to realize aim of lifting goods.

It is basis model that our company offers forklift truck which lift 3 meter high. It is especial model that our company offers forklift truck which lift height else (2m ~6 m).

DOUBLE FULL FREE LIFT MAST (INCLUDING CONTAINER MAST) Double full free lift mast is also composed of inner mast, outer mast, fork arm carrier, and etc, is also belong to high visibility mast. It is different from common standard type mast that two postpose long lifting jacks are both pole stopper type cylinder. One piston rod is hollow; hole of piston rod is by passed for hydraulic pressure oil flowing into free lifting jack. End of piston rod in two long lifting jacks is joined with upper branch of inner mast. Besides, short lifting jack who is installed middle of inner mast is named as free lifting jack. Free lifting jack is also pole stopper type cylinder.

Fork arm can rise or falling when height go beyond 1400mm, because inner mast don’t rising when free lifting jack rising or falling. There are different specifications in this series of height, 2.5m, 2.7 m, 3 m, 3.3m, 4 m and etc. Free lifting height is commonly about 1050~2100mm.

When lowest height of mast ≥2200mm, lift height is 3m, full free lift height is about 1500mm. It can work inside container mast which include side-shift is named container fork lift truck mast. Side shift cylinder of container fork lift truck mast can be side shifting only when goods don’t placed appropriate position. In another condition, side cylinder should set center.

TRIPLE FULL FREE LIFT MAST Triple full free lift mast is composed of outer mast, middle mast, and inner mast, middle mast and inner mast can flex. There are different specifications in this series of height, 4m,4.3m, 4.5m, 4.8m, 5m, 5.5m, 6m,6.5m,7m ,etc. It is different from double full free mast that mostly it includes middle mast, and its two postpone long lifting jacks are both piston type cylinder, and its oil system rather complex than oil system of double full free mast.

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60

MAST CHARACTERISTICS AND SPECIFICATIONS

DOUBLE AND TRIPLE MAST TILT ANGLE Mast type

lifting height

Mast tilt angle Forward

Mast tilt angle Backward

2 to 3.6 meter

6.5°

6.5°

4 to 4.5 meter

3.5°

5°

Duplex levée libre

2.7 to 3.3 meter

6°

6°

Triplex levée libre

4 to 6 meter

3.5°

5°

Duplex visibilité totale

Fork arm carrier roller

Adopt combination roller and side roller if rated capacity is less than 3 .5t.

BASIC MODEL MAST WEIGHT Model truck

(23/10/2013)

Weight mast

1,5t - 1,8t

515

2t - 2,5t

652

3t

731

3,5t

836

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MAST CHARACTERISTICS AND SPECIFICATIONS

60

4

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MAST COMPONENTS LOCATION

pages MAST COMPONENTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 – DOUBLE STAGE WIDE VIEW MAST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – DOUBLE STAGE FULL FREE LIFTING MAST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

60

– DOUBLE STAGE CONTAINERS MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – TRIPLE STAGE FULL FREE MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

(28/10/2013)

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MAST COMPONENTS LOCATION

MAST COMPONENTS LOCATION

60

DOUBLE STAGE WIDE VIEW MAST

1 2 3 4 5

-

Outer mast Inner mast Load-backrest Fork arm carrier Fork arms

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6 7 8 9 10

-

Chain Left lifting cylinder Right lifting cylinder Tilting cylinder Roller

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MAST COMPONENTS LOCATION

3

60

DOUBLE STAGE FULL FREE LIFTING MAST

1 2 3 4 5

-

Outer mast Inner mast Chain Free lifting cylinder Fork arm carrier

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6 7 8 9 10

-

Fork arms Left lifting cylinder Right lifting cylinder Load-backrest Tilting cylinder

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4

MAST COMPONENTS LOCATION

60

DOUBLE STAGE CONTAINERS MAST

1 2 3 4 5 6

-

Outer mast Inner mast Chain Free lifting cylinder Fork arm carrier Fork arms

60-03-M227EN

7 8 9 10 11

-

Side move cylinder Left lifting cylinder Right lifting cylinder Load-backrest Tilting cylinder

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MAST COMPONENTS LOCATION

5

60

TRIPLE STAGE FULL FREE MAST

1 2 3 4 5 6

-

Outer mast Middle mast Inner mast Front cylinder chain Free lifting cylinder Fork arm carrier

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7 8 9 10 11 12

-

Fork arms Chain Left lifting cylinder Right lifting cylinder Load-backrest Tilting cylinder

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MAST COMPONENTS LOCATION

60

6

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MAST CONTROL AND ADJUSTMENT

pages MAST CONTROL AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 – INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 MAST DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

60

– REMOVE LIFTING JACK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – REMOVE ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – REMOVE INNER MAST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ASSEMBLY AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 – LIFT ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – LIFT ROLLER-TO-MAST CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – CLEARANCE OF GUIDE PLATE AND MAST CHANNEL STEEL . . . . . . . . . . . . . . . . . . . . . . . 5 – MAST REFIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 LEFT AND RIGHT CYLINDER HEIGHT INITIAL ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . .6 LIFTING CHAIN ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 CLEARANCE OF FORK ARM CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 DISASSEMBLY AND INSTALLATION OF LIFTING JACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 – DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALL AND REPLACE FAULTY PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 DISASSEMBLY AND INSTALLATION OF TILTING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . .10 – DISASSEMBLY OF PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 – INSTALL TILTING CYLINDER AFTER REPLACING RING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 NOTICING PROCEEDING OF DEBUGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

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MAST CONTROL AND ADJUSTMENT

MAST CONTROL AND ADJUSTMENT INSPECTION AND ADJUSTMENT Composants Place

Assembly clearance (mm)

Repair clearance (mm)

Mast to lift roller

0,1 to 0,8

0,2 to 1

Shims

0,5 - 1,0 - 2,0

Mast to back up metal

0,1 to 0,8

Shims

0,2 to 1 0,5 - 1,0 - 2,0

Inner mast to carriage side roller

0,1 to 0,6

0,2 to 1

Shims

0,5 - 1,0 - 2,0

Lift chain deflection

25 to 30

60

Shims 824282

Adjusting screw

2 Shims M10 : 828769 M12 : 828765

2 Adjusting screw 1,5t-1,8t : shim 828348 2t-3,5t : shim 824622 60-04-M227EN

Adjusting screw (23/10/2013)

MAST CONTROL AND ADJUSTMENT

3

MAST DISASSEMBLY

b

Be careful when disassembling the masts as they are heavy.

REMOVE LIFTING JACK

1) Place mast flat on ground. Remove lifting jack attaching boltsbolts and tighten screw.

2) Slide inner mast, then remove lifting cylinders.

1) Slide inner mast out until rollers are exposed and remove little rollers with bearing puller. Make two pieces of round board about 10mm thick and their diameter are 53mm and 58mm, covered on the seat of roller. Then remove the compound roller and main roller with bearing puller.

2) Unclench rollers carefully if no bearing puller or rollers would be smashed.

REMOVE INNER MAST

Attach wire rope to middle of inner mast and slide it out with a lifting device.

INSPECTION 1) Check lift rollers, roller shafts, and associated parts for wear or damage.

2) Replace damaged parts as required.

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REMOVE ROLLER

4

MAST CONTROL AND ADJUSTMENT

ASSEMBLY AND ADJUSTMENT

b

Be careful when assembling the masts as they are heavy.

LIFT ROLLER

Slide inner mast into outer mast and securely attach lift rollers.

LIFT ROLLER-TO-MAST CLEARANCE ADJUSTMENT

60

1) Set roller pitch of inner and outer masts to “L” dimension.

Then proceed with the following adjustment.

Dimension “L” unit : mm Max lift height (mm)

Model 2t - 3,5t

Model 3t

2500 to 3300

328

368

3600

348

388

4000

378

418

4500

403

443

2) Adjustable range “A” with shims: - 1,5t to 2t, Dimension A : 0,1 to 0,6 mm - 2,5t to 3t, Dimension A : 0 to 0,5 mm.

One or two may not using rubber pad; Dimension : 0.1mm to 0.6mm if no rubber pad.

Orientation pin ensure that side roller is vertical to inner mast track.

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MAST CONTROL AND ADJUSTMENT

5

3) It is suitable that clearance of roller and outer mast is about 0.8mm to 1mm.Clearance can’t be adjustable. Replace it if roller wears too much.

4) Apply lubrication (butter) to interface of inner mast and outer mast, interface of roller and channel steel guide.

To prevent sand from entering, it is decided whether to apply lubrication or not in the area where sand blown by wind heavily.

CLEARANCE OF GUIDE PLATE AND MAST CHANNEL STEEL

Adjust clearance “B” to 0.1mm to 0.8mm with shims between guide plate and inner mast pole, which may not use.

60

Thickness of shim is 0.5mm or 1mm.

MAST REFIT

Apply a coat of grease to back-up metals.

Install mast and lifting jack on forklift truck.

Connect circle tube and high-pressure tube.

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MAST CONTROL AND ADJUSTMENT

LEFT AND RIGHT CYLINDER HEIGHT INITIAL ADJUSTMENT. 1) Install left and right lifting jack on mast, pin must be installed into orientation hole of outer mast lower cross beam.

2) Install upper side of piston rod into cylinder seat on inner mast. Inner mast lay evenly in the direction of left, right, upper and lower. If it is not even, please adjust by putting washer between hole of cylinder support and upper end of piston rod.

3) Installs U-bolt onto cylinder, hand-tighten nuts and lock it with two tighten nuts. Screws down tighten bolt and nuts to avoiding loosing.

LIFTING CHAIN ADJUSTMENT Installs fork arm carrier on inner mast, and install lifting chain, then install two nuts on end of every side.

60

With mast set straight up, lower carriage completely.

Temporarily adjust clearance of carriage to 74mm -76mm above ground.

If necessary, adjust with chain adjusting nut.

To adjust tension of lift chain, lower lifting jack until fork is on the ground ,and adjust chain adjusting nut (three every side) so that dimension C will be as listed below when the middle portion of chain is pressed by a finger.

Dimension C: 25 mm ~30 mm

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MAST CONTROL AND ADJUSTMENT

7

CLEARANCE OF FORK ARM CARRIER ASSEMBLY AND ROLLERS ADJUSTMENT

1) Measure inside width “A” between inner masts. Make measurements at the top, bottom and center (cross beam) sections.

A

2) Measure right and left pitches,B,B’,B” of carriage side roller, carriage roller and thrust metal.

60

3) Calculate A-B,A-B’and A- B’’.Each result shows clearances between each roller and inner mast. Adjust shims of each roller evenly on the left and right and make clearances, between smallest part of inner mast and carriage side roller.

A- B = 0.2mm to 1 mm A- B’ = 0.1mm to 0.8 mm A- B’’ = 0.1mm to 0.8 mm

Shims : 0.5mm to 1 mm a. Number of shims must be the same on the right and left sides, when using shims. b. After clearance adjustment, push carriage assembly to see if it operates properly.

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MAST CONTROL AND ADJUSTMENT

DISASSEMBLY AND INSTALLATION OF LIFTING JACK

b

Keep body away from equipment

1 - Turn out engine, then make lifting jack falling into lowest condition that lower of piton rod is touched bottom of cylinder body so as to oil flowing back tank completely.

2 - Unscrew piston rod and bolt.

3 - Disconnect circle oil pipe, remove high pressure tubes.

4 - Remove U-bolt of outer mast fixation board and tighten skew of other side.

5 - Remove chain of outer mast.

6 - Attach wire rope to inner mast and remove left and right lifting jack with a lifting device.

DISASSEMBLY

60

Rated capacity is less than 2.5 t, remove cylinder head and guiding bush.

Rated capacity is more than 3 t, removes tighten skew and nylon stopper, then remove cylinder head.

1) Remove dust gasket ring.

2) Remove Y-ring with screwdriver.

b

Please not use dust gasket ring removed, O-ring, Y-ring again,must replace.

3) Draw out piston rod , remove Y-ring on end of piston.

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MAST CONTROL AND ADJUSTMENT

9

INSTALL AND REPLACE FAULTY PARTS.

1) Cleanup parts with clean oil before installation.

2) Then cleanup guiding bush and piston with hydraulic pressure oil the same as oil box trademark.

3) Dust or dunghill doesn’t drop into lifting jack.

4) The order of installation is reverse the order of disassembly.

5) Install Y-ring on piston.

6) Install piston rod assembly into clean cylinder body.

b

The end of cylinder body mast slick and clean, installation must set center, avoid scratching Y-ring.

7) Install replacing dust gasket ring and Y-ring in guiding bush and cylinder head.

60

NOTICE: Apply hydraulic pressure grease which trademark is the same as tank on guide sleeve installed gasket ring.

8) Rip cylinder head into piston rod, screw down cylinder body.

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MAST CONTROL AND ADJUSTMENT

DISASSEMBLY AND INSTALLATION OF TILTING CYLINDER

b

Notices proceedings when removing cylinders.

- Attach wire rope to outer mast, avoiding mast fall down after removing tilting cylinder.

- Keep body away from equipment, no standing under the fork arm carrier.

1) Lay down fork arm carrier completely.

2) Remove bolt on the left and right bracket of outer mast, moreover pull axis out (Rep.1).

3) Remove oil pipe to the inlet of tilting cylinder.

4) Remove bolt on the bracket of Chassis, and pull pin out, then move tilting cylinder.

60

5) The order of installation is reverse the order of disassembly.

Disassembly of parts

1) Squeeze tilting cylinder with pliers, then pull piston rod comeand-go as opening of inlet and outlet on the tilting cylinder, so remaining oil is discharged tilting cylinder.

2) Screw earring bolts (Rep. 2) loosely, and screw earring (Rep. 1) out.

3) Remove cylinder head guiding bush (Rep. 3).

4) Draw out piston rod assembly (Rep. 4).

5) Remove all dust gasket rings, O-ring and Y-ring.

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MAST CONTROL AND ADJUSTMENT

11

6) Remove dust gasket ring in the cylinder head. Means is the same as discharging of dust gasket ring in the cylinder head of lifting jack § «Disassembly and installation of lifting jack» 7) Remove O-ring outside in the guiding bush.

8) Remove O-ring and Y-ring in the inner hole of guiding bush § «disassembly and installation of lifting jack»

b

CAUTION: No using dust gasket ring and Y-ring removed.

Install tilting cylinder after replacing ring

60

The order of installation is reverse to the order of disassembly, but should notice follow proceedings 1) Lubricate parts with clean hydraulic pressure oil.

2) Avoid dust and oil dirty dropping into tilting cylinder.

3) Avoid scratching the end of cylinder body, and inlet and outlet for oil.

4) Push piston rod to cylinder body when setting center, especially avoid scratching Y-ring.

5) Before installing guiding bush, wipe hydraulic pressure oil backing boardched with employment oil trademark in the middle of O-ring and Y-ring in the inner hole of guiding bush.

6) Don’t scratch O-ring outside in the guiding bush when installing.

7) Remember install nylon stopper and tighten screw after screw cylinder head.

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MAST CONTROL AND ADJUSTMENT

NOTICING PROCEEDING OF DEBUGGING 1. Adjust Forward and Backward of the mast Place fork lift truck on the level ground, operate control lever to realize that mast inclined forward or backward extremely.

As assembly debugging data required, adjust combined screw thread length till according with data of Backward. Then lock earring ring close. tightening torque table of «Mast refit»

2. Adjust installation position of left and right lifting jack again a. Adjust washer in the middle of piston rod and inner mast bracket if one lifting jack is not synchronization with the others when rising or falling, and if one lifting jack is different height from the others.

60

b. Loose two nuts on the U-bolt. Mast is not rise and lower until relative position of U-bolt and lifting jack is suitable. Then screw down nuts and tightening screw on the U-bolt. Thus lifting jack can be used longer and wear of piston rod can be reduced. tightening torque table of «Mast refit»

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MAST SECTIONS AND DIAGRAMS

pages MAST SECTIONS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 – LIFTING CYLINDER - A TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – LIFTING CYLINDER - B TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

60

– FREE LIFTING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(28/10/2013)

60-05-M227EN

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MAST SECTIONS AND DIAGRAMS

MAST SECTIONS AND DIAGRAMS

60

LIFTING CYLINDER - A TYPE

1.

2.

3.

4.

5.

6.

Piston Dust ring Gasket ring O-ring Guide sleeve Cylinder

60-05-M227EN

7.

8.

9.

10.

11.

Piston Support ring Protect ring gasket ring Oil nozzle assembly (without left lifting cylinder) 12. O-ring

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MAST SECTIONS AND DIAGRAMS

3

60

LIFTING CYLINDER - B TYPE

1.

2.

3.

4.

5.

6.

Dust ring Cylinder cover Protect ring ISI ring O-ring Compound bushing

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7.

8.

9.

10.

11.

12.

O-ring Bolt Piston rod Cylinder WR Wearing ring Piston

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MAST SECTIONS AND DIAGRAMS

60

FREE LIFTING CYLINDER

1.

2.

3.

4.

5.

6.

Dust ring Cylinder cover Guide sleeve O-ring Stop piece Plunger rod assembly

60-05-M227EN

7.

8.

9.

10.

11.

Support ring Piston Check ring Cylinder ISI ring

(28/10/2013)

MAST REMOVAL

pages MAST REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

60

– REMOVE FORKS AND MAST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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60-06-M227EN

2

MAST REMOVAL

MAST REMOVAL

b

Be careful when removing and installing the forks, carriage and mast as they are heavy (500 to 900 kg).

REMOVE FORKS AND MAST ASSEMBLY

1) After screwing the captive bolts Unlock fork lock pins by pulling them and move forks to cutout portion in the middle of carriage bracket assembly.

2) Pull lower portion of fork to remove its lower jaw and lift it out.

60

b

a. Keep hands and feet away from forks. When removing and installing forks carefully, keep feet and hands clear. b. Do not remove forks from the end of the fork bar.

Severe injury can result if the fork is dropped.

1) Attach wire ropes to carriage bracket assembly and lift carriage bracket assembly up with a lifting device.

b

For more security, place a hold under the carriage to maintain the position.

2) Remove chain attaching nuts, and detach chains from carriage bracket assembly.

3) Remove carriage bracket assembly from inner mast.

4) Detach high pressure hose, lift hose and low pressure hose.

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MAST REMOVAL

3

5) Support mast assembly with wire ropes.

Disconnect the flexible circuit accessories, if there.

60

6) Pull out tilt cylinder pivot pin.

7) Remove mast support caps and U-bolt.

8) Remove mast assembly.

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60-06-M227EN

MAST REMOVAL

60

4

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MAST REFIT

pages MAST REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

60

– TIGHTENING TORQUE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(28/10/2013)

60-07-M227EN

2

MAST REFIT

MAST REFIT TIGHTENING TORQUE

Place

Lift chain lock nut Mast support cap blot Tilt cylinder lock nut Lift cylinder bolt(top) Lift cylinder bolt(bottom)

N•m

1.5t-1.8t

193-257 (M16)

2t to 3.5t

245-314 (M20)

1.5t-1.8t

124-165 (M14)

2t to 3.5t

176-216 (M18)

1.5t-1.8t 2t to 3.5t 1.5t-1.8t 2t to 3.5t

89-118 (M14) 76-107 (M12)

1.5t-1.8t

22-30 (M8)

2 to 3.5t

44-58 (M10)

1.5t-1.8t 2t to 3.5t

76-107 (M12)

60

Lift cylinder fixing bolt (cylinder clamp bolt)

Model or Lifting capacity

60-07-M227EN

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MAST TROUBLESHOOTING

pages

60

TROUBLE DIAGNOSES AND CORRECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

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2

MAST TROUBLESHOOTING

TROUBLE DIAGNOSES AND CORRECTIONS Condition

Probable cause

Fork arm carrier or 1.Tilt cylinder and ring abraded excessively mast tilt by itself. 2. The hydraulic control valve spring is inoperative.

The fork arms carrier 1. Caused by piston jamming or bent piston rod. moves up and down 2. Too much dirt is accumulated in the cylinder. sluggishly.

1. Carriage bracket assembly out of adjustment.

2. Insufficient clearance between inner and outer masts or rollers and mast.

Forks are lifted or lowered non3. Biting foreign materials between moving part. smoothly.

4. Insufficient lubrication.

Forks are lifted unevenly

Replace it.

Replace the faulty parts.

Strip it down and clean.

Adjust clearance with thrust metal and carriage side roller.

Adjust clearance with rollers.

Remove foreign material Apply grease on contact surfaces of sliding parts. (butter) Repair or replace.

1. Lift chains out of adjustment.

Adjust lift chains.

1. Insufficient lubrication.

2. Improperly adjusted lift roller, side roller and back-up metal.

Clean and lubricate lift rollers.

Adjust.

Lubricate.

Adjust.

By adjusting shims and rubber pad, piston rod is in 3. Rubber pad on lower of outer mast is useless for container fork lift truck. touch with bottom of cylinder body after inner mast is in touch with rubber pad.

1. Excessive wear occurs between the oil pump body and gears, causing too much clearance.

60

Replace piston ring tilt cylinder.

5. Bent carriage bracket assembly.

1. Grease stiffened or dirt accumulated on lift roller and mast sliding Lift roller does not surfaces. rotate 2. Improperly adjusted lift rollers.

Excessive mast noise

Corrective action

2. The lifting jack piston Y-ring has worn, resulting in excessive inner leaks.

Replace the worn parts or the oil pump Replace Y-ring.

3. Springs of the multiple control and its relief valve are inoperative oil leaks.

Replace.

4. Excessive wear occurs of the hydraulic control valve, resulting in excessive oil leaks.

Replace.

Insufficient lift power or no lift movement. 5. Oil leaks occur between the hydraulic control valve sections.

6. Leakage occurs in the hydraulic pipe.

Dismantle for regrinding the joint surfaces and reassemble the valve.

Tighten the joint nuts and inspect the seal for damage.

Change the wrong hydraulic oil or stop operation for 7. The hydraulic oil temperature is too high. Oil viscosity is too low and the reducing the oil temperature. Find out the reasons for rate is insufficient. high oil temperature and eliminate the trouble.

8. The load carried is beyond the designed capacity.

60-08-M227EN

Observe the lifting capacity limit.

(28/10/2013)

HYDRAULIC

- HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS - HYDRAULIC SCHEMATIC DIAGRAMS - HYDRAULIC COMPONENTS LOCATION - HYDRAULIC CONTROL AND ADJUSTMENT - COMPONENT DIAGRAMS AND CROSS SECTIONS

70

- HYDRAULIC TROUBLESHOOTING

HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS

pages OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 TILT-UP CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 DUPLEX OR TRIPLEX MAST LIFTING CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 FREE-ACTING LIFTING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 POWER-ASSISTED STEERING SYSTEM - PUMP MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 XCEL45 WITH VLC PRIORITY VALVE (BOPV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

70

STEERING UNIT AND BOPV DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 DESCRIPTION OF HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 ADDITIONAL EHPS SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 DESCRIPTION OF THE STEERING UNIT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

(9/20/2013)

70-01-M227EN

2

HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS

OIL PUMP TONNAGE

UNIT

1,5 TO 2 T

Model

/

Type of power take-off

/

Gear to pump motor

Max. pressure

Mpa

25

Nominal pressure / Nominal rpm

Mpa / rpm

20 / 2000

Max. rpm

Rpm

3000

Capacity

ml/r

16

TONNAGE

UNIT

Relief valve model (2 spools)

/

Main relief valve opening pressure

Mpa

Type of relief valve

/

Type of cartridge

Type of plunger

/

Type of cylinder, system with return spring

Normal flow rate

L/mn

60 - 65

Nominal flow rate

L/mn

62

70

DISTRIBUTOR

Type

70-01-M227EN

1,5 T

1,6 TO 2 T

15

18

Double spool distributor, with overflow and tilt-lock valve

(9/20/2013)

HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS

3

TILT-UP CYLINDER TYPE

TYPE OF PISTON (1,5 TO 2 T)

/

Lift height ≤ 4m Tilt angle (6°/6°)

Lift height ≥ 4m Tilt angle (3,5°/5°)

Travel (mm)

77

55

Cylinder inner diameter (mm)

63

Cylinder outer diameter (mm)

77

Piston rod diameter (mm)

25

DUPLEX OR TRIPLEX MAST LIFTING CYLINDER DUPLEX MAST WITH ALL-ROUND VISION (DUPLEX)

COMPLETE THREE-STAGE LIFTING MAST (TRIPLEX)

Travel (mm)

Type of piston (1,5 to 2,0t)

55

Travel (mm)

S16M300 (Lift height 3 000 mm)

S16N450 (Lift height 4 500 mm)

Travel (mm)

1500

1500

Cylinder inner diameter (mm)

45

45

Cylinder outer diameter (mm)

55

55

Piston rod diameter (mm)

35

35

TYPE OF PLUNGER (1,5 TO 2 T)

TYPE OF PLUNGER (1,5 TO 2 T)

70

TYPE

FREE-ACTING LIFTING CYLINDER TYPE Model

S16U300 (Lift height 3 000 mm)

Travel (mm)

1500

755

Cylinder inner diameter (mm)

45

80

Cylinder outer diameter (mm)

57

93

Piston rod diameter (mm)

32

70

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70-01-M227EN

4

HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS

POWER-ASSISTED STEERING SYSTEM - PUMP MOTOR

With a single large hydraulic motor supplying flow for the steering as well as all hydraulic functions, the need for a dedicated power-steering pump is eliminated and maintenance is reduced. The majority of today's forklift trucks have adopted this approach.

DATA: Pump motor model XQD-8.6-2 (DC), made in China.

70

PUMP MOTOR DATA

70-01-M227EN

Rated capacity

8,6 kw

Mixture

S2 5min

Excitation mode

Series

Ingress protection level

IP22

Max rpm

4200

Nominal rpm

1600

Rated current (A)

248

Rated voltage (V)

48

Insulation level

H

Cooling mode

Fan, IC01

Weight (kg)

72

(9/20/2013)

HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS

5

XCEL45 WITH VLC PRIORITY VALVE (BOPV)

Port EF Priority valve (BOPV)

Port P Tank port V2

Cylinder Port R

Cylinder Port L V1

L: R: P: T: EF: LS: V1: V2:

(9/20/2013)

Control unit steering column mounting

XCEL45 steering control unit

70

LS

Left-hand steering inlet port Right-hand steering inlet port High pressure oil inlet port (normally 8 to 10 Mpa approx.)

Oil outlet port =>to oil tank Priority valve =>to distributor Pressure test port, hydraulic contactor, M12x1.25 screw Main relief valve – adjustable Main (priority) relief valve – adjustable

70-01-M227EN

6

HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS

STEERING UNIT AND BOPV DATA

Specification data • Steering unit model • Model with VLC priority valve (BOPV)

423-7982-15 880-1580

Capacity

50 ml/r

Max. system pressure Max. return pressure

190 bar 21 bar

Normal flow: 50 to 125 cc/r

7,5 to 15 LPM

Input torque: Standard torque: Low torque 1,3 to 2,2 Nm non-motorized

1,7 to 2,8 Nm 136 Nm

70

System max. operating temperature Max. differential between steering unit and other system temperatures Fluid petroleum-based fluids Recommended filtration

93°C 28°C ATF Type A and most ISO 18/13 cleanliness level

Valve combination • Cylinder relief valve: • Anti-cavitation valve: • Non-return inlet valve: • Manual steering non-return valve:

Included Included NONE Included

DESCRIPTION OF HYDRAULIC CIRCUITS Non-load reaction to a dynamic LS signal LS dynamic steering units have the following advantages: – Steering compensated without sudden changes in pressure due to load variations in the steering system, having no effect on the behavior of the axle or the maximum steering rate.

– Genuine power beyond the system's capacity, due to the division of the system into two separate circuits. Transient pressures are isolated in each circuit.

Only the flow needed to operate the steering is delivered to the steering system.

Flow not needed by the steering system remains available for the auxiliary systems.

70-01-M227EN

(9/20/2013)

HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS

7

– Reliable operation as the steering system always has priority of pressure and flow.

The dynamic signal also provides the following advantages – Quicker steering response.

– Improved cold weather start-up.

70

– Increased flexibility to resolve system performance and stability performance problems.

(9/20/2013)

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8

HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS

ADDITIONAL EHPS SYSTEM

EHPS (Electrical Hydraulic Power Steering) system.

For more information, refer to the hydraulic system schematic diagram.

There is a growing trend for FLT batteries using this technology in their steering system. Such as LINDE, JUNGHEINRICH, SHINKO and TOYOTA. Transmission cut-off module managed by driver presence (driver presence sensor under the seat).

EHPS system

Steering wheel

Sensor

Gearing

Valve

70

Oil tank Pump

Pump motor

Steering sensor Steering cylinder Controller

70-01-M227EN

(9/20/2013)

HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS

9

DESCRIPTION OF THE STEERING UNIT VALVE

Inlet relief valve Or LS relief valve

Cylinder port anticavitation valves

70

Cylinder relief valve

Non-return valve

Non-return inlet valve - prevents the return of oil via the steering unit when the oil pressure on the cylinder side exceeds the pressure on the inlet side, in order to prevent a drive wheel return.

Inlet relief valve - limits the maximum pressure drop on the steering unit by protecting the steering system Internal non-return valve - converts the unit into a manual pump to limit manual steering. Included in all units. Steering units with a capacity exceeding 200 cc/r may require a separate source of power for limited operation.

Cylinder port damping valve - protects the hoses against suction conditions (cavitation).

LS relief valve - limits the inlet pressure from the safety valve.

(9/20/2013)

70-01-M227EN

HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS

70

10

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(9/20/2013)

HYDRAULIC SCHEMATIC DIAGRAMS

pages ME 315 / 316 / 318 / 320 SERIES 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 – KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

70

– HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(10/11/2013)

70-02-M227EN

2

HYDRAULIC SCHEMATIC DIAGRAMS KEY

ME 315 / 316 / 318 / 320 Series 2 Item

Designation

CA

Suction strainer

D

3 component distributor

EA

Attachment component

EAV

Front axle

EAR

Rear axle

EDL

Side-shift component

EE

Inlet element

EI

Tilting element

EL

Lifting element

DD

Steering system

FR

Return filter

MP

Pump electric motor Power (ME425) Power (ME430)

11 kW 12,8 kW

P

Hydraulic pump Capacity (ME425) Capacity (ME430)

16 cm3/rev.

20 cm3/rev.

R

Hydraulic tank

RD

Flow reducer

V

Steering wheel ( Ø 350 )

VD

Steering cylinder

VDDP

Priority flow divider valve

VI

Tilting cylinder

VL

Lifting cylinder TLL DVT Side-shift cylinder

70

VDL

Triple mast with free-acting lift Double mast with all-round vision

1,5T / 2T MASTS DVT

DLL

TLL

Ø rod

Ø 35

Ø 32

Body Ø int.

Ø 45

Ø 45

Reducer flow rate ± 10%

Free acting lifting cylinders

Side cylinders

Distributor calibration

70-02-M227EN

Ø rod

Ø 70

Body Ø int.

Ø 80

(10/11/2013)

HYDRAULIC SCHEMATIC DIAGRAMS HYDRAULIC DIAGRAM

3

ME 315 / 316 / 318 / 320 Series 2

VL TLL

DVT

VI

RD

RD

RD

VCD A1

VDL

A1

A1

FT

A1

A2

B2

A3

B3

A4 B4

T

T

155b 1T5 180b 1T6 0 2T

P

EE

EL

EDL

EI

OPTION

EA OPTION

L

FT

125cm3

V

R

70

10

EAV

D 62l/min

DD

190b LS

T

LS

EAR

P

CF

EF

VD

VDDP

P

250b

FT

MP

P M

FR

FT

CA R

(10/11/2013)

70-02-M227EN

HYDRAULIC SCHEMATIC DIAGRAMS

70

4

70-02-M227EN

(10/11/2013)

HYDRAULIC COMPONENTS LOCATION

pages – POSITION OF OTHER HYDRAULIC PARTS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

70

– CONTROL DISTRIBUTOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(9/20/2013)

70-03-M227EN

2

HYDRAULIC COMPONENTS LOCATION

POSITION OF OTHER HYDRAULIC PARTS.

O-ring

70

Inlet filter collar Nuts: 4 - M6x16 Tightening torque: 8 to 10,2 Nm

Fill here

Replace the O-ring seal each time it is removed.

Breather

To the lifting cylinder

Seal

Oil tank

Screw: 12-M6x12 Tightening torque: 8 to 10,2 Nm

70-03-M227EN

(9/20/2013)

HYDRAULIC COMPONENTS LOCATION

3

CONTROL DISTRIBUTOR COMPONENTS

Side-shift lever Tilting lever Lifting lever

Case rod Return spring

70

Return spring

Distributor Pump motor ON/ OFF switch.

Lift the rod, then tilt it to open the battery cover; otherwise the cover will obstruct the handle of the control distributor lever.

(9/20/2013)

70-03-M227EN

HYDRAULIC COMPONENTS LOCATION

70

4

70-03-M227EN

(9/20/2013)

HYDRAULIC CONTROL AND ADJUSTMENT

pages HYDRAULIC PIPING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 REMOVING THE PUMP MOTOR AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 REMOVING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 – PRECAUTIONS FOR FITTING AND USE (PUMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – EXPLODED VIEW OF THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CONTROL BLOCK DIS-ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

(9/20/2013)

70-04-M227EN

70

STEERING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2

HYDRAULIC CONTROL AND ADJUSTMENT

HYDRAULIC PIPING DIAGRAM Description: The oil under high pressure goes from the main pump to the distributor, then towards the lifting or the tilting cylinder. When the lifting or tilting cylinder spool is in the neutral position, the lifting pump is at rest. Pulling on the lifting spool causes the high pressure oil to enter the bottom of the lifting cylinder, then pushes on the piston rod while the translation movement is performed. When the lifting spool is pushed, the bottom of the lifting cylinder connects to the low pressure line, and the piston rod is lowered under the effect of the counterweight and the weight of the load. At that moment, the oil goes from the lifting cylinder through the unidirectional flow reducer to control the rate of decent and to place the lifting pump at rest. While the tilting spool is in operation, one chamber of the tilting cylinder is connected to the high pressure line and the other to the low pressure line to tilt the mast backwards or forwards.

70

This hydraulic circuit uses the LS UNIT AND PRIORITY VALVE technology. The application presents the LS circuit, the priority valve with steering unit is called a BOPV. The complete system comprises an LS unit and priority valve. When the steering wheel is turned, the LS port transfers the pressure signal to the priority valve, then pushes the priority spool to transfer oil to into the steering unit circuit so that it can start to operate. If the steering wheel is not turned, the spool of the priority valve shifts and the steering circuit stops. When the steering unit operates, the oil from the priority valve passes into the rotor pump unit via a sleeve spool. At the same time, the star will turn with the steering wheel. The oil will enter the L or R port, then push the piston, and the steering wheel moves. The other lateral piston drives the return oil towards port T of the steering unit to return the oil to the oil tank, completing one cycle.

Hydraulic motor

HYDRAULIC HOSE DIAGRAM Oil tank

Oil filter

Lifting cylinder Steering cylinder Distributor

Switch

Tilting cylinder

70-04-M227EN

Pump motor

Pump (9/20/2013)

HYDRAULIC CONTROL AND ADJUSTMENT

3

REMOVING THE PUMP MOTOR AND PUMP

Brake pedal

1 - Remove the floor mat and the floor plate.

2 - Disconnect the pump motor connection cable.

3 - Remove the brake pedal control assembly from the frame.

4 - Disconnect the oil pump inlet and outlet hoses.

5 - Disconnect the other oil hoses.

6 - Loosen the motor fastening screws and straps.

7 - Attach a hoist ring to the pump motor and lift the pump/motor assembly.

8 - To remove only the pump, undo the two screws attaching it to the motor and then remove the pump from the motor.

70

2-M10x30 screws

Oil hose Hoist attachment hole

Fastening screw and strap

(9/20/2013)

70-04-M227EN

4

HYDRAULIC CONTROL AND ADJUSTMENT

REMOVING THE OIL PUMP 1 - When removing the pump, clean the surface of the pump and the drive shaft. Set the dismantled components down on a clean cloth or sheet of paper. Take care not to stain, scratch or damage the components.

2 - Secure the pump in a vise with the pump's mounting flange facing downwards. Cover the jaws of the vise with a soft material, such as a piece of wood, an aluminum or copper plate.

3 - Remove the hexagonal head bolts and the clamping washers.

4 - Remove the casing by pulling it straight off along its axis. Tap with a wooden mallet if it is difficult to remove. Remove the flat seals and the anti-extrusion ring.

5 - Remove the pressure plate. This can be easily removed by slightly lifting the drive sprocket / driven gear shaft.

6 - Mark the ends of the sprocket shaft and the driven gear, then remove the gears.

7 - Remove the pressure plate from beneath the gear plate, taking care not to tilt the pressure plate.

8 - Before removing, mark the gear plate to identify the cover side and the mounting flange side of the gear plate.

9 - Remove the seal and the anti-extrusion ring from the mounting flange. Remove the circlip, followed by the oil seal. Remove the seal by passing it from the inside with the help of a standard screwdriver.

Take care, during this operation, not to damage the connection port or the oil seal bearing port.

10 - Set down the dismantled components in such a way that their original location and orientation can be easily understood.

70

PRECAUTIONS FOR FITTING AND USE (PUMP) 1 - Before starting-up, carefully check the oil ports a,d ensure that the direction of rotation of the pump matches that shown on the label, otherwise damage will occur.

2 - Use a flexible coupling between the shaft and the pump drive. Out-of-alignment must not exceed 0,1 mm.

3 - The pump shaft must offer no resistance along its axis or under radial force. Mount the pump with care to avoid damage.

4 - The suction head must be less than 0,5 mm.

5 - The oil port flange must not be damaged. The inlet seal must be well sealed to prevent any intake of air that could cause noisy vibrations, air bubbles and a loss of volumetric efficiency.

6 - The inlet pipe must be such that the speed of the fluid circulating within it is less than 1,5 m/s.

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(9/20/2013)

HYDRAULIC CONTROL AND ADJUSTMENT

5

EXPLODED VIEW OF THE OIL PUMP

PUMP COMPONENTS

(9/20/2013)

(2) (2) (2) (2)

70

1 - Locking ring 2 - Shaft seal 3 - Front casing 4 - Seal 1 5 - Seal 2 6 - Seal 3 7 - Drive gear 8 - Driven gear 9 - Body 10 - Bearing 11 - Plug 12 - Rear casing 13 - Flat washer 14 - Spring washer 15 - Socket head screw

(2) (4) (4) (4) (4)

70-04-M227EN

6

HYDRAULIC CONTROL AND ADJUSTMENT

CONTROL BLOCK DIS-ASSEMBLY Safety valve Using a wrench, undo the safety valve unit from the valve housing.

Comment: If the safety valve is faulty, replace as a complete unit.

Clean the inside of the distributor before reuse.

Main safety valve pressure adjustment The main safety valve pressure is already set in the factory and does not, therefore, generally require adjustment.

Pressure adjustment procedure based on the example of a 1,6 T vehicle.

70

1 - Place 125% of the rated load (2000 kg) securely on the fork.

2 - Apply the parking brake and stop the vehicle on flat, level ground. Pull the lifting lever. If the lift truck can raise the load to a height of 300 mm, the safety valve is operating correctly. If not, adjust as indicated in step 3.

3 - If the lift truck will not lift, increase the pressure of the main safety valve, remove the front shoe, undo the main safety valve retaining nut. If the lifting height exceeds 300 mm, reduce the pressure by turning the adjustment nut anti-clockwise.

4 - Check that the forklift truck can raise goods to a height of between 0 and 300 mm. If not, adjust it as indicated in step 3.

5 - Re-tighten the retaining nut, refit the front shoe.

WARNING The load must be made stable. Do not alter the pressure if it is already correctly set.

70-04-M227EN

(9/20/2013)

HYDRAULIC CONTROL AND ADJUSTMENT

7

STEERING COLUMN

Bolt: M8x25 T: 22 - 29 Nm

Pinion locking nut.

Steering shaft

Articulation

Bearing seat supports

Apply grease to the bearings and shafts before refitting the column.

70

Apply grease here!

(9/20/2013)

70-04-M227EN

8

HYDRAULIC CONTROL AND ADJUSTMENT STEERING COLUMN

Splined shaft

M6x6 screw T: 8,5 - 10,2 Nm

Bearing seat supports

70

Apply grease here!

Bracket

CHECK After assembly: 1. Check that the splined shaft turns smoothly and without obstruction.

2. Check that there is a clearance of approximately 1 to 2 mm.

70-04-M227EN

(9/20/2013)

HYDRAULIC CONTROL AND ADJUSTMENT

9

Power-assisted steering system - Mounting the steering column on the front protection panel

PROCEDURE : 1 - Mount the column assembly on the front protection panel of the vehicle (as shown in the figure of the left). Next, check the force of the steering to ensure that it turns smoothly and does not stick. The steering force at the wheel center button is of the order of 9 to 12 N for an unladen vehicle with power steering enabled.

Screw and clamping washer

2 - After mounting the steering column onto the front protection panel, fit the steering switch, the steering wheel, the dashboard assembly, etc. onto the column support.

Screw and locking ring on each side

70

Locking handle

(9/20/2013)

70-04-M227EN

10

HYDRAULIC CONTROL AND ADJUSTMENT

STEERING CIRCUIT (Double super-elastic rubber guide wheel)

The steering shaft is produced by BORGHI IVAN of Italy.

This special steering shaft is widely used in three-wheel forklift trucks.

Characteristics

70

A - The design of the steering shaft is simple, but no less precise.

B - Made of one piece, with cast steel power-assisted steering pistons and housings, the J series FLT three-wheel steering shaft ensures prolonged, smooth operation. The rack and pinion gearing is immersed in oil to minimize wear.

C - The sealed system will never require lubrication or adjustment.

D - Its hinge-free design ensures that it is maintenance- and repair-free.

E - The closed system provides leak-free operation.

Cross sectional view of the steering shaft

70-04-M227EN

(9/20/2013)

HYDRAULIC CONTROL AND ADJUSTMENT

11

REAR AXLE Assembled

70

Disassembled axle

(9/20/2013)

70-04-M227EN

HYDRAULIC CONTROL AND ADJUSTMENT

70

12

70-04-M227EN

(9/20/2013)

HYDRAULIC COMPONENT SECTIONS AND DIAGRAMS

pages LIFTING CYLINDER (DOUBLE MAST, LEFT/RIGHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 FREE-ACTING LIFTING CYLINDER (TRIPLE, MIDDLE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 LIFTING CYLINDER (TRIPLE, LEFT/RIGHT)/ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

70

EXPLODED VIEW OF REAR AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

(10/3/2013)

70-05-M227EN

2

HYDRAULIC COMPONENT SECTIONS AND DIAGRAMS

70

LIFTING CYLINDER (DOUBLE MAST, LEFT/RIGHT)

70-05-M227EN

(10/3/2013)

HYDRAULIC COMPONENT SECTIONS AND DIAGRAMS

3

70

FREE-ACTING LIFTING CYLINDER (TRIPLE, MIDDLE)

(10/3/2013)

70-05-M227EN

4

HYDRAULIC COMPONENT SECTIONS AND DIAGRAMS

70

LIFTING CYLINDER (TRIPLE, LEFT/RIGHT)/

70-05-M227EN

(10/3/2013)

HYDRAULIC COMPONENT SECTIONS AND DIAGRAMS

5

1. Screw 2. Bracket 3. Nut 4. Screw 5. Washer 6. Locknut 7. Lock washer 8. Cover 9. Seal 10. Bearing 11. Rack and pinion 12. Seal 13. Guide bush 14. Seal 15. Cylinder body 16. Seal 17. Cylinder head 18. Center body 19. Bearing 20. Seal

(10/3/2013)

70

EXPLODED VIEW OF REAR AXLE

21. Steering pivot pin 22. Shaft 23. Tube 24. Shim 25. Seal 26. Bearing 27. Hub 28. Bearing 29. Washer 30. Pin 31. Nut 32. Cap 33. Plug

70-05-M227EN

HYDRAULIC COMPONENT SECTIONS AND DIAGRAMS

70

6

70-05-M227EN

(10/3/2013)

HYDRAULIC TROUBLESHOOTING

pages MAIN OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

70

STEERING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

(10/3/2013)

70-08-M227EN

2

HYDRAULIC TROUBLESHOOTING

MAIN OIL PUMP

CONDITION

LIKELY CAUSE

CORRECTIVE ACTION

Low oil level in oil tank

Add oil to the specified level

Clogged inlet pipe or strainer

Clean the oil line and the tank. If the oil is dirty, change it.

Defective anti-extrusion ring, O-ring seal or pressure plate with worn bearing

Repair defective parts

Incorrect safety valve adjustment

Reset to the specified pressure using a pressure gage

Presence of air in the circuit

Re-tighten the suction side line. Add oil. Check the pump's oil seal. Do not operate the pump until all bubbles have disappeared from the tank.

Cavitation due to a blocked inlet pipe or strainer

Clean the strainer and repair the clogged hose.

Air drawn in through a loose seal on the suction side

Re-tighten the seals

Cavitation due to high oil viscosity

Replace the oil with one of suitable viscosity for the temperature at which the pump is required to operate

Bubbles in the hydraulic fluid

Determine and correct the cause of the bubbles. It may be due to air leakage. Change the oil.

Defective pump oil seal, defective O-ring seal on the body, defective plate seal or worn pump rubbing surfaces

Replace defective parts

No oil coming from the oil pump

70

Low discharge pressure on the oil pump

Noisy oil pump

Oil leak from the oil pump

70-08-M227EN

(10/3/2013)

HYDRAULIC TROUBLESHOOTING

3

ANOMALY

Unstable or low safety valve pressure

Fork tilts forward when the control lever is operated with the motor stopped.

Mast unstable in forward tilt position

Mast lowered a long way when distributor spool is centered

Distributor spool does not return to neutral position

Leak

(10/3/2013)

LIKELY CAUSE

CORRECTIVE ACTION

Loosen the pressure adjustment screw

Adjust and re-tighten

Deformed or damaged pressure adjustment spring

Replace

Worn or blocked safety valve core

Replace or clean

Pump reduced

Examine and repair the pump

Worn or damaged tilt lock valve

Replace the tilt lock valve and valve core as a unit

Broken tilt lock spring

Replace the spring

Damaged tilt valve plunger O-ring seal

Replace the O-ring seal

Tilt safety valve malfunction

Replace complete tilt safety valve

Worn valve body and distributor spool with an excessive gap between them

Replace the distributor spool with the specified gap

Distributor spool not centered

Hold it in the center

Reduced valve seal

Examine and repair the cylinder

Plunger valve worn or blocked by dirt

Replace or clean plunger valve

Damaged or deformed re-positioning spring

Replace the spring

Presence of dirt between the valve body and the distributor spool

Clean

Control system jammed

Adjust

No coaxial component repositioned

Reinstall. Make coaxial.

Damaged O-ring

Replace

Seal not leak-tight

Check and re-tighten

Loose sealing plate

Clean the sealing plate and re-tighten the screws

Loose safety valve locknut and fastening nut between plates

Re-tighten 70-08-M227EN

70

DISTRIBUTOR

4

HYDRAULIC TROUBLESHOOTING

STEERING CIRCUIT

CONDITION

PROBABLE CAUSE

1. Oil leak between sections

CORRECTIVE ACTION Re-tighten the nuts and replace the seals

2. Damaged seal in offset constriction

Replace

6. Damaged seal in check valve

Replace

Steering system leak

4. Set screw limiting shim not flat

Grind down or replace the shim

1. Insufficient oil taken by the pump

Adjust the distributor

2. Air inside the steering unit piping

Remove air

3. Insufficient oil level in the tank 4. Pressure adjustment of the safety valve in the separating valve or valve blockage

70

5. Oil too viscous Large steering force required or impossible to turn the steering system

6. Steering cannot return to its natural position due to a broken lock spring or insufficient spring pressure 7. Failure or deformation of the pivot pin

Replace the defective spring Replace

9. Spring or valve defect

Replace the spring

1. Damaged pivot pin bearing 2. Excessive play in the wheel rim 3. Excessive play between the sleeve and the body of an obitrol and reduction of volumetric efficiency

70-08-M227EN

Change the oil

Replace the sleeve

11. Deformed steering shaft

The front left and front right wheels do not correspond to the rear wheel

Adjust the pressure or remove the dirt

8. Failure or deformation of sleeve

10. Excessive steering cylinder leakage

Play in the steering wheel and wheels outof-alignment

Add oil

Incorrect controller parameter

Replace the seal or the cylinder Repair Replace the bearing Adjust Replace sleeve and body

Adjust

(10/3/2013)

ELECTRICITY

- ELECTRICAL CHARACTERISTICS AND SPECIFICATIONS - ELECTRICAL SCHEMATIC DIAGRAMS - ELECTRICAL COMPONENTS LOCATION - ELECTRICAL CONTROL AND ADJUSTMENT

80

- ELECTRICAL TROUBLESHOOTING

ELECTRICAL CHARACTERISTICS AND SPECIFICATIONS

pages ELECTRICAL AND ELECTRONIC SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

80

ELECTRICAL AND ELECTRONIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

(10/31/2013)

80-01-M227EN

2

ELECTRICAL CHARACTERISTICS AND SPECIFICATIONS

ELECTRICAL AND ELECTRONIC SYSTEM OVERVIEW

Levier de Frein à main Parking brake

Brake pedal Forward / reverse lever

Dashboard

Accelerator pedal potentiometer

CAN

ACS 23 P

ACS 35 P

80

Controllers Front right-hand wheel motor

Front left-hand wheel motor Pump motor

Hydraulic distributor

Driver presence

Steering DC - DC

Hydraulic function Driver presence Transmission function 80-01-M227EN

(10/31/2013)

ELECTRICAL CHARACTERISTICS AND SPECIFICATIONS

3

ELECTRICAL AND ELECTRONIC COMPONENTS PHOTOGRAPH

CHARACTERISTICS

Front working light

Voltage: 24V Standard: GB10485-89/SEA Power rating: 12W

Position light

Voltage: 28V Standard: GB10485-89 Power rating: 0,84W/0,14W

Rear light

Voltage: 28V Power rating: 0,56W(Flashing)/ 0,84W (Braking)/ 0,10W (Position)/ 0,56W (Reversing) Standard: GB10485-89/SEA

Rotating beacon light

Voltage: 10 to 30V Service life: min. 1 x 107 times Standard: GB/T13954-92

Road sound alarm

Voltage: 24V 105 - 125 db (A)

Reverse warning indicators

Voltage: 24V 88 dB (A) 70 - 90 / MIN < 60 mA

(10/31/2013)

80-01-M227EN

80

COMPONENTS

4

ELECTRICAL CHARACTERISTICS AND SPECIFICATIONS

ACS 23 P

ACS 35 P

Model

CURTIS

Front left-hand traction controller

Front right-hand traction controller

ACS48S-35 P

ACS48S-23 P

Hydraulic pump speed controller

ME 315 Series 2 ME 316 Series 2 1253-4801

ME 318 Series 2

80

ME 320 Series 2

80-01-M227EN

(10/31/2013)

ELECTRICAL SCHEMATIC DIAGRAMS

CODES ON THE ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 ME 315 / 316 / 318 / 320 SERIES 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2 – KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2

80

– ELECTRICAL DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3

(10/30/2013)

80-02-M227EN

2

ELECTRICAL SCHEMATIC DIAGRAMS

CODES ON THE ELECTRICAL DIAGRAMS 1

2

3

4

5

6

7

8

9

10

1

11

12

13

14

15

11

A

5

S1

30

30

J

J

17

17

50

19

19

54 15

58

III II I O P

R

R

F21

V BC BC

7

C

R C

4

F27

9

F25

F23

F26

1

E

G1

BC

J

8

V

3

N

Y1 M1

10

OR

7

F

N

0

BC

N

5

G

9

1

K1

S12

5

S15

F4

6 J

L

10

K7

G2

M

N

M8

8 M

7

3

80

K7 10

R1

R1

R1

R1

E15

E16

7

I

Example of marking on cables and components on an electrical diagram

Key: 1 2 3 4 5 6

-

Vbat supply Post contact supply (APC) Electrical component Electrical connector Electrical component designation Electrical connector designation

80-02-M227EN

7 8 9 10 11

-

Splice Wire color Electrical connector PIN N° designation Grounds Marking grid

(10/30/2013)

A1

80

ELECTRICAL SCHEMATIC DIAGRAMS

(10/30/2013)

80-02-M227FR

A2

ELECTRICAL SCHEMATIC DIAGRAMS KEY

ME 315 / 316 / 318 / 320 Series 2

Item

Connectors Item P1

Designation Diagnostic plug Ignition switch

S2

Sidelight / working light stalk switch

S3

Forward/reverse shuttle

S4

Indicator light stalk switch

Position on diagram

ACS35P

I5 I14 / I24 I13

Seat switch

I24

S6

Brake pedal switch

I24

S7

Handbrake switch

I24

S8

Road sound alarm switch

I19

S9

Rotating beacon light switch

I20

S10

Accelerator off-neutral *

K24

S11

Tilting switch

I35

S12

Steering switch

I35

S13

Lifting switch

I35

S14

Emergency stop switch

C22

S15

Lowering cut-off valve control switch

I24

S16

TDL switch

I35

Electrical component codes

80

Designation

Color codes Item

Colours

1

Battery

BC

White

2

Rear left position light

BL

Blue

3

Rear right position light

G

Grey

4

Front left position light

J

Yellow

5

Front right position light

M

Brown

6

Front working headlight relay

N

Black

7

Front left working light

O

Orange

8

Front right working light

R

Red

9

Front left indicator light

RE

Pink

10

Rear left indicator light

VT

Green

11

Flashing unit

V

Purple

12

Front right indicator light

13

Rear right indicator light

14

Left hand reverse light

15

Right hand reverse light

16

Reverse warning indicators

17

Left hand brake light

18

Right hand brake light

19

Road sound alarm

20

Reverse warning relay

21

Rotating beacon light

22

Emergency stop

23

Steering potentiometer

24

Accelerator potentiometer

25

Display

26

Right wheel controller and variable speed drive

27

Left wheel variable speed drive

28

DC pump motor

80-02-M227FR

ACS23P

Designation

Position on diagram

Right wheel controller and variable speed drive

I26

Left wheel variable speed drive

I32

DC pump motor

I38

E1

Rear left position light

M4

E2

Rear right position light

M5

E3

Front left position light

M6

E4

Front right position light

M7

E5

Front left working light

M9

E6

Rear right working light

M10

E7

Front left indicator light

M10

E8

Rear left indicator light

M11

E9

Front right indicator light

M12

E10

Rear right indicator light

M13

E11

Left hand reverse light

M14

E12

Right hand reverse light

M15

EVC255-4803

G23

S5

Item

Hydraulic equivalence code

M24

S1

Electrical components

E13

Left hand brake light

M16

E14

Right hand brake light

M17

E15

Rotating beacon light

M20

G1

Battery

M2

M1

Reverse warning indicators

M14

M2

Road sound alarm

M18

M3

Accelerator Potentiometer

K23

M4

Steering potentiometer

K23

M5

Pump motor

M39

M6

Right traction motor

K29

M7

Left traction motor

K34

M8

Seat cut-off time delay

I22

M9

Charging circuit

C24

Display

O23

Mast lowering cut-off electrovalve

G29

OPT10 Y1

Hydraulic equivalence code

FUSES Item

Designation

Position on diagram

FP1

Hydraulic control motor (300A)

G41

FP2

Front right-hand wheel motor (250A)

E26

FP3

Front left-hand wheel motor (250A)

E32

F1

Control circuit (10A)

E21

F2

Main circuit (10A)

E22

F3

Lighting (10A)

G6

F4

Spare (10A)

E25 RELAYS

Item K1

Designation

Position on diagram

Start-up authorization relay

G41 / I35

K2

Reverse warning relay

I18 / I19

K3

Front working light relay

I9 / M8

K4

Flashing unit

G12

K5

Line breaker

C24 / I28

(10/30/2013)

ELECTRICAL SCHEMATIC DIAGRAMS ELECTRICAL DIAGRAM 1

2

3

A3

ME 315 / 316 / 318 / 320 Series 2 4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

A

42

A

K5

C

C

S14 F P2

M9

FP1

F P3

F4

E

F1

F3

E

F2

r/bc r/bc

r/bc

r/bc

r/bc

r/bc

r/bc

r/bc

G

G

S1 1

J1

2 3

S5

M8

K3

S2 0

1

S4 L

2

m

bl/bc

r

0

r

bc

bl

K2

S6

S3

S9

S8

vt

bc/n

M3 M4

M4

DC-DC + M

Open Drain Out 2 16 Open Drain Out 3 25

18 DI5

Open Drain Out 4 24

30 ID6 34 ID8

Open Drain Out 5 27

Motor temp 26

K5

Y1

ACS23P

KEY

Encoder 12v

5

1 2

Encoder CH2

8

3 4

120 Ω

Motor temp Motor temp GND Encoder 12v Encoder CH1

V

Encoder CH2

CAN_H2 33

23

CAN_L2 21

15

CAN_GND2 10

8

CAN_120 15 B-

EVC255-4803

9

I

10

J2

M6

U

W

8

12

Encoder GND 6

INANA2

7

1

32 Alim ANA 20 INANA1

6

11

17 ID7

9

1

B+

2

ID11

31 GNDANA

48V

5

S12 S13 S11 S16

Open Drain Out 6 13

Encoder CH1 7

S10

r

4

11 DI4

1

M3

K

Open Drain Out 1

35 ID9 2 ID10

S15

bl/bc

4

HIGH SIDE OUT 29

23 DI3

R

ACS35P HIGH SIDE IN 28

19 DI2

S6 S7

I

B+

12 DI1

S3

bl/o

KEY

Encoder GND CAN_H1

17 3 5 6 4

1 2 1 2

M7

B-

M-

K

B+

3 4

A2

U

CAN_L1

CAN_GND1 9 CAN_120

16

V

120 Ω

D2

W

M5

B-

M

G1 E1

-

E2

E3

K3

E4

E5

E6

E7

E8

E9

E10

E11

M1

E12

E13

6

E14

E15

7

P1

M2

2 3

CAN_H CAN_L CAN_GND

9

O

O

n

n

n

n

n

n

n

n

n

n

n

n

n

n

n

n

n

n

n

1 2

OPT10

3 5 6

B+ 0v CAN_GND CAN_L CAN_H

Q

Q 1

S

(10/30/2013)

2

3

4

5

6

7

8

9

10 11 12

13

16

14

15

17

18

19

20

21

22

25 23 24

26

27

28

S

80-02-M227FR

80

K2

K4

3

ELECTRICAL SCHEMATIC DIAGRAMS

80

A4

80-02-M227FR

(10/30/2013)

80

ELECTRICAL COMPONENTS LOCATION

(10/3/2013)

80-03-M227EN

2

ELECTRICAL COMPONENTS LOCATION

Front left-hand traction controller Front right-hand traction controller

Charging circuit

Hydraulic pump speed controller

Line breaker

80

Front left-hand wheel motor

Front right-hand wheel motor

Pump motor

DC-DC transformer 80-03-M227EN

(10/3/2013)

ELECTRICAL COMPONENTS LOCATION

Driver presence module

3

Steering switch

Handbrake switch

Positioning switch

Lowering switch

80

Brake switch

(10/3/2013)

80-03-M227EN

ELECTRICAL COMPONENTS LOCATION

80

4

80-03-M227EN

(10/3/2013)

ELECTRICAL CONTROL AND ADJUSTMENT

pages DASHBOARD - OPT 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2 – PRINCIPLE OF BDI OPERATION (3 WHEELS AND 4 WHEELS): . . . . . . . . . . . . . . . . . . . . . . A3 CONTROL PANEL SET-UP AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4 – EXTERNAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4 – NORMAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4

VARIABLE SPEED DRIVES: 6TH GENERATION ACS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B

80

PUMP VARIABLE SPEED DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C

(10/4/2013)

80-04-M227EN

A2

ELECTRICAL CONTROL AND ADJUSTMENT

DASHBOARD - OPT 10

Supply voltage: Current: P

D

12

k m/h

B AT%

1

2

3

80

5

4

Temperature: (in operation)

24 to 80 V DC 90 mA (at 24V DC) -30 / +55°

-30 / +70° (in storage) Protective glass: IP65 (front) Connector: AMPSEAL (8 pins)

1 - Wide 24V to 80V operating voltage range with built-in protection against undervoltage, overvoltage or polarity reversal.

2 - Standard mode can open an interface allowing simple and reliable communication.

3 - Two feature levels for standard users and maintenance staff.

4 - System of configurable diagnostics and parameter settings menus.

5 - Management of performance modes in conjunction with the user.

6 - Password management.

7 - Buzzer.

Press twice on the "*" key. The instruction "INPUT PASSWORD" will appear.

Enter the password

80

* *

PASSWORD: 55555

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ELECTRICAL CONTROL AND ADJUSTMENT

A3

Press on the green curve to asses the BDI when the key switches from OFF to ON and the measured BDI value according to the voltage. As follows: 51,0V --100%; 47,0V --0%. If the selected value is not correct, the previously saved value is chosen.

Press on the red curve to assess the BDI when the key switches to ON. Check the voltage per second and take the average value. Renew the BDI every 5 seconds. If the value of the BDI is less than the current value, lower by 5%, but not more than 5% each time. When lowered by 5%, the value of the BDI must not rise again.

You will be warned when the discharge level reaches 25%. The alarm will sound with a reading of 20%, while operating at reduced speed.

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PRINCIPLE OF BDI OPERATION (3 WHEELS AND 4 WHEELS):

A4

ELECTRICAL CONTROL AND ADJUSTMENT

CONTROL PANEL SET-UP AND OPERATION EXTERNAL VIEW A

M

C

B

D

E

F

P

D

12

k m/h

B AT%

1

G

H

2

3

I

J

A - Communication indicator LED B - Anomaly indicator LED C - Low battery indicator LED D - Reduced speed indicator LED E - Acceleration indicator LED F - Parking indicator LED G - Menu button

80

4

K

5

L

H - Switch to low speed button I - Acceleration button J - Backup button K - Steering angle indication button L - Time display button M - LCD screen

NORMAL OPERATION

80

DESCRIPTION OF THE SIX FOLLOWING INDICATORS:

LED A: Communication Flashes only during software download.

LED B: Anomaly Lights if an incorrect operation is performed or in, the even,t of a problem with the forklift truck. The LCD screen then displays the error codes, together with a brief explanatory sentence.

LED C: Low battery Lights when the battery's state of charge reaches 20% of full charge. The driver will then hear the buzzer and the message "Low Battery" will appear on the LCD screen. The battery requires charging.

LED D: Reduced speed If lit, the lift truck is operating at less than slow mode, i.e. the lift truck's maximum driving speed is reduced. Button "1" allows switching between slow and fast modes.

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ELECTRICAL CONTROL AND ADJUSTMENT

A5

LED E : Acceleration If lit, the lift truck is operating at less than slow acceleration mode, i.e the lift truck's maximum driving acceleration is reduced. Button "2" is used to switch between slow and fast acceleration modes.

P

LED F: Parking Lit when parked.

Button G: Menu Only used in diagnostic mode.

Button H: Switch to low speed Used to switch between fast and slow driving modes.

1

Button I: Change of acceleration Used to switch between fast and slow acceleration modes.

2

Button J: Backup Spare button.

Button K: Change to steering angle display Used to switch to the steering angle display menu. The following image may appear on the LCD screen.

3 4

80

The squares on the first line indicate the guide wheel steering angle. The black square moves to the left when the guide wheel turns to the left and the the right when it turns to the right.

Time display button L Used to display the total KEY on time.

The following display appears after pressing the button once.

5

The following display appears when the button is pressed a second time.

The display is returned to the original image by pressing the button one more time.

LCD SCREEN M Each time that KEY is activated, the lift truck performs a self-check, and the six LEDs (A to F) flash in turn.

The drive speed and the BDI are displayed on the LCD screen after start-up. The LCD screen provides information on the operating characteristics.

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ELECTRICAL CONTROL AND ADJUSTMENT

80

A6

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ELECTRICAL CONTROL AND ADJUSTMENT

B1

80

VARIABLE SPEED DRIVES: 6TH GENERATION ACS

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ELECTRICAL CONTROL AND ADJUSTMENT

80

B2

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B3

80

ELECTRICAL CONTROL AND ADJUSTMENT

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ELECTRICAL CONTROL AND ADJUSTMENT

80

B4

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B5

80

ELECTRICAL CONTROL AND ADJUSTMENT

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ELECTRICAL CONTROL AND ADJUSTMENT

80

B6

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B7

80

ELECTRICAL CONTROL AND ADJUSTMENT

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ELECTRICAL CONTROL AND ADJUSTMENT

80

B8

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B9

80

ELECTRICAL CONTROL AND ADJUSTMENT

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ELECTRICAL CONTROL AND ADJUSTMENT

80

B10

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B11

80

ELECTRICAL CONTROL AND ADJUSTMENT

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ELECTRICAL CONTROL AND ADJUSTMENT

80

B12

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B13

80

ELECTRICAL CONTROL AND ADJUSTMENT

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ELECTRICAL CONTROL AND ADJUSTMENT

80

B14

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B15

80

ELECTRICAL CONTROL AND ADJUSTMENT

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ELECTRICAL CONTROL AND ADJUSTMENT

80

B16

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B17

80

ELECTRICAL CONTROL AND ADJUSTMENT

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ELECTRICAL CONTROL AND ADJUSTMENT

80

B18

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B19

80

ELECTRICAL CONTROL AND ADJUSTMENT

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ELECTRICAL CONTROL AND ADJUSTMENT

80

B20

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B21

80

ELECTRICAL CONTROL AND ADJUSTMENT

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ELECTRICAL CONTROL AND ADJUSTMENT

80

B22

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B23

80

ELECTRICAL CONTROL AND ADJUSTMENT

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ELECTRICAL CONTROL AND ADJUSTMENT

80

B24

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ELECTRICAL CONTROL AND ADJUSTMENT

CI

80

PUMP VARIABLE SPEED DRIVE

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ELECTRICAL CONTROL AND ADJUSTMENT

80

CII

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ELECTRICAL CONTROL AND ADJUSTMENT

CIII

#/.4%.43

(10/4/2013)

).34!,,!4)/. !.$ 7)2).'

-OUNTING THE #ONTROLLER ,OW #URRENT #ONNECTIONS (IGH #URRENT #ONNECTIONS 7IRING 3TANDARD #ONlGURATION 7IRING 4HROTTLES #ONTACTOR 3WITCHES AND /THER (ARDWARE

02/'2!--!",% 0!2!-%4%23 3PEED 0ARAMETERS -AXIMUM 3PEED 33 n33 4HROTTLE -AXIMUM 3PEED -INIMUM 3PEED !CCELERATION 2ATE 4HROTTLE 0ARAMETERS 4HROTTLE 4YPE 4HROTTLE $EADBAND 4HROTTLE -AXIMUM 4HROTTLE -AP &INAL 3PEED 2EQUEST 0ARAMETERS !DD -ODE &INAL !DD -ODE &AULT 0ARAMETERS ,OCKOUT 4YPE ,IFT ,OCKOUT 33 n33 ,IFT ,OCKOUT 4HROTTLE 4HROTTLE &AULT $ETECTION 3TARTUP ,OCKOUT 5NDERVOLTAGE 0ARAMETERS ,OW 6OLTAGE #UTBACK ,OW 6OLTAGE #UTBACK 2ATE #ONTACTOR #ONTROL 0ARAMETERS 0UMP #ONTACTOR #ONTROL #ONTACTOR 0ULL IN 6OLTAGE #ONTACTOR (OLDING 6OLTAGE 33 $ELAY )NTERLOCK $ELAY 0RECHARGE

80

/6%26)%7

80-04-M227EN

CIV

ELECTRICAL CONTROL AND ADJUSTMENT

).34!,,!4)/. #(%#+/54 $)!'./34)#3 !.$ 42/5",%3(//4).'

0ROGRAMMER $IAGNOSTICS ,%$ $IAGNOSTICS -!).4%.!.#%

6EHICLE $ESIGN #ONSIDERATIONS

!00%.$)8 "

#URTIS 7%%% 2O(3 3TATEMENT

!00%.$)8 #

0ROGRAMMING $EVICES AND -ENUS

!00%.$)8 $

3PECIlCATIONS #URTIS #ONTROLLER

80

!00%.$)8 !

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ELECTRICAL CONTROL AND ADJUSTMENT

CV

&)'52%3

&)'

#URTIS HYDRAULIC SYSTEM CONTROLLER

&)'

-OUNTING DIMENSIONS #URTIS CONTROLLER

&)' A 3TANDARD WIRING CONlGURATION

USING #URTIS GAUGE FOR LIFT LOCKOUT &)' B 3TANDARD WIRING CONlGURATION

USING #URTIS GAUGE FOR LIFT LOCKOUT &)' C 3TANDARD WIRING CONlGURATION

USING #URTIS h3UPERSPYv FOR LIFT LOCKOUT &)' D 3TANDARD WIRING CONlGURATION

USING #URTIS EN'AGE­ )6 FOR LIFT LOCKOUT

&)'

7IRING FOR WIRE KΩn POTENTIOMETER h4YPE v

&)'

7IRING FOR WIRE n KΩ POTENTIOMETER h4YPE v

&)'

7IRING FOR SINGLE ENDED n 6 INPUT h4YPE v

&)'

7IRING FOR SINGLE ENDED n KΩ WIRE POT h4YPE v

&)'

%FFECT OF ADJUSTING THE THROTTLE DEADBAND PARAMETER

&)'

%FFECT OF ADJUSTING THE THROTTLE MAX PARAMETER

&)' 4HROTTLE MAPS FOR CONTROLLER

WITH MAXIMUM SPEED SET AT &)' )NFLUENCE OF VARIOUS PARAMETERS ON CONTROLLER

OUTPUT RESPONSE TO THROTTLE DEMAND &)' 3PEED CONDITIONING &)' "ENCH TEST SETUP

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&)' 4HROTTLE MAPS FOR CONTROLLER

WITH MAXIMUM SPEED SET AT

CVI

ELECTRICAL CONTROL AND ADJUSTMENT

4!",%3

4!",%

4HROTTLE WIPER INPUT THRESHOLD VALUES

4!",%

0ROGRAMMABLE THROTTLE INPUT SIGNAL TYPES

4!",%

0ROGRAMMABLE LIFT LOCKOUT SIGNAL TYPES

4!",%

0RECHARGE FUNCTION AND FAULT DETECTION

4!",%

4ROUBLESHOOTING CHART

4!",%

3TATUS ,%$ FAULT CODES

!",% $ 4

3PECIlCATIONS CONTROLLER $

80

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ELECTRICAL CONTROL AND ADJUSTMENT

C1

/6%26)%7 4HE #URTIS PROVIDES A COST EFFECTIVE SOLUTION FOR CONTROL OF HIGH POWER $# SERIES WOUND HYDRAULIC PUMP MOTORS )TS SYSTEM INTEGRATION FEATURES ARE DESIGNED PRIMARILY FOR #LASS ) AND #LASS )) MATERIAL HANDLING VEHICLES 4YPICAL AP PLICATIONS INCLUDE THE PUMP SYSTEMS OF MATERIAL HANDLING TRUCKS COUNTERBALANCE TRUCKS REACH TRUCKS AERIAL LIFT PLATFORMS SCISSOR LIFTS ARTICULATING TELESCOPING BOOMS AND OTHER INDUSTRIAL VEHICLES 4HE ACCEPTS INPUTS FROM UP TO FOUR 3PEED 3ELECT SWITCHES AND ALSO FROM AN ANALOG THROTTLE )TS INTERNAL MICROPROCESSOR BASED LOGIC CONTROLLER PRO VIDES MAXIMUM mEXIBILITY AT MINIMUM COST )TS PERFORMANCE CHARACTERISTICS CAN BE TAILORED THROUGH AN ARRAY OF PROGRAMMABLE PARAMETERS 4HE CONTROLLER IS FULLY PROGRAMMABLE THROUGH A #URTIS HANDHELD PROGRAMMER OR 0# 0ROGRAMMING 3TATION 4HE PROGRAMMING DEVICE PROVIDES DIAGNOSTIC AND TEST CAPABILITY IN ADDITION TO CONlGURATION mEXIBILITY

80

&IG #URTIS HYDRAULIC PUMP MOTOR CONTROLLER

,IKE ALL #URTIS MOTOR CONTROLLERS THE OFFERS SUPERIOR OPERATOR CONTROL OF MOTOR SPEED AND TORQUE 3MOOTH AND 1UIET #ONTROL

✓ 0ROGRAMMABLE ACCELERATION RATES PROVIDE SMOOTH APPLICATION OF PUMP MOTOR TORQUE K(Z 07- FREQUENCY FOR NEAR SILENT OPERATION

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C2

ELECTRICAL CONTROL AND ADJUSTMENT

0ROGRAMMABLE &LEXIBILITY

✓ %ASILY PROGRAMMABLE THROUGH A #URTIS PROGRAMMING DEVICE &OUR 3PEED 3ELECT INPUTS 33 n33 WITH INDIVIDUALLY PROGRAMMABLE TOP SPEEDS 0ROGRAMMABLE THROTTLE INPUT FOR PRECISE SPEED CONTROL WITH A VARIETY OF SIGNAL SOURCES 0ROGRAMMABLE TURN OFF DELAY ALLOWS 33 TO BE USED FOR POWER STEERING !DJUSTABLE MINIMUM SPEED SETTING TO ENSURE PUMP LUBRICATION AND TO MAINTAIN STEERING SYSTEM PRESSURE 2OBUST 3AFETY AND 2ELIABILITY

)NTERLOCK FEATURE DISABLES THE CONTROLLER WHEN OPERATOR IS NOT PRESENT ✓ 0ROGRAMMABLE STARTUP LOCKOUT PREVENTS INADVERTENT OPERATION 3EAMLESS INTEGRATION WITH #URTIS GAUGES MODELS

AND EN'AGE­ )6 FOR LIFT LOCKOUT FUNCTION ,IFT LOCKOUT DISABLES THE CONTROLLER AT LOW BATTERY STATE OF CHARGE 2EDUNDANT WATCHDOG TIMER CIRCUITS ENSURE PROPER SOFTWARE OPERATION %XTERNAL 3TATUS ,%$ OUTPUT FOR EASY TROUBLESHOOTING 3HORT CIRCUIT PROTECTION ON MAIN CONTACTOR DRIVER 0RECHARGE CONTROL PREVENTS PITTING OF CONTACTOR TIPS AT STARTUP 4HERMAL CUTBACK PROVIDES PROTECTION TO THE CONTROLLER 2UGGED HOUSING MEETS )0 ENVIRONMENTAL RATINGS

80

&ULL POWER OPERATION OVER THE # n # HEATSINK TEMPERATURE RANGE

&AMILIARITY WITH YOUR #URTIS CONTROLLER WILL HELP YOU INSTALL AND OPERATE IT PROP ERLY 7E ENCOURAGE YOU TO READ THIS MANUAL CAREFULLY )F YOU HAVE QUESTIONS

PLEASE CONTACT THE #URTIS OFlCE NEAREST YOU

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ELECTRICAL CONTROL AND ADJUSTMENT

).34!,,!4)/. !.$ 7)2).'

-/5.4).' 4(% #/.42/,,%2 4HE CONTROLLER CAN BE ORIENTED IN ANY POSITION AND MEETS THE )0 RATINGS FOR ENVIRONMENTAL PROTECTION AGAINST DUST AND WATER (OWEVER THE LOCATION SHOULD BE CAREFULLY CHOSEN TO KEEP THE CONTROLLER CLEAN AND DRY )F A CLEAN

DRY MOUNTING LOCATION CANNOT BE FOUND A COVER MUST BE USED TO SHIELD THE CONTROLLER FROM WATER AND CONTAMINANTS 4HE CONTROLLER S OUTLINE AND MOUNTING HOLE DIMENSIONS ARE SHOWN IN &IGURE 7HEN SELECTING THE MOUNTING POSITION BE SURE TO ALSO TAKE INTO CONSIDERATION THAT ACCESS IS NEEDED AT THE END OF THE CONTROLLER TO PLUG THE PROGRAMMER INTO ITS CONNECTOR 4O ENSURE FULL RATED POWER THE CONTROLLER SHOULD BE FASTENED TO A CLEAN

mAT METAL SURFACE WITH FOUR MM DIAMETER SCREWS USING THE HOLES

80

C3

&IG -OUNTING DIMENSIONS #URTIS CONTROLLER

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C4

ELECTRICAL CONTROL AND ADJUSTMENT

PROVIDED !LTHOUGH NOT USUALLY NECESSARY A THERMAL JOINT COMPOUND CAN BE USED TO IMPROVE HEAT CONDUCTION FROM THE CONTROLLER HEATSINK TO THE MOUNT ING SURFACE 9OU WILL NEED TO TAKE STEPS DURING THE DESIGN AND DEVELOPMENT OF YOUR END PRODUCT TO ENSURE THAT ITS %-# PERFORMANCE COMPLIES WITH APPLICABLE REGULATIONS SUGGESTIONS ARE PRESENTED IN !PPENDIX !

# !5 4 ) / .

7ORKING ON ELECTRICAL SYSTEMS IS POTENTIALLY DANGEROUS 9OU SHOULD PROTECT YOURSELF AGAINST UNCONTROLLED OPERATION HIGH CURRENT ARCS AND OUTGASSING FROM LEAD ACID BATTERIES 5.#/.42/,,%$ /0%2!4)/. 3OME CONDITIONS COULD CAUSE THE HYDRAULIC

PUMP SYSTEM TO RUN OUT OF CONTROL $ISCONNECT THE MOTOR OR MAKE SURE THE PUMP SYSTEM HAS ENOUGH ROOM TO OPERATE BEFORE ATTEMPTING ANY WORK ON THE MOTOR CONTROL CIRCUITRY .OTE )F THE WRONG THROTTLE INPUT SIGNAL TYPE IS SELECTED WITH THE PROGRAMMING DEVICE THE PUMP SYSTEM MAY SUDDENLY BEGIN TO OPERATE ()'( #522%.4 !2#3 "ATTERIES CAN SUPPLY VERY HIGH POWER AND ARCS CAN

OCCUR IF THEY ARE SHORT CIRCUITED !LWAYS OPEN THE BATTERY CIRCUIT BEFORE WORKING ON THE MOTOR CONTROL CIRCUIT 7EAR SAFETY GLASSES AND USE PROPERLY INSULATED TOOLS TO PREVENT SHORTS ,%!$ !#)$ "!44%2)%3 #HARGING OR DISCHARGING GENERATES HYDROGEN GAS

80

WHICH CAN BUILD UP IN AND AROUND THE BATTERIES &OLLOW THE BATTERY MANUFACTURER S SAFETY RECOMMENDATIONS 7EAR SAFETY GLASSES

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ELECTRICAL CONTROL AND ADJUSTMENT

C5

,/7 #522%.4 #/..%#4)/.3 4WO LOW CURRENT CONNECTORS ARE BUILT INTO THE CONTROLLER 4HEY ARE LOCATED ON THE END OF THE CONTROLLER

4HE PIN CONNECTOR * PROVIDES THE LOGIC CONTROL CONNECTIONS 4HE MATING CONNECTOR IS A PIN -OLEX -INI &IT *R CONNECTOR PART NUMBER USING TYPE TERMINALS

* *

+EYSWITCH )NPUT +3)

*

0OT (IGH

*

0OT 7IPER

*

0OT ,OW

*

)NTERLOCK

*

3TATUS ,%$

INPUT AND RETURN FOR MAIN CONTACTOR COIL 6 SUPPLY POT WIPER INPUT OR 6 THROTTLE INPUT TO GROUND THROUGH OHM RESISTOR INPUT FROM OPERATOR PRESENT SWITCH TIED TO " ,%$ DRIVER LOW SIDE OUTPUT

33

*

33

*

33

* 33 * ,IFT ,OCKOUT * #ONTACTOR

* * * *

4HE PIN CONNECTOR * IS FOR THE PROGRAMMER EITHER THE HANDHELD PROGRAMMER OR THE 0# 0ROGRAMMING 3TATION ! COMPLETE PROGRAMMER KIT WITH THE APPROPRIATE CONNECTING CABLE CAN BE ORDERED #URTIS P N FOR THE 5SER 0ROGRAMMER MODEL -

2X $ATA " 4X $ATA 6 *

./4% 4HE HAND

HELD PROGRAMMER HAS BEEN SUPERSEDED IF YOU ARE USING A MORE RECENT MODEL PLEASE REFER TO ITS DOCUMENTATION

(10/4/2013)

3PEED 3ELECT INPUT 3PEED 3ELECT INPUT 3PEED 3ELECT INPUT 3PEED 3ELECT INPUT INPUT TO THE INHIBIT LIFT FEATURE MAIN CONTACTOR COIL DRIVER LOW SIDE OUTPUT

#URTIS P N FOR THE /%- 0ROGRAMMER MODEL -

)F A HANDHELD PROGRAMMER IS ALREADY AVAILABLE BUT HAS AN INCOMPATIBLE CABLE

THE MATING CABLE CAN BE ORDERED AS A SEPARATE PART #URTIS P N 7ITH A 0# PROGRAMMING STATION THE INTERFACE BOX AND CABLE CON NECT THE COMPUTER TO THE CONTROLLER P N 0# 0ROGRAMMING 3TATION 5SER #$ 2/

P N 0# 0ROGRAMMING 3TATION /%- #$ 2/P N )NTERFACE "OX P N -OLEX CABLE FOR )NTERFACE "OX

80-04-M227EN

80

*

C6

ELECTRICAL CONTROL AND ADJUSTMENT

()'( #522%.4 #/..%#4)/.3 4HREE TIN PLATED SOLID COPPER BUS BARS ARE PROVIDED FOR THE HIGH CURRENT CON NECTIONS TO THE BATTERY " AND " AND THE MOTOR ARMATURE -

7)2).' 3TANDARD #ONlGURATION &IGURE SHOWS THE TYPICAL WIRING CONlGURATION FOR MOST APPLICATIONS 4HE IN TERLOCK SWITCH IS TYPICALLY A SEAT SWITCH TILLER SWITCH OR FOOT SWITCH 4HE THROTTLE SHOWN IS A WIRE POT OTHER TYPES OF THROTTLES CAN ALSO BE USED ,IFT LOCKOUT CAN BE PROVIDED THROUGH ANY OF FOUR #URTIS GAUGES

A #URTIS

B #URTIS

C #URTIS h3UPERSPYv

D #URTIS EN'AGE­ )6 !S EACH OF THESE GAUGES IS WIRED SOMEWHAT DIFFERENTLY TO PROVIDE LIFT LOCKOUT

FOUR INDIVIDUAL WIRING DIAGRAMS ARE INCLUDED &IGS A B C D 0OWER 7IRING

80

-OTOR WIRING IS STRAIGHTFORWARD WITH THE lELD S 3 CONNECTION GOING TO THE CONTROLLER S " BUS BAR AND THE ARMATURE S ! CONNECTION GOING TO THE CONTROLLER S - BUS BAR #ONTROL 7IRING

# !5 4 ) / .

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4HE MAIN CONTACTOR COIL SHOULD BE WIRED DIRECTLY TO THE CONTROLLER AS SHOWN IN &IGURE 4HE CONTROLLER USES THE MAIN CONTACTOR COIL DRIVER OUTPUT TO REMOVE POWER FROM THE CONTROLLER AND PUMP MOTOR IN THE EVENT OF VARIOUS FAULTS )F THE MAIN CONTACTOR COIL IS NOT WIRED TO 0IN THE CONTROLLER WILL NOT BE ABLE TO OPEN THE MAIN CONTACTOR IN SERIOUS FAULT CONDITIONS

80-04-M227EN

C7

80

ELECTRICAL CONTROL AND ADJUSTMENT

&IG A 3TANDARD WIRING CONlGURATION

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#URTIS CONTROLLER WITH #URTIS PROVIDING LIFT LOCKOUT

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ELECTRICAL CONTROL AND ADJUSTMENT

80

C8

&IG B 3TANDARD WIRING CONlGURATION

#URTIS CONTROLLER WITH #URTIS PROVIDING LIFT LOCKOUT

80-04-M227EN

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C9

80

ELECTRICAL CONTROL AND ADJUSTMENT

&IG C 3TANDARD WIRING CONlGURATION

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#URTIS CONTROLLER WITH #URTIS h3UPERSPYv PROVIDING LIFT LOCKOUT

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ELECTRICAL CONTROL AND ADJUSTMENT

80

C10

&IG D 3TANDARD WIRING CONlGURATION

#URTIS CONTROLLER WITH #URTIS EN'AGE­ )6 PROVIDING LIFT LOCKOUT

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ELECTRICAL CONTROL AND ADJUSTMENT

C11

7)2).' 4HROTTLES 6ARIOUS THROTTLES CAN BE USED WITH THE CONTROLLER 4HEY ARE CATEGORIZED AS ONE OF FOUR TYPES IN THE 0ROGRAM -ENU 4YPE 4YPE 4YPE 4YPE

TWO WIRE n KΩ POTENTIOMETER THROTTLES TWO WIRE KΩn POTENTIOMETER THROTTLES SINGLE ENDED n 6 THROTTLES SINGLE ENDED THREE WIRE KΩn KΩ POT THROTTLES

4ABLE SUMMARIZES THE OPERATING SPECIlCATIONS FOR THESE FOUR THROTTLE TYPES 4ABLE 7)0%2 ).054 4(2/44,% 4(2%3(/,$ 6!,5%3

4(2/44,%

490% 0!2!-%4%2

-).)-5- 4(2/44,% &!5,4

4(2/44,% $%!$"!.$ SPEED REQUEST

34!2450 ,/#+/54

4(2/44,% -!8 MODULATION

-!8)-54(2/44,% &!5,4

7IPER 6OLTAGE 7IPER 2ESISTANCE

6 KΩ

OUT OF DEADBAND

6 KΩ

6 KΩ

7IPER 6OLTAGE 7IPER 2ESISTANCE

6 KΩ

OUT OF DEADBAND

6 KΩ

6 KΩ

7IPER 6OLTAGE 7IPER 2ESISTANCE

6

OUT OF DEADBAND

6

6

7IPER 6OLTAGE 7IPER 2ESISTANCE

6

6 KΩ

OUT OF DEADBAND

6 KΩ

6

.OTES 4HE UPPER AND LOWER DEADBANDS ARE VALID FOR NOMINAL KΩ POTENTIOMETERS OR 6 SOURCES WITH THE DEFAULT 4HROTTLE $EADBAND AND 4HROTTLE -AX PARAMETER SETTINGS OF AND RESPECTIVELY 4HESE VALUES WILL CHANGE WITH VARIATIONS IN THE 4HROTTLE $EADBAND AND 4HROTTLE -AX PARAMETER SETTINGS SEE 3ECTION PAGES AND 4HE STARTUP LOCKOUT THRESHOLD FOR ALL THROTTLE TYPES IS SET BY THE 4HROTTLE $EADBAND

&OR POTENTIOMETERS THE PROVIDES COMPLETE THROTTLE FAULT PROTECTION THAT MEETS ALL APPLICABLE %%# REGULATIONS &OR VOLTAGE THROTTLES THE PROTECTS AGAINST OUT OF RANGE WIPER VOLTAGES SEE 4ABLE BUT DOES NOT DETECT WIRING FAULTS IT IS THEREFORE THE RESPONSIBILITY OF THE /%- TO PROVIDE FULL THROTTLE FAULT PROTECTION IN VEHICLES USING VOLTAGE THROTTLES 7IRING FOR THE MOST COMMON THROTTLES IS DESCRIBED BELOW )F THE THROTTLE YOU ARE PLANNING TO USE IS NOT COVERED CONTACT THE #URTIS OFlCE NEAREST YOU .OTE )N THE TEXT THROTTLES ARE IDENTIlED BY THEIR NOMINAL RANGE E G

KΩn POT AND NOT BY THEIR ACTUAL OPERATING RANGE

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C12

ELECTRICAL CONTROL AND ADJUSTMENT

n KΩ 4HROTTLE h4YPE v

4HE n KΩ THROTTLE h4YPE v IN THE 0ROGRAM -ENU IS A WIRE RESISTIVE THROTTLE THAT CONNECTS BETWEEN THE 0OT 7IPER AND 0OT ,OW PINS AS SHOWN IN &IGURE :ERO SPEED CORRESPONDS TO Ω MEASURED BETWEEN THE TWO PINS AND FULL SPEED CORRESPONDS TO KΩ &IG 7IRING FOR

0OT 7IPER INPUT 0IN *

n KΩ THROTTLE h4YPE v &!34%2

0OT ,OW INPUT 0IN *

n K7

)F THE TOTAL RESISTANCE BETWEEN THE 0OT 7IPER AND 0OT ,OW PINS IS GREATER THAN KΩ THE CONTROLLER S UPPER FAULT LIMIT WILL BE EXCEEDED SEE 4ABLE AND THE THROTTLE S INPUT VALUE WILL BE ZEROED 4HIS PROVIDES BROKEN WIRE PROTECTION

AND ALSO SERVES AS AN INDICATION THAT THE POTENTIOMETER S RESISTANCE HAS INCREASED BEYOND THE ACCEPTABLE RANGE AND THAT THE POT THEREFORE NEEDS TO BE REPLACED

KΩn 4HROTTLE h4YPE v

4HE KΩn THROTTLE h4YPE v IN THE 0ROGRAM -ENU IS A WIRE RESISTIVE THROTTLE THAT CONNECTS BETWEEN THE 0OT 7IPER AND 0OT ,OW PINS AS SHOWN IN &IGURE :ERO SPEED CORRESPONDS TO A NOMINAL KΩ MEASURED BETWEEN THE TWO PINS AND FULL SPEED CORRESPONDS TO Ω &IG 7IRING FOR KΩn THROTTLE h4YPE v

0OT 7IPER INPUT 0IN * &!34%2

0OT ,OW INPUT 0IN *

K7n

80

)F THE TOTAL RESISTANCE BETWEEN THE 0OT 7IPER AND 0OT ,OW PINS IS GREATER THAN KΩ THE CONTROLLER S UPPER FAULT LIMIT WILL BE EXCEEDED SEE 4ABLE AND THE THROTTLE S INPUT VALUE WILL BE ZEROED 4HIS PROVIDES BROKEN WIRE PROTECTION

AND ALSO SERVES AS AN INDICATION THAT THE POTENTIOMETER S RESISTANCE HAS INCREASED BEYOND THE ACCEPTABLE RANGE AND THAT THE POT THEREFORE NEEDS TO BE REPLACED

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ELECTRICAL CONTROL AND ADJUSTMENT

C13

3INGLE %NDED n 6 6OLTAGE 3OURCE h4YPE v

7ITH THIS THROTTLE h4YPE v IN THE 0ROGRAM -ENU THE CONTROLLER LOOKS FOR A VOLTAGE SIGNAL AT THE 0OT 7IPER PIN :ERO SPEED CORRESPONDS TO 6 AND FULL SPEED TO 6 &IG 7IRING FOR

n 6 THROTTLES h4YPE v

"

4HE ACTIVE RANGE FOR THIS THROTTLE IS FROM 6 AT 4HROTTLE $EADBAND TO 6 AT 4HROTTLE -AX MEASURED RELATIVE TO " 4HE SIGNAL IS MEASURED AT THE 0OT 7IPER PIN )T IS THE RESPONSIBILITY OF THE /%- TO PROVIDE APPROPRIATE THROTTLE FAULT DETECTION FOR n 6 THROTTLES

3INGLE %NDED KΩn KΩ WIRE POT h4YPE v

4HE WIRE POTENTIOMETER IS USED IN ITS VOLTAGE DIVIDER MODE WITH THE VOLTAGE SOURCE AND RETURN BEING PROVIDED BY THE CONTROLLER 0OT (IGH PROVIDES A CURRENT LIMITED 6 SOURCE TO THE POT AND 0OT ,OW PROVIDES THE RETURN PATH 7IRING IS SHOWN IN &IGURE AND IS ALSO SHOWN IN THE STANDARD WIRING DIAGRAMS

&IGURE &IG 7IRING FOR WIRE

POTENTIOMETER THROTTLE h4YPE v

7HEN A WIRE POT IS USED THE CONTROLLER PROVIDES FULL FAULT PROTECTION 0OTENTIOMETERS WITH TOTAL RESISTANCE VALUES BETWEEN KΩ AND KΩ CAN BE USED

#/.4!#4/2 37)4#(%3 AND /4(%2 (!2$7!2% -AIN #ONTACTOR

! MAIN CONTACTOR SHOULD BE USED WITH THE CONTROLLER /THERWISE THE CONTROLLER S FAULT DETECTION WILL NOT BE ABLE TO FULLY PROTECT THE CONTROLLER AND HYDRAULIC SYSTEM FROM DAMAGE IN A FAULT CONDITION 4HE MAIN CONTACTOR ALLOWS THE CONTROLLER AND MOTOR TO BE DISCONNECTED FROM THE BATTERY 4HIS PROVIDES A SIGNIlCANT SAFETY FEATURE BECAUSE IT MEANS THE BATTERY POWER CAN BE REMOVED

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&!34%2

C14

ELECTRICAL CONTROL AND ADJUSTMENT

FROM THE HYDRAULIC SYSTEM IF A CONTROLLER OR WIRING FAULT RESULTS IN BATTERY POWER BEING APPLIED TO THE MOTOR INAPPROPRIATELY 4HE PROVIDES A LOW SIDE CONTACTOR COIL DRIVER AT 0IN * FOR THE MAIN CONTACTOR 4HE DRIVER OUTPUT IS RATED AT AMP AND IS SHORT CIRCUIT PROTECTED ! BUILT IN COIL SUPPRESSION DIODE IS CONNECTED BETWEEN THE MAIN CONTACTOR COIL DRIVER OUTPUT AND THE KEYSWITCH INPUT 4HIS PROTECTS THE CONTACTOR COIL DRIVER FROM INDUCTIVE VOLTAGE KICKBACK SPIKES WHEN THE CONTACTOR IS TURNED OFF +EYSWITCH AND )NTERLOCK 3WITCH

4HE VEHICLE SHOULD HAVE A MASTER ON OFF SWITCH TO TURN THE SYSTEM OFF WHEN NOT IN USE 4HE KEYSWITCH INPUT PROVIDES LOGIC POWER FOR THE CONTROLLER 4HE INTERLOCK SWITCH WHICH IS TYPICALLY IMPLEMENTED AS A SEATSWITCH OR A HAND FOOT ACTIVATED DEADMAN SWITCH PROVIDES A SAFETY INTERLOCK TO ENSURE THAT AN OPERATOR IS PRESENT IN ORDER FOR THE SYSTEM TO RUN 4HE KEYSWITCH AND INTERLOCK SWITCH PROVIDE CURRENT TO DRIVE THE MAIN CONTACTOR COIL AS WELL AS THE CONTROLLER S INTERNAL LOGIC CIRCUITRY AND MUST BE RATED TO CARRY THESE CURRENTS 3PEED 3ELECT 3WITCHES

4HESE INPUT SWITCHES CAN BE ANY TYPE OF SINGLE POLE SINGLE THROW 3034 SWITCH CAPABLE OF SWITCHING THE BATTERY VOLTAGE AT M! 2EVERSE 0OLARITY 0ROTECTION $IODE

&OR REVERSE POLARITY PROTECTION A DIODE SHOULD BE ADDED TO THE CONTROL CIRCUIT 4HIS DIODE WILL PROHIBIT MAIN CONTACTOR OPERATION AND CURRENT mOW IF THE BATTERY PACK IS ACCIDENTALLY WIRED WITH THE " AND " TERMINALS REVERSED )T SHOULD BE SIZED APPROPRIATELY FOR THE MAXIMUM CONTACTOR COIL CURRENT REQUIRED FROM THE CONTROL CIRCUIT 4HE REVERSE POLARITY PROTECTION DIODE SHOULD BE WIRED AS SHOWN IN THE STANDARD WIRING DIAGRAMS &IGURE

80

#IRCUITRY 0ROTECTION $EVICES

4O PROTECT THE CONTROL CIRCUITRY FROM ACCIDENTAL SHORTS A LOW CURRENT FUSE AP PROPRIATE FOR THE MAXIMUM CURRENT DRAW SHOULD BE CONNECTED IN SERIES WITH THE BATTERY FEED TO THE KEYSWITCH !DDITIONALLY A HIGH CURRENT FUSE SHOULD BE WIRED IN SERIES WITH THE MAIN CONTACTOR TO PROTECT THE MOTOR CONTROLLER AND BATTERIES FROM ACCIDENTAL SHORTS IN THE POWER SYSTEM 4HE APPROPRIATE FUSE FOR EACH APPLICATION SHOULD BE SELECTED WITH THE HELP OF A REPUTABLE FUSE MANUFAC TURER OR DEALER 4HE STANDARD WIRING DIAGRAMS &IGURE SHOW THE RECOMMENDED LOCATION FOR EACH FUSE

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./4% 4HE HAND

HELD PROGRAMMER HAS BEEN SUPERSEDED IF YOU ARE USING A MORE RECENT MODEL PLEASE REFER TO ITS DOCUMENTATION

02/'2!--!",% 0!2!-%4%23 4HE S PROGRAMMABLE PARAMETERS ALLOW THE PUMP SYSTEM S PERFORMANCE CHARACTERISTICS TO BE CUSTOMIZED TO lT THE NEEDS OF INDIVIDUAL APPLICATIONS OR SYSTEM OPERATORS 0ROGRAMMING CAN BE DONE WITH A HANDHELD PROGRAM MER OR A 0# 0ROGRAMMING 3TATION 4HE DISCONTINUED HANDHELD PROGRAMMER IS ALSO FULLY COMPATIBLE WITH THE CONTROLLER #URTIS OFFERS TWO VERSIONS OF THE PROGRAMMER THE IS THE 5SER PROGRAMMER WHICH CAN ADJUST ONLY THOSE PARAMETERS WITH 5SER ACCESS RIGHTS AND THE IS THE /%- PROGRAMMER WHICH CAN ADJUST ALL THE PARAMETERS WITH 5SER OR /%- ACCESS RIGHTS 3IMILARLY THE 0# 0ROGRAM MING 3TATION SOFTWARE IS AVAILABLE IN TWO VERSIONS AND 3EE !PPENDIX # FOR MORE INFORMATION ABOUT THE PROGRAMMERS )N THE FOLLOWING DESCRIPTIONS THE S PARAMETERS ARE ARRANGED IN GROUPS 4HE PARAMETER NAMES ARE LISTED HERE IN THE ABBREVIATED FORMS THAT APPEAR ON THE HANDHELD PROGRAMMER S CHARACTER ,#$ SCREEN .OT ALL OF THESE PARAM ETERS ARE AVAILABLE ON ALL CONTROLLERS THE PARAMETERS FOR ANY GIVEN CONTROLLER ARE DEPENDENT ON ITS SPECIlCATIONS &OR A LIST OF THE PARAMETERS IN THE ORDER IN WHICH THEY APPEAR IN THE 0RO GRAM -ENU SEE !PPENDIX #

-«ii`Ê-i iVÌÊ*>À> iÌiÀÃ

>Õ ÌÊ*>À> iÌiÀÃ

30%%$ 33 n33 4(24, -!8 30$ -).)-5- 30%%$ !##%, 2!4%

/ À ÌÌ iÊ*>À> iÌiÀÃ

4(2/44,% 490% 4(24, $%!$"!.$ 4(2/44,% -!8 4(2/44,% -!0

> Ê-«ii`Ê,iµÕiÃÌÊ*>À> iÌiÀÃ

(10/4/2013)

!$$ -/$% &).!, !$$ -/$%

,/#+/54 490% ,)&4 ,/#+ 33 n33 4(24, ,)&4,/#+ 4(24, &!5,4 34!2450 ,/#+

1 `iÀÛ Ì>}iÊ*>À> iÌiÀÃ

,/6/,4 #54"!#+ ,/6/,4 #" 2!4%

Ì>VÌ ÀÊ À ÛiÀÊ*>À> iÌiÀÃ

#/.4!#4 #.42, #/.4 05,, ). #/.4 (/,$).'

33 $%,!9 ).4%2,/#+ $,9 02%#(!2'%

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C15

C16

ELECTRICAL CONTROL AND ADJUSTMENT

-«ii`Ê*>À> iÌiÀÃ 4HE CONTROLLER CAN ACCEPT INPUTS FROM UP TO FOUR INDIVIDUAL SPEED SELECT SWITCHES 33 n33 AND FROM AN ANALOG THROTTLE 4HE CONTROLLER ADJUSTS THE PUMP MOTOR S 07- OUTPUT IN RESPONSE TO THESE INPUTS USING THE ALGORITHM PRESCRIBED BY THE PROGRAMMED ACCELERATION RATE TO REACH THE APPROPRIATE MAXIMUM SPEED 4HE PROGRAMMED -INIMUM 3PEED AND !CCELERATION 2ATE ARE IN EFFECT REGARDLESS OF WHETHER THE SPEED REQUEST COMES FROM A SPEED SELECT SWITCH OR A THROTTLE 33 n33 30%%$ 4HE 33 MAXIMUM SPEED PARAMETER DElNES THE MAXIMUM ALLOWED ARMATURE 07- OUTPUT OF THE PUMP MOTOR )T CAN BE SET INDEPENDENTLY FOR UP TO FOUR INDIVIDUAL SPEED SELECT SWITCHES I E 33 30%%$ 33 30%%$ ETC 4HE MAXIMUM SPEED PARAMETER IS ADJUSTABLE FROM TO OF THE FULL OUTPUT 4(24, -!8 30%%$ 4HE THROTTLE MAXIMUM SPEED PARAMETER DElNES THE MAXIMUM ALLOWED ARMATURE 07- OUTPUT IN RESPONSE TO THROTTLE INPUT 4HE MAXIMUM SPEED PARAMETER IS ADJUSTABLE FROM TO OF THE CONTROLLER S FULL OUTPUT

-).)-5- 30%%$ 4HE MINIMUM SPEED PARAMETER DElNES THE MINIMUM ALLOWED ARMATURE 07- OUTPUT OF THE PUMP MOTOR AND IS ADJUSTABLE FROM TO OF THE FULL OUTPUT 4HE MINIMUM SPEED FEATURE ENSURES THAT ADEQUATE PRESSURE IS MAINTAINED FOR THE POWER STEERING SYSTEM AND FOR PUMP LUBRICATION !##%, 2!4%

80

4HE ACCELERATION RATE PARAMETER DElNES THE TIME IT TAKES FOR THE CONTROLLER TO ACCELERATE FROM OUTPUT TO OUTPUT WHEN A SPEED SELECT SWITCH IS CLOSED OR A FULL THROTTLE REQUEST IS MADE 4HE ACCELERATION RATE IS ADJUSTABLE FROM TO SECONDS / À ÌÌ iÊ*>À> iÌiÀÃ -OST APPLICATIONS USE A THROTTLE TO PROVIDE VARIABLE SPEED CONTROL OF A SPECIlC HYDRAU LIC OPERATION E G LIFT REACH TILT SHIFT ROTATE ! THROTTLE GIVES THE OPERATOR MORE mEXIBILITY AND CONTROL OVER PERFORMANCE THAN IS PROVIDED BY SWITCH INPUTS 4(2/44,% 490% 4HE CONTROLLER ACCEPTS A VARIETY OF THROTTLE INPUTS INCLUDING KΩn AND n KΩ TWO WIRE RHEOSTATS WIRE POTS AND n 6 THROTTLES 4HE STANDARD THROTTLE INPUT SIGNAL TYPE OPTIONS 4YPES h v THROUGH h v IN THE 0ROGRAM -ENU ARE

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C17

LISTED IN 4ABLE 7IRING INFORMATION AND PERFORMANCE CHARACTERISTICS FOR EACH TYPE ARE PRESENTED IN 3ECTION )F NO THROTTLE IS USED IN THE APPLICATION THE THROTTLE FAULT PARAMETER SEE PAGE SHOULD BE PROGRAMMED /FF OTHERWISE THE CONTROLLER WILL REGISTER A THROTTLE FAULT 4ABLE 02/'2!--!",% 4(2/44,% ).054 3)'.!, 490%3

4(2/44,% 490%

$%3#2)04)/.

n KΩ WIRE RHEOSTAT

KΩn WIRE RHEOSTAT

SINGLE ENDED n 6 INPUT

SINGLE ENDED WIRE POTENTIOMETER KΩ TO KΩ RANGE

4(24, $%!$"!.$ 4HE THROTTLE DEADBAND PARAMETER DElNES THE POT WIPER VOLTAGE RANGE THE CON TROLLER INTERPRETS AS NEUTRAL )NCREASING THE THROTTLE DEADBAND SETTING INCREASES THE NEUTRAL RANGE 4HIS PARAMETER IS ESPECIALLY USEFUL WITH THROTTLE ASSEMBLIES THAT DO NOT RELIABLY RETURN TO A WELL DElNED NEUTRAL POINT BECAUSE IT ALLOWS THE &IG %FFECT OF ADJUSTING

80

THE THROTTLE DEADBAND PARAMETER THROTTLE TYPES AND

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ELECTRICAL CONTROL AND ADJUSTMENT

&IG CONT D %FFECT OF

ADJUSTING THE THROTTLE DEADBAND PARAMETER THROTTLE TYPES AND

DEADBAND TO BE DElNED WIDE ENOUGH TO ENSURE THAT THE CONTROLLER GOES INTO NEUTRAL WHEN THE THROTTLE MECHANISM IS RELEASED %XAMPLES OF DEADBAND SETTINGS

ARE SHOWN IN &IGURE FOR THROTTLE TYPES THROUGH USING A NOMINAL KΩn POTENTIOMETER WHERE APPLICABLE 4HE PROGRAMMER DISPLAYS THE THROTTLE DEADBAND PARAMETER AS A PERCENT AGE OF THE NOMINAL WIPER VOLTAGE RANGE AND IS ADJUSTABLE FROM TO

IN INCREMENTS 4HE DEFAULT DEADBAND SETTING IS 4HE NOMINAL WIPER VOLTAGE RANGE DEPENDS ON THE THROTTLE TYPE SELECTED 3EE 4ABLE PAGE FOR THE CHARACTERISTICS OF YOUR SELECTED THROTTLE TYPE

4(2/44,% -!8

80

4HE THROTTLE MAX PARAMETER SETS THE THROTTLE WIPER VOLTAGE REQUIRED TO PRODUCE CONTROLLER OUTPUT $ECREASING THE THROTTLE MAX SETTING REDUCES THE WIPER VOLTAGE AND THEREFORE THE FULL STROKE NECESSARY TO PRODUCE FULL CONTROLLER OUTPUT 4HIS FEATURE ALLOWS REDUCED RANGE THROTTLE ASSEMBLIES TO BE ACCOMMODATED %XAMPLES ARE SHOWN IN &IGURE FOR THROTTLE TYPES THROUGH USING A NOMINAL KΩ POTENTIOMETER WHERE APPLICABLE 4HESE EXAMPLES ILLUSTRATE THE EFFECT OF THREE DIFFERENT MAX OUTPUT SETTINGS

ON THE FULL STROKE WIPER VOLTAGE REQUIRED TO ATTAIN CONTROLLER OUTPUT 4HE PROGRAMMER DISPLAYS THROTTLE MAX AS A PERCENTAGE OF THE THROTTLE S ACTIVE VOLTAGE RANGE 4HE NOMINAL VOLTAGE RANGE DEPENDS ON THE THROTTLE TYPE SELECTED 3EE 4ABLE PAGE FOR THE CHARACTERISTICS OF YOUR SELECTED THROTTLE TYPE 4HE THROTTLE MAX PARAMETER CAN BE ADJUSTED FROM TO IN INCREMENTS

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ELECTRICAL CONTROL AND ADJUSTMENT

C19

&IG %FFECT OF ADJUSTING

80

THE THROTTLE MAX PARAMETER

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C20

ELECTRICAL CONTROL AND ADJUSTMENT

4(2/44,% -!0 4HE THROTTLE MAP PARAMETER MODIlES THE RESPONSE TO THE THROTTLE INPUT 4HIS PARAMETER DETERMINES THE CONTROLLER OUTPUT FOR A GIVEN AMOUNT OF APPLIED THROTTLE 3ETTING THE THROTTLE MAP PARAMETER AT PROVIDES A LINEAR OUTPUT RESPONSE TO THROTTLE POSITION 6ALUES BELOW REDUCE THE CONTROLLER OUTPUT AT LOW THROTTLE REQUESTS PROVIDING ENHANCED SLOW SPEED CONTROL 6ALUES ABOVE GIVE THE FUNCTION A FASTER JUMPIER FEEL AT LOW THROTTLE REQUESTS 4HE THROTTLE MAP CAN BE PROGRAMMED IN INCREMENTS BETWEEN AND 4HE NUMBER REFERS TO THE CONTROLLER OUTPUT AT HALF THROTTLE AS A PERCENT AGE OF THE THROTTLE S FULL ACTIVE RANGE 4HE THROTTLE S ACTIVE RANGE IS THE VOLTAGE OR RESISTANCE BETWEEN THE OUTPUT POINT THROTTLE DEADBAND AND THE OUTPUT POINT THROTTLE MAX &OR EXAMPLE IF MAXIMUM SPEED IS SET AT

A THROTTLE MAP SETTING OF WILL GIVE OUTPUT AT HALF THROTTLE 4HE SETTING CORRESPONDS TO A LINEAR RESPONSE 3IX THROTTLE MAP PROlLES

AND ARE SHOWN AS EXAMPLES IN &IGURE WITH THE MAXIMUM SPEED SET AT &IG 4HROTTLE MAPS FOR

CONTROLLER WITH MAXIMUM SPEED SET AT

80

,OWERING THE MAX SPEED LIMITS THE CONTROLLER S OUTPUT RANGE 4HROTTLE MAP PROlLES WITH THE MAX SPEED REDUCED FROM TO ARE SHOWN IN &IGURE 4HE THROTTLE MAP IS ALWAYS A PERCENTAGE OF THE CONTROLLER S OUTPUT RANGE 3O IN THESE EXAMPLES THE THROTTLE MAP IS A PERCENTAGE OF THE n OUTPUT RANGE A THROTTLE MAP SETTING WILL GIVE OUTPUT AT HALF THROTTLE OF #ONTROLLER OUTPUT WILL BEGIN TO INCREASE AS SOON AS THE THROTTLE IS ROTATED OUT OF ITS NORMAL NEUTRAL RANGE DEADBAND #ONTROLLER OUTPUT WILL CONTINUE TO INCREASE FOLLOWING THE CURVE DElNED BY THE THROTTLE MAP SETTING AS THE THROTTLE INPUT INCREASES AND WILL REACH MAXIMUM OUTPUT WHEN THE THROTTLE INPUT ENTERS THE UPPER DEADBAND CROSSES THE THROTTLE MAX THRESHOLD

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C21

&IG 4HROTTLE MAPS FOR

CONTROLLER WITH MAXIMUM SPEED SET AT

4HE 4HROTTLE -AP OPERATES WITHIN THE WINDOW ESTABLISHED BY THE 4HROTTLE -AX 3PEED 4HROTTLE $EADBAND AND 4HROTTLE -AX PARAMETERS AS SHOWN BELOW IN &IGURE 4HROTTLE -AX 3PEED DElNES THE CONTROLLER S OUTPUT RANGE WHILE 4HROTTLE $EADBAND AND 4HROTTLE -AX DElNE THE THROTTLE S ACTIVE RANGE 4HESE THREE PARAMETERS TOGETHER WITH THE 4HROTTLE -AP DETERMINE THE CONTROLLER S OUTPUT RESPONSE TO THROTTLE DEMAND &IG )NmUENCE OF VARIOUS

80

PARAMETERS ON CONTROLLER OUTPUT RESPONSE TO THROTTLE DEMAND

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C22

ELECTRICAL CONTROL AND ADJUSTMENT

> Ê-«ii`Ê,iµÕiÃÌÊ*>À> iÌiÀÃ 4HE lNAL SPEED REQUEST PARAMETERS DElNE HOW THE CONTROLLER WILL HANDLE MULTIPLE REQUESTS FROM MORE THAN ONE SPEED SELECT SWITCH OR FROM A COMBINATION OF SPEED SELECT SWITCHES AND THE THROTTLE )T IS THIS SINGLE lNAL CALCULATED SPEED THAT IS DEMANDED OF THE PUMP MOTOR 7HEN MULTIPLE REQUESTS ARE RECEIVED THE CONTROLLER CAN ADD THEM hADD MODEv OR ACCEPT ONLY THE lRST REQUEST hlRST ON MODEv DEPENDING ON HOW THE !DD -ODE PARAMETERS ARE SET 33 !$$ -/$%

80

4HE SPEED SELECT !DD -ODE PARAMETER ENABLES !DD -ODE FOR SPEED SELECT SWITCHES 33 n33 !DD -ODE IS ENABLED OR DISABLED PROGRAMMED /N OR /FF FOR ALL FOUR SWITCHES AS A GROUP 7HEN 33 !DD -ODE IS /FF THE CONTROLLER RESPONDS TO THE lRST REQUEST IT RECEIVES AND IGNORES OR hLOCKS OUTv ANY SUBSEQUENT REQUESTS THIS IS CALLED h&IRST /N -ODE v )F 33 IS THE lRST SPEED SELECT SWITCH TO BE CLOSED THE CONTROLLER ACCELERATES TO THE PROGRAMMED 33 MAXIMUM OUTPUT )F 33 IS THEN CLOSED THE CONTROLLER OUTPUT AND THE PUMP SPEED REMAIN THE SAME AND THE 33 OPERATION IS SLOWED BECAUSE IT MUST SHARE THE AVAILABLE HYDRAULIC PRESSURE WITH THE 33 OPERATION )F TWO OR MORE SPEED SELECT SWITCHES ARE CLOSED SIMULTANEOUSLY THE CONTROLLER RESPONDS TO THE LOWEST NUMBERED SWITCH I E 33 TAKES PRECEDENCE OVER 33 ETC 7HEN 33 !DD -ODE IS /N THE CONTROLLER INCREASES THE PUMP SPEED IN ORDER TO MAINTAIN THE LEVEL OF WORK REQUESTED BY EACH SPEED SELECT SWITCH INPUT THIS IS CALLED h!DD -ODE v BECAUSE THE INDIVIDUAL REQUESTS ARE ADDED TOGETHER )F 33 IS THE lRST SPEED SELECT SWITCH TO BE CLOSED THE CONTROLLER ACCELERATES TO THE PROGRAMMED 33 MAXIMUM OUTPUT )F 33 IS THEN CLOSED THE CONTROLLER OUTPUT AND THE PUMP SPEED INCREASE SO THAT EACH OPERATION IS PERFORMED AT THE SAME LEVEL OF EFFORT AS IF IT WERE OPERATING ALONE 4HE CONTROLLER SENDS THE PUMP THE REQUIRED AMOUNT OF POWER UP TO OF MAXIMUM OUTPUT TO PROVIDE ENOUGH HYDRAULIC PRESSURE TO PERFORM ALL THE REQUESTED OPERATIONS AT THEIR INDIVIDUALLY SPECIlED MAXIMUM SPEEDS

&).!, !$$ -/$% 4YPICALLY SOME OPERATIONS ARE CONTROLLED BY SPEED SELECT SWITCHES AND OTHERS BY THE THROTTLE 4HE &INAL !DD -ODE PARAMETER DETERMINES WHETHER THE CONTROLLER WILL RESPOND TO THE lRST REQUEST IT RECEIVES EITHER THE 33 REQUEST OR THE THROTTLE REQUEST OR WHETHER IT WILL ADD THEM )F &INAL !DD -ODE IS PROGRAMMED /FF

THE PUMP SPEED WILL BE DElNED BY THE lRST REQUEST IT RECEIVES 33 OR THROTTLE

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ELECTRICAL CONTROL AND ADJUSTMENT

C23

)F &INAL !DD -ODE IS PROGRAMMED /N THE CONTROLLER WILL SUM THE TWO REQUESTS UP TO OUTPUT 4HE hlNALv SPEED REQUEST THAT IS SENT TO THE MOTOR IS OF COURSE TEMPORARY THE lNAL REQUEST IS CONSTANTLY RECALCULATED IN RESPONSE TO CHANGES IN THE INPUTS 3PEED CONDITIONING IS SHOWN IN DETAIL IN &IGURE

80

&IG 3PEED CONDITIONING DIAGRAM

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C24

ELECTRICAL CONTROL AND ADJUSTMENT

>Õ ÌÊ*>À> iÌiÀÃ ,/#+/54 490% 4HE ,IFT LOCKOUT TYPE PARAMETER DElNES HOW THE CONTROLLER WILL INTERPRET THE LIFT LOCKOUT INPUT SIGNAL AT 0IN * 4HE LOCKOUT TYPE OPTIONS 4YPES h v THROUGH h v IN THE 0ROGRAM -ENU ARE LISTED IN 4ABLE 4ABLE 02/'2!--!",% ,)&4 ,/#+/54 3)'.!, 490%3

,/#+/54 490%

$%3#2)04)/.

,OW ENABLE LOCKOUT (IGH /PEN DISABLE LOCKOUT

#URTIS #URTIS EN'AGE­ )6

(IGH /PEN ENABLE LOCKOUT ,OW DISABLE LOCKOUT

#URTIS #URTIS 3UPERSPY

(IGH ENABLE LOCKOUT ,OW /PEN DISABLE LOCKOUT

,OW /PEN ENABLE LOCKOUT (IGH DISABLE LOCKOUT

!00,)#!4)/.

4HE LOCKOUT TYPE SHOULD BE PROGRAMMED APPROPRIATELY FOR THE GAUGE YOU ARE USING TO PROVIDE LIFT LOCKOUT 7ITH THE #URTIS AND EN'AGE­ )6 SET THE LOCKOUT TYPE TO 7ITH THE #URTIS AND h3UPERSPY v SET THE LOCKOUT TYPE TO 4HE OTHER TWO TYPES ARE AVAILABLE FOR OTHER SYSTEM CONlGURATIONS ,)&4 ,/#+ 33 n33

80

4HE ,IFT LOCKOUT FEATURE IS DESIGNED TO PREVENT ,IFT OPERATION DURING UNDERVOLT AGE CONDITIONS 4HE 33 LIFT LOCKOUT PARAMETER CAN BE PROGRAMMED /N OR /FF INDEPENDENTLY FOR EACH OF THE SPEED SELECT SWITCHES 7HEN PROGRAMMED /N IF 0IN * RECEIVES AN ENABLE LOCKOUT SIGNAL DURING A ,IFT OPERATION THE ,IFT IN PROGRESS WILL BE COMPLETED BUT FURTHER ,IFT REQUESTS WILL BE IGNORED AS LONG AS THE LOCKOUT ENABLE SIGNAL IS PRESENT )F PROGRAMMED /FF THE ,IFT WILL CONTINUE TO OPERATE JUST AS IF 0IN * WERE NOT RECEIVING A LOCKOUT SIGNAL 7HEN 33 IS USED FOR POWER STEERING 07- OUTPUT WILL BE SHUT DOWN WHEN LIFT LOCKOUT IS ACTIVATED )F YOU DO NOT WANT LOW BATTERY LOCKOUT OF POWER STEERING 33 LIFT LOCKOUT SHOULD BE PROGRAMMED /FF 4(24, ,)&4,/#+ 4HE 4HROTTLE LIFT LOCKOUT PARAMETER CAN BE PROGRAMMED /N OR /FF AND WORKS JUST LIKE 33 LIFT LOCKOUT 7HEN PROGRAMMED /N IF 0IN * RECEIVES AN ENABLE LOCKOUT SIGNAL DURING A ,IFT OPERATION THE ,IFT IN PROGRESS WILL BE COMPLETED BUT FURTHER ,IFT REQUESTS WILL BE IGNORED AS LONG AS THE LOCKOUT ENABLE SIGNAL IS PRESENT )F PROGRAMMED /FF THE ,IFT WILL CONTINUE TO OPERATE JUST AS IF 0IN * WERE NOT RECEIVING A LOCKOUT SIGNAL

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ELECTRICAL CONTROL AND ADJUSTMENT

C25

4(24, &!5,4 7HEN THE THROTTLE FAULT PARAMETER IS PROGRAMMED /N THE ISSUES A FAULT IF THERE IS A PROBLEM WITH THE THROTTLE OR ITS WIRING 4HIS PARAMETER SHOULD BE PROGRAMMED /FF IF THERE IS NO THROTTLE IN THE SYSTEM TO PREVENT A THROTTLE FAULT FROM BEING ISSUED ON A NONEXISTENT THROTTLE 2EGARDLESS OF HOW THE THROTTLE FAULT PARAMETER IS SET IF THERE IS NO CON NECTION TO THE THROTTLE THE THROTTLE INPUT IS ASSUMED TO BE ZERO )F THE THROTTLE FAULT PARAMETER IS PROGRAMMED /FF THE THROTTLE INPUT IS ASSUMED TO BE ZERO EVEN IF A THROTTLE IS CONNECTED 34!2450 ,/#+/54 4HE STARTUP LOCKOUT FEATURE PREVENTS THE PUMP MOTOR FROM RUNNING IF ANY OF THE SPEED SELECT INPUTS 33 n33 IS HIGH OR THE THROTTLE INPUT IS OUTSIDE THE NEUTRAL DEADBAND WHEN THE CONTROLLER IS TURNED ON 4HE STARTUP LOCKOUT PARAMETER IS USED TO SET THE TYPE OF LOCKOUT 4WO TYPES OF LOCKOUT ARE AVAILABLE LOCKOUT ON +3) INPUT ALONE OR LOCKOUT ON +3) PLUS INTERLOCK INPUTS 3TARTUP LOCKOUT CAN ALSO BE DISABLED .O 3TARTUP ,OCKOUT 4YPE

3TARTUP LOCKOUT FUNCTION IS DISABLED

4O START THE PUMP MOTOR THE CONTROLLER MUST RECEIVE A +3) INPUT BEFORE RECEIVING A SPEED SELECT INPUT OR A THROTTLE INPUT OUTSIDE THE NEUTRAL DEADBAND #ONTROLLER OPERATION WILL BE DISABLED IMMEDIATELY IF AN INAPPROPRIATE SPEED REQUEST IS ACTIVE AT THE TIME +3) IS ENABLED AND A SEQUENCE ERROR FAULT WILL BE DECLARED )F THE INAPPROPRIATE SPEED REQUEST IS RECEIVED BEFORE THE INTERLOCK SWITCH IS CLOSED BUT AFTER THE +3) INPUT HAS BEEN ENABLED THE MOTOR WILL ACCELERATE TO THE REQUESTED SPEED AS SOON AS THE INTERLOCK SWITCH IS CLOSED .ORMAL OPERATION IS REGAINED BY REDUCING ANY THROTTLE REQUEST TO WITHIN THE NEUTRAL DEADBAND AND OPENING ANY SPEED SELECT SWITCHES THAT WERE ALREADY CLOSED )NTERLOCK TYPE 3TARTUP ,OCKOUT 4YPE

4O START THE PUMP MOTOR THE CONTROLLER MUST RECEIVE AN INTERLOCK SWITCH INPUT IN ADDITION TO A +3) INPUT BEFORE RECEIVING A SPEED SELECT INPUT OR A THROTTLE INPUT OUTSIDE THE NEUTRAL DEADBAND #ONTROLLER OPERATION WILL BE DISABLED IM MEDIATELY IF AN INAPPROPRIATE SPEED REQUEST IS ACTIVE AT THE TIME THE INTERLOCK SWITCH IS CLOSED AND A SEQUENCE ERROR FAULT WILL BE DECLARED .ORMAL OPERATION IS REGAINED BY REDUCING ANY THROTTLE REQUESTS TO WITHIN THE NEUTRAL DEADBAND AND OPENING ANY SPEED SELECT SWITCHES THAT WERE ALREADY CLOSED

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+3) TYPE 3TARTUP ,OCKOUT 4YPE

C26

ELECTRICAL CONTROL AND ADJUSTMENT

1 `iÀÛ Ì>}iÊ*>À> iÌiÀÃ ,/6/,4 #54"!#+ 4HE LOW VOLTAGE CUTBACK PARAMETER SETS THE UNDERVOLTAGE THRESHOLD !T THIS THRESHOLD VOLTAGE THE OUTPUT CURRENT STARTS TO TAPER OFF /UTPUT CURRENT IS REDUCED UNTIL REACHING ZERO AT THE RATE ESTABLISHED BY THE LOW VOLTAGE CUTBACK RATE PARAMETER SEE BELOW ,OW VOLTAGE CUTBACK CAN BE SET FROM n 6 FOR 6 MODELS AND FROM n 6 FOR 6 MODELS ,/6/,4 #" 2!4% 4HE LOW VOLTAGE CUTBACK RATE PARAMETER DETERMINES HOW SHARPLY THE CURRENT LIMIT DECREASES WHEN THE BATTERY VOLTAGE FALLS BELOW THE UNDERVOLTAGE THRESHOLD SEE ABOVE 4HE LOW VOLTAGE CUTBACK RATE CAN BE SET FROM TO WITH CUTBACK RESPONSE BEING MORE GRADUAL AT LOWER VALUES AND MORE ABRUPT AT HIGHER VALUES ! SETTING OF DISABLES THE CUTBACK FUNCTION ENTIRELY THIS IS NOT RECOMMENDED

AS THE CUTBACK FUNCTION PROTECTS THE SYSTEM FROM OPERATING AT VOLTAGES LOWER THAN ITS ELECTRONICS WERE DESIGNED FOR

Ì>VÌ ÀÊ ÌÀ Ê*>À> iÌiÀÃ #/.4!#4 #.42, 4HE MAIN CONTACTOR CONTROL PARAMETER IS PROGRAMMED TO CORRESPOND TO THE WAY THE CONTACTOR IS WIRED )F THE CONTACTOR IS PART OF THE CIRCUIT THIS PARAMETER SHOULD BE PROGRAMMED /N )F THE CONTACTOR IS CONTROLLED EXTERNALLY

THIS PARAMETER SHOULD BE PROGRAMMED /FF #/.4 05,, ).

80

4HE MAIN CONTACTOR PULL IN VOLTAGE PARAMETER ALLOWS A HIGH INITIAL VOLTAGE WHEN THE CONTACTOR DRIVER lRST TURNS ON TO ENSURE CONTACTOR CLOSURE !FTER THE CONTROLLER DETECTS THAT THE CONTACTOR IS CLOSED THIS PEAK VOLTAGE WILL BE APPLIED FOR SECOND TO ENSURE A RELIABLE CLOSE THE VOLTAGE WILL THEN DROP TO THE PRO GRAMMED CONTACTOR HOLDING VOLTAGE SEE BELOW &OR 6 MODELS THE PULL IN VOLTAGE CAN BE SET FROM n 6 &OR 6 MODELS THE RANGE IS n 6 #/.4 (/,$).'

4HE CONTACTOR HOLDING VOLTAGE PARAMETER ALLOWS A REDUCED AVERAGE VOLTAGE TO BE APPLIED TO THE CONTACTOR COIL ONCE IT HAS CLOSED 4HE HOLDING VOLTAGE MUST BE SET HIGH ENOUGH TO HOLD THE CONTACTOR CLOSED UNDER ALL SHOCK AND VIBRATION CONDITIONS IT WILL BE SUBJECTED TO &OR 6 MODELS THE CONTACTOR HOLDING VOLTAGE RANGE IS n 6 WITH 6 BEING THE TYPICAL DEFAULT SETTING &OR 6 MODELS THE RANGE IS n 6

WITH 6 BEING THE TYPICAL DEFAULT SETTING

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ELECTRICAL CONTROL AND ADJUSTMENT

C27

33 $%,!9 4HE 33 DELAY PARAMETER CAN BE SET TO ALLOW THE 33 OUTPUT TO CONTINUE FOR A PERIOD OF TIME AFTER THE 33 SWITCH IS OPENED 4HE DELAY IS USEFUL FOR MAINTAINING POWER TO AUXILIARY FUNCTIONS SUCH AS A STEERING PUMP MOTOR THAT MAY BE USED FOR A SHORT TIME AFTER THE OPERATOR HAS GOTTEN UP FROM THE SEAT 4HE 33 DELAY CAN BE SET FROM TO SECONDS WITH CORRESPONDING TO NO DELAY

).4%2,/#+ $%,!9 4HE INTERLOCK DELAY PARAMETER CAN BE SET TO ALLOW THE 07- OUTPUT TO CONTINUE FOR A PERIOD OF TIME THE INTERLOCK DELAY AFTER THE INTERLOCK SWITCH IS OPENED 4HE DELAY IS USEFUL FOR MAINTAINING POWER TO AUXILIARY FUNCTIONS SUCH AS A STEERING PUMP MOTOR THAT MAY BE USED FOR A SHORT TIME AFTER THE OPERATOR HAS GOTTEN UP FROM THE SEAT 4HE INTERLOCK DELAY CAN BE SET FROM TO SECONDS WITH CORRESPONDING TO NO DELAY

02%#(!2'% 4HE PRECHARGE PARAMETER ENABLES OR DISABLES THE PRECHARGE FUNCTION 0RECHARGE PROVIDES A LIMITED CURRENT CHARGE OF THE CONTROLLER S INTERNAL CAPACITOR BANK BEFORE THE MAIN CONTACTOR IS CLOSED 4HIS DECREASES THE ARCING THAT WOULD OTHERWISE OCCUR WHEN THE CONTACTOR IS CLOSED WITH THE CAPACITOR BANK DISCHARGED 0RECHARGING AND THE PRECHARGE FAULT DETECTION DEPEND ON THE SETTING OF BOTH THE PRECHARGE AND THE CONTACTOR CONTROL PARAMETERS AS SHOWN IN 4ABLE 4ABLE 02%#(!2'% &5.#4)/. !.$ &!5,4 $%4%#4)/.

0!2!-%4%2 3%44).'

02%#(!2'% #/.4!#4 #.42,

02%#(!2'% 0%2&/2-%$

02%#(!2'% &!5,4 $%4%#4)/.

(10/4/2013)

/.

/.

9%3

9%3

/.

OFF

9%3

9%3

OFF

/.

NO

NO

OFF

OFF

9%3

NO

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C28

ELECTRICAL CONTROL AND ADJUSTMENT

).34!,,!4)/. #(%#+/54 #AREFULLY COMPLETE THE FOLLOWING CHECKOUT PROCEDURE BEFORE OPERATING THE HYDRAULIC SYSTEM )F YOU lND A PROBLEM DURING THE CHECKOUT REFER TO THE DIAG NOSTICS AND TROUBLESHOOTING SECTION 3ECTION FOR FURTHER INFORMATION 4HE INSTALLATION CHECKOUT IS TYPICALLY CONDUCTED WITH THE HANDHELD PRO GRAMMER /THERWISE IF YOU HAVE CONNECTED AN EXTERNAL 3TATUS ,%$ TO 0IN *

YOU CAN OBSERVE THIS ,%$ FOR FAULT CODES THE CODES ARE LISTED IN 3ECTION "EFORE STARTING THE PROCEDURE CHECK THAT THE HYDRAULIC HOSES ARE SECURE

AND THE SYSTEM PRIMED WITH OIL

# !5 4 ) / .

$RIVE THE VEHICLE TO A LOCATION THAT WILL PROVIDE ENOUGH ROOM FOR ALL THE HYDRAULIC FUNCTIONS TO BE TESTED IF INDOORS

BE SURE THE CEILING HEIGHT IS ADEQUATE $O NOT STAND OR ALLOW ANYONE ELSE TO STAND DIRECTLY IN FRONT OF OR BESIDE THE VEHICLE DURING THE CHECKOUT -AKE SURE THE KEYSWITCH IS OFF THE THROTTLES ARE IN NEUTRAL

AND ALL THE HYDRAULIC SYSTEM SWITCHES ,IFT ,OWER 2EACH

4ILT 3HIFT 2OTATE ETC ARE OPEN 7EAR SAFETY GLASSES AND USE WELL INSULATED TOOLS

)F A PROGRAMMER IS AVAILABLE CONNECT IT TO THE PROGRAMMER CONNEC TOR

80

4URN THE KEYSWITCH ON 4HE CONTROLLER SHOULD POWER UP THE PROGRAM MER SHOULD PRESENT AN INITIAL DISPLAY AND THE 3TATUS ,%$ SHOULD BEGIN BLINKING A SINGLE mASH

)F NOT CHECK FOR CONTINUITY IN THE KEYSWITCH CIRCUIT AND CONTROLLER GROUND )F YOU ARE USING A PROGRAMMER SCROLL TO THE &AULTS -ENU 4HE DISPLAY SHOULD INDICATE h.O +NOWN &AULTS v #LOSE THE INTERLOCK SWITCH IF ONE IS USED IN YOUR APPLICATION 4HE 3TATUS ,%$ SHOULD CONTINUE BLINKING A SINGLE mASH AND THE PROGRAMMER SHOULD CONTINUE TO INDICATE NO FAULTS

)F THERE IS A PROBLEM THE ,%$ WILL mASH A FAULT CODE AND THE PRO GRAMMER WILL DISPLAY A FAULT MESSAGE )F YOU ARE CONDUCTING THE CHECKOUT WITHOUT A PROGRAMMER LOOK UP THE ,%$ FAULT CODE IN 3ECTION

7HEN THE PROBLEM HAS BEEN CORRECTED IT MAY BE NECESSARY TO CYCLE THE KEYSWITCH IN ORDER TO CLEAR THE FAULT )F YOU ARE USING A PROGRAMMER SCROLL TO THE -ONITOR -ENU 3CROLL DOWN TO OBSERVE THE STATUS OF THE INTERLOCK AND FOUR SPEED SELECT SWITCHES

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C29

33 n33 #YCLE EACH SWITCH IN TURN OBSERVING THE PROGRAMMER 4HE PROGRAMMER SHOULD DISPLAY THE CORRECT STATUS FOR EACH SWITCH 5SE THE THROTTLE TO OPERATE THE PUMP MOTOR )T SHOULD ACCELERATE SMOOTHLY 6ERIFY THAT 3TARTUP ,OCKOUT PERFORMS AS DESIRED 2EQUEST MULTIPLE OPERATIONS IN VARIOUS COMBINATIONS TO CONlRM THAT MOTOR SPEED RESPONDS ACCORDING TO THE SETTINGS YOU MADE FOR THE 33 !DD -ODE AND &INAL !DD -ODE PARAMETERS )F YOU USED A PROGRAMMER DISCONNECT IT WHEN YOU HAVE COMPLETED THE CHECKOUT PROCEDURE

"%.#( 4%34).' 7)4( 4(% 02/'2!--%2 7ITH THE SIMPLE BENCH TEST SETUP SHOWN IN &IGURE THE CONTROLLER PARAMETERS CAN BE VERIlED OR ADJUSTED WITHOUT THE CONTROLLER BEING WIRED INTO A VEHICLE 4HE COMPLETE IN VEHICLE INSTALLATION CHECKOUT AS DESCRIBED ABOVE IN 3TEPS n SHOULD STILL BE CONDUCTED BEFORE THE VEHICLE IS OPERATED &IG "ENCH TEST SETUP

80

FOR VERIFYING AND ADJUSTING THE CONTROLLER S PARAMETERS

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C30

ELECTRICAL CONTROL AND ADJUSTMENT

$)!'./34)#3 !.$ 42/5",%3(//4).'

4HE CONTROLLER PROVIDES DIAGNOSTICS INFORMATION TO ASSIST TECHNICIANS IN TROUBLESHOOTING PUMP SYSTEM PROBLEMS 4HE DIAGNOSTICS INFORMATION CAN BE OBTAINED BY OBSERVING THE APPROPRIATE DISPLAY ON THE HANDHELD PROGRAMMER OR THE FAULT CODES ISSUED BY THE OPTIONAL 3TATUS ,%$ 2EFER TO THE TROUBLESHOOTING CHART 4ABLE FOR SUGGESTIONS COVERING A WIDE RANGE OF POSSIBLE FAULTS 02/'2!--%2 $)!'./34)#3 4HE PROGRAMMER PRESENTS COMPLETE DIAGNOSTIC INFORMATION IN PLAIN LANGUAGE &AULTS ARE DISPLAYED IN THE &AULTS -ENU SEE COLUMN IN THE TROUBLESHOOTING CHART AND THE STATUS OF THE CONTROLLER INPUTS OUTPUTS IS DISPLAYED IN THE -ONI TOR -ENU !CCESSING THE &AULT (ISTORY -ENU PROVIDES A LIST OF THE FAULTS THAT HAVE OCCURRED SINCE THE FAULT HISTORY lLE WAS LAST CLEARED #HECKING AND CLEARING THE FAULT HISTORY lLE IS RECOMMENDED EACH TIME THE VEHICLE IS BROUGHT IN FOR MAINTENANCE 4HE FOLLOWING STEP PROCESS IS RECOMMENDED FOR DIAGNOSING AND TROU BLESHOOTING AN INOPERATIVE PUMP SYSTEM VISUALLY INSPECT THE VEHICLE FOR OBVIOUS PROBLEMS DIAGNOSE THE PROBLEM USING THE PROGRAMMER TEST THE CIRCUITRY WITH THE PROGRAMMER AND CORRECT THE PROBLEM 2EPEAT THE LAST THREE STEPS AS NECESSARY UNTIL THE PUMP SYSTEM IS OPERATIONAL

%XAMPLE ! VEHICLE THAT CANNOT PERFORM THE OPERATION REQUESTED BY

3PEED 3ELECT IS BROUGHT IN FOR REPAIR

34%0

%XAMINE THE VEHICLE AND ITS WIRING FOR ANY OBVIOUS PROBLEMS

SUCH AS BROKEN WIRES OR LOOSE CONNECTIONS

#ONNECT THE PROGRAMMER SELECT THE &AULTS -ENU AND READ THE DISPLAYED FAULT INFORMATION )N THIS EXAMPLE THE DISPLAY SHOWS h.O +NOWN &AULTS v INDICATING THAT THE CONTROLLER HAS NOT DETECTED ANYTHING OUT OF THE NORM

80

34%0

34%0

3ELECT THE -ONITOR -ENU AND OBSERVE THE STATUS OF THE 33 INPUT )N THIS EXAMPLE THE DISPLAY SHOWS THAT THE SWITCH DOES NOT CLOSE WHEN 33 IS SELECTED WHICH MEANS THE PROBLEM IS EITHER IN THE 33 SWITCH OR THE SWITCH WIRING

34%0

#HECK OR REPLACE THE 33 SWITCH AND WIRING AND REPEAT THE TEST )F THE PROGRAMMER SHOWS THE 33 SWITCH CLOSING AND THE SYSTEM NOW OPERATES NORMALLY THE PROBLEM HAS BEEN CORRECTED

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C31

4ABLE 42/5",%3(//4).' #(!24 02/'2!--%2 ,#$ $)30,!9

04'$ņ !|

%80,!.!4)/.

0/33)",% #!53%

%%02/- FAULT .OTE 5SUALLY CAN BE CLEARED BY MODIFYING ANY PARAMETER VALUE IN THE 0ROGRAM -ENU

%%02/- DATA LOST OR DAMAGED %%02/- CHECKSUM ERROR

ņ !5

3ELF TEST OR WATCHDOG FAULT

-/3&%4 SHORTED #ONTROLLER DEFECTIVE

$'|'4ņ5 '4|

-OTOR SHORTED

-OTOR IS SHORTED

% 4 '!| ņ |'

5NDERVOLTAGE CUTOFF

"ATTERY VOLTAGE "6" /Ê 1/" ÊSETTING

! |ņ!' ' |

,IFT OPERATION LOCKED OUT DUE TO UNDERVOLTAGE

#ONTROLLER RECEIVED APPROPRIATE LIFT LOCK OUT SIGNAL )NAPPROPRIATE LIFT LOCKOUT SIGNAL --Ê " "1/ PARAMETER NOT SET CORRECTLY

3TARTUP LOCKOUT

7IPER SIGNAL OUT OF RANGE POT LOW FAULT

4HROTTLE INPUT WIRE OPEN OR SHORTED 4HROTTLE DEFECTIVE / ,"// Ê/9* PARAMETER NOT SET CORRECTLY

-AIN CONTACTOR COIL OVERCURRENT

-AIN CONTACTOR COIL SHORTED #ONTROLLER DEFECTIVE

-AIN CONTACTOR WELDED

-AIN CONTACTOR STUCK CLOSED

" /Ê /, PARAMETER NOT SET CORRECTLY -AIN CONTACTOR DRIVER SHORTED

0RECHARGE FAULT

0RECHARGE CIRCUIT FAILURE %XTERNAL SHORT OR LEAKAGE BETWEEN " AND "

-AIN CONTACTOR DID NOT CLOSE

-AIN CONTACTOR COIL CONNECTION LOOSE -AIN CONTACTOR DID NOT CLOSE

" /Ê /, PARAMETER NOT SET CORRECTLY

,OW BATTERY VOLTAGE

/VERVOLTAGE

"ATTERY VOLTAGE OVERVOLTAGE SHUTDOWN THRESHOLD 6EHICLE OPERATING WITH CHARGER ATTACHED

/VER UNDERTEMPERATURE CUTBACK

5 3 % ņ 44'4

| 4'||! ņ !|

'%|ņ 4 4ņ'

$ %ņ '%|ņ !

04 4 ņ !|

$ %ņ '%|ņ %

!' ņ || 4 ņ '!|

' 4 '!|

| 4$ !ņ |

(10/4/2013)

)MPROPER SEQUENCE OF THROTTLE OR 33 AND +3) OR +3) PLUS INTERLOCK -/ ,/1*Ê " "1/ PARAMETER NOT SET CORRECTLY -ISADJUSTED THROTTLE

"ATTERY VOLTAGE UNDERVOLTAGE CUTBACK THRESHOLD #ORRODED BATTERY TERMINAL ,OOSE BATTERY OR CONTROLLER TERMINAL

4EMPERATURE # OR # %XCESSIVE LOAD ON PUMP MOTOR )MPROPER MOUNTING OF CONTROLLER /PERATION IN EXTREME ENVIRONMENT 4HERMISTOR FAILURE

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,%$ #/$%

C32

ELECTRICAL CONTROL AND ADJUSTMENT

,%$ $)!'./34)#3 4HE CONTROLLER HAS A 3TATUS ,%$ OUTPUT THAT CAN BE USED TO DRIVE AN EX TERNAL ,%$ 4HIS 3TATUS ,%$ DISPLAYS FAULT CODES WHEN THERE IS A PROBLEM WITH THE CONTROLLER OR WITH THE INPUTS TO THE CONTROLLER $URING NORMAL OPERATION

WITH NO FAULTS PRESENT THE 3TATUS ,%$ mASHES STEADILY ON AND OFF )F THE CONTROLLER DETECTS A FAULT A DIGIT FAULT IDENTIlCATION CODE IS mASHED CONTINUOUSLY UNTIL THE FAULT IS CORRECTED &OR EXAMPLE CODE h v WELDED MAIN CONTACTOR APPEARS AS fff ff fff ff fff ff

4HE CODES ARE LISTED IN 4ABLE 4ABLE 34!453 ,%$ &!5,4 #/$%3

80

,%$ #/$%3

%80,!.!4)/.

,%$ OFF SOLID ON

NO POWER OR DEFECTIVE CONTROLLER CONTROLLER OR MICROPROCESSOR FAULT

N

f f f ff f fff f ffff

%%02/- FAULT HARDWARE FAILSAFE FAULT MOTOR SHORTED ;NOT USED=

ff f ff ff ff fff ff ffff

UNDERVOLTAGE LIFT LOCKOUT SEQUENCE ERROR STARTUP LOCKOUT THROTTLE FAULT

fff f fff ff fff fff fff ffff

MAIN CONTACTOR COIL SHORTED WELDED MAIN CONTACTOR PRECHARGE FAULT MAIN CONTACTOR MISSING OR DID NOT CLOSE

ffff f ffff ff ffff fff ffff ffff

LOW BATTERY VOLTAGE OVERVOLTAGE THERMAL CUTBACK DUE TO OVER UNDER TEMP ;NOT USED=

f

CONTROLLER OPERATIONAL NO KNOWN FAULTS

.OTE /NLY ONE FAULT IS INDICATED AT A TIME AND FAULTS ARE NOT QUEUED UP 2EFER TO THE TROUBLESHOOTING CHART 4ABLE FOR SUGGESTIONS ABOUT POSSIBLE CAUSES OF THE VARIOUS FAULTS

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ELECTRICAL CONTROL AND ADJUSTMENT

C33

-!).4%.!.#% 4HERE ARE NO USER SERVICEABLE PARTS IN THE #URTIS CONTROLLER .O ATTEMPT SHOULD BE MADE TO OPEN REPAIR OR OTHERWISE MODIFY THE CONTROLLER $OING SO MAY DAMAGE THE CONTROLLER AND WILL VOID THE WARRANTY )T IS RECOMMENDED THAT THE CONTROLLER BE KEPT CLEAN AND DRY THAT ITS FAULT HISTORY lLE BE CHECKED AND CLEARED PERIODICALLY

#,%!.).'

# !5 4 ) / .

0ERIODICALLY CLEANING THE CONTROLLER EXTERIOR WILL HELP PROTECT IT AGAINST CORROSION AND POSSIBLE ELECTRICAL CONTROL PROBLEMS CREATED BY DIRT GRIME AND CHEMICALS THAT ARE PART OF THE OPERATING ENVIRONMENT AND THAT NORMALLY EXIST IN BATTERY POWERED SYSTEMS 7HEN WORKING AROUND ANY BATTERY POWERED SYSTEM PROPER SAFETY PRECAUTIONS SHOULD BE TAKEN 4HESE INCLUDE BUT ARE NOT LIMITED TO PROPER TRAINING WEARING EYE PROTECTION AND AVOIDING LOOSE CLOTHING AND JEWELRY 5SE THE FOLLOWING CLEANING PROCEDURE FOR ROUTINE MAINTENANCE .EVER USE A HIGH PRESSURE WASHER TO CLEAN THE CONTROLLER 2EMOVE POWER BY DISCONNECTING THE BATTERY $ISCHARGE THE CAPACITORS IN THE CONTROLLER BY CONNECTING A LOAD SUCH AS A CONTACTOR COIL ACROSS THE CONTROLLER S " AND " TERMINALS 2EMOVE ANY DIRT OR CORROSION FROM THE POWER AND SIGNAL CONNECTOR AREAS 4HE CONTROLLER SHOULD BE WIPED CLEAN WITH A MOIST RAG $RY IT BEFORE RECONNECTING THE BATTERY

&!5,4 ()34/29 4HE PROGRAMMER CAN BE USED TO ACCESS THE CONTROLLER S FAULT HISTORY lLE 4HE PROGRAMMER WILL READ OUT ALL THE FAULTS THAT THE CONTROLLER HAS EXPERIENCED SINCE THE LAST TIME THE FAULT HISTORY lLE WAS CLEARED 4HE FAULTS MAY BE INTERMITTENT FAULTS FAULTS CAUSED BY LOOSE WIRES OR FAULTS CAUSED BY OPERATOR ERRORS &AULTS SUCH AS CONTACTOR FAULTS MAY BE THE RESULT OF LOOSE WIRES CONTACTOR WIRING SHOULD BE CAREFULLY CHECKED &AULTS SUCH AS STARTUP LOCKOUT OR OVERTEMPERATURE MAY BE CAUSED BY OPERATOR HABITS OR BY OVERLOADING !FTER A PROBLEM HAS BEEN DIAGNOSED AND CORRECTED IT IS A GOOD IDEA TO CLEAR THE DIAGNOSTIC HISTORY lLE 4HIS ALLOWS THE CONTROLLER TO ACCUMULATE A NEW lLE OF FAULTS "Y CHECKING THE NEW FAULT HISTORY lLE AT A LATER DATE YOU CAN READILY DETERMINE WHETHER THE PROBLEM WAS INDEED lXED

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-AKE SURE THE CONNECTIONS ARE TIGHT

ELECTRICAL CONTROL AND ADJUSTMENT

80

C34

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ELECTRICAL CONTROL AND ADJUSTMENT

C35

!00%.$)8 !

6%()#,% $%3)'. #/.3)$%2!4)/.3 2%'!2$).' %,%#42/-!'.%4)# #/-0!4)"),)49 %-# !.$ %,%#42/34!4)# $)3#(!2'% %3$

%,%#42/-!'.%4)# #/-0!4)"),)49 %-# %LECTROMAGNETIC COMPATIBILITY %-# ENCOMPASSES TWO AREAS EMISSIONS AND IMMUNITY %MISSIONS ARE RADIO FREQUENCY 2& ENERGY GENERATED BY A PRODUCT 4HIS ENERGY HAS THE POTENTIAL TO INTERFERE WITH COMMUNICATIONS SYSTEMS SUCH AS RADIO TELEVISION CELLULAR PHONES DISPATCHING AIRCRAFT ETC )MMUNITY IS THE ABILITY OF A PRODUCT TO OPERATE NORMALLY IN THE PRESENCE OF 2& ENERGY %-# IS ULTIMATELY A SYSTEM DESIGN ISSUE 0ART OF THE %-# PERFORMANCE IS DESIGNED INTO OR INHERENT IN EACH COMPONENT ANOTHER PART IS DESIGNED INTO OR INHERENT IN END PRODUCT CHARACTERISTICS SUCH AS SHIELDING WIRING AND LAYOUT AND lNALLY A PORTION IS A FUNCTION OF THE INTERACTIONS BETWEEN ALL THESE PARTS 4HE DESIGN TECHNIQUES PRESENTED BELOW CAN ENHANCE %-# PERFORMANCE IN PRODUCTS THAT USE #URTIS MOTOR CONTROLLERS

3IGNALS WITH HIGH FREQUENCY CONTENT CAN PRODUCE SIGNIlCANT EMISSIONS IF CON NECTED TO A LARGE ENOUGH RADIATING AREA CREATED BY LONG WIRES SPACED FAR APART #ONTACTOR DRIVERS AND THE MOTOR DRIVE OUTPUT FROM #URTIS CONTROLLERS CAN CONTRIBUTE TO 2& EMISSIONS "OTH TYPES OF OUTPUT ARE PULSE WIDTH MODULATED SQUARE WAVES WITH FAST RISE AND FALL TIMES THAT ARE RICH IN HARMONICS .OTE CONTACTOR DRIVERS THAT ARE NOT MODULATED WILL NOT CONTRIBUTE TO EMISSIONS 4HE IMPACT OF THESE SWITCHING WAVEFORMS CAN BE MINIMIZED BY MAKING THE WIRES FROM THE CONTROLLER TO THE CONTACTOR OR MOTOR AS SHORT AS POSSIBLE AND BY PLACING THE WIRES NEAR EACH OTHER BUNDLE CONTACTOR WIRES WITH #OIL 2ETURN BUNDLE MOTOR WIRES SEPARATELY &OR APPLICATIONS REQUIRING VERY LOW EMISSIONS THE SOLUTION MAY INVOLVE ENCLOSING THE CONTROLLER INTERCONNECT WIRES CONTACTORS AND MOTOR TOGETHER IN ONE SHIELDED BOX %MISSIONS CAN ALSO COUPLE TO BATTERY SUPPLY LEADS AND THROTTLE CIRCUIT WIRES OUTSIDE THE BOX SO FERRITE BEADS NEAR THE CONTROLLER MAY ALSO BE REQUIRED ON THESE UNSHIELDED WIRES IN SOME APPLICATIONS )T IS BEST TO KEEP THE NOISY SIGNALS AS FAR AS POSSIBLE FROM SENSITIVE WIRES )MMUNITY )MMUNITY TO RADIATED ELECTRIC lELDS CAN BE IMPROVED EITHER BY REDUCING OVERALL CIRCUIT SENSITIVITY OR BY KEEPING UNDESIRED SIGNALS AWAY FROM THIS CIRCUITRY 4HE CONTROLLER CIRCUITRY ITSELF CANNOT BE MADE LESS SENSITIVE SINCE IT MUST ACCURATELY DETECT AND PROCESS LOW LEVEL SIGNALS FROM SENSORS SUCH AS THE THROTTLE POTENTI OMETER 4HUS IMMUNITY IS GENERALLY ACHIEVED BY PREVENTING THE EXTERNAL 2& ENERGY FROM COUPLING INTO SENSITIVE CIRCUITRY 4HIS 2& ENERGY CAN GET INTO THE CONTROLLER CIRCUITRY VIA CONDUCTED PATHS AND RADIATED PATHS

(10/4/2013)

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80

%MISSIONS

ELECTRICAL CONTROL AND ADJUSTMENT

#ONDUCTED PATHS ARE CREATED BY THE WIRES CONNECTED TO THE CONTROLLER 4HESE WIRES ACT AS ANTENNAS AND THE AMOUNT OF 2& ENERGY COUPLED INTO THEM IS GENERALLY PROPORTIONAL TO THEIR LENGTH 4HE 2& VOLTAGES AND CURRENTS INDUCED IN EACH WIRE ARE APPLIED TO THE CONTROLLER PIN TO WHICH THE WIRE IS CONNECTED #URTIS CONTROLLERS INCLUDE BYPASS CAPACITORS ON THE PRINTED CIRCUIT BOARD S THROTTLE WIRES TO REDUCE THE IMPACT OF THIS 2& ENERGY ON THE INTERNAL CIRCUITRY )N SOME APPLICATIONS ADDITIONAL lLTERING IN THE FORM OF FERRITE BEADS MAY ALSO BE REQUIRED ON VARIOUS WIRES TO ACHIEVE DESIRED PERFORMANCE LEVELS 2ADIATED PATHS ARE CREATED WHEN THE CONTROLLER CIRCUITRY IS IMMERSED IN AN EXTERNAL lELD 4HIS COUPLING CAN BE REDUCED BY PLACING THE CONTROLLER AS FAR AS POSSIBLE FROM THE NOISE SOURCE OR BY ENCLOSING THE CONTROLLER IN A METAL BOX 3OME #URTIS CONTROLLERS ARE ENCLOSED BY A HEATSINK THAT ALSO PROVIDES SHIELDING AROUND THE CONTROLLER CIRCUITRY WHILE OTHERS ARE PARTIALLY SHIELDED OR UNSHIELDED )N SOME APPLICATIONS THE VEHICLE DESIGNER WILL NEED TO MOUNT THE CONTROLLER WITHIN A SHIELDED BOX ON THE END PRODUCT 4HE BOX CAN BE CONSTRUCTED OF JUST ABOUT ANY METAL ALTHOUGH STEEL AND ALUMINUM ARE MOST COMMONLY USED -OST COATED PLASTICS DO NOT PROVIDE GOOD SHIELDING BECAUSE THE COATINGS ARE NOT TRUE METALS BUT RATHER A MIXTURE OF SMALL METAL PARTICLES IN A NON CON DUCTIVE BINDER 4HESE RELATIVELY ISOLATED PARTICLES MAY APPEAR TO BE GOOD BASED ON A DC RESISTANCE MEASUREMENT BUT DO NOT PROVIDE ADEQUATE ELECTRON MOBILITY TO YIELD GOOD SHIELDING EFFECTIVENESS %LECTROLESS PLATING OF PLASTIC WILL YIELD A TRUE METAL AND CAN THUS BE EFFECTIVE AS AN 2& SHIELD BUT IT IS USUALLY MORE EXPENSIVE THAN THE COATINGS ! CONTIGUOUS METAL ENCLOSURE WITHOUT ANY HOLES OR SEAMS KNOWN AS A &ARADAY CAGE PROVIDES THE BEST SHIELDING FOR THE GIVEN MATERIAL AND FREQUENCY 7HEN A HOLE OR HOLES ARE ADDED 2& CURRENTS mOWING ON THE OUTSIDE SURFACE OF THE SHIELD MUST TAKE A LONGER PATH TO GET AROUND THE HOLE THAN IF THE SURFACE WAS CONTIGUOUS !S MORE hBENDINGv IS REQUIRED OF THESE CURRENTS MORE ENERGY IS COUPLED TO THE INSIDE SURFACE AND THUS THE SHIELDING EFFECTIVENESS IS REDUCED 4HE REDUCTION IN SHIELDING IS A FUNCTION OF THE LONGEST LINEAR DIMENSION OF A HOLE RATHER THAN THE AREA 4HIS CONCEPT IS OFTEN APPLIED WHERE VENTILATION IS NECESSARY IN WHICH CASE MANY SMALL HOLES ARE PREFERABLE TO A FEW LARGER ONES !PPLYING THIS SAME CONCEPT TO SEAMS OR JOINTS BETWEEN ADJACENT PIECES OR SEGMENTS OF A SHIELDED ENCLOSURE IT IS IMPORTANT TO MINIMIZE THE OPEN LENGTH OF THESE SEAMS 3EAM LENGTH IS THE DISTANCE BETWEEN POINTS WHERE GOOD OHMIC CONTACT IS MADE 4HIS CONTACT CAN BE PROVIDED BY SOLDER WELDS OR PRESSURE CONTACT )F PRESSURE CONTACT IS USED ATTENTION MUST BE PAID TO THE CORROSION CHARACTERISTICS OF THE SHIELD MATERIAL AND ANY CORROSION RESISTANT PROCESSES APPLIED TO THE BASE MATERIAL )F THE OHMIC CONTACT ITSELF IS NOT CONTINUOUS THE SHIELDING EFFECTIVENESS CAN BE MAXIMIZED BY MAKING THE JOINTS BETWEEN ADJACENT PIECES OVERLAPPING RATHER THAN ABUTTED 4HE SHIELDING EFFECTIVENESS OF AN ENCLOSURE IS FURTHER REDUCED WHEN A WIRE PASSES THROUGH A HOLE IN THE ENCLOSURE 2& ENERGY ON THE WIRE FROM AN EXTERNAL lELD IS RE RADIATED INTO THE INTERIOR OF THE ENCLOSURE 4HIS COUPLING MECHANISM CAN BE REDUCED BY lLTERING THE WIRE WHERE IT PASSES THROUGH THE SHIELD BOUNDARY

80

C36

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ELECTRICAL CONTROL AND ADJUSTMENT

C37

'IVEN THE SAFETY CONSIDERATIONS INVOLVED IN CONNECTING ELECTRICAL COMPONENTS TO THE CHASSIS OR FRAME IN BATTERY POWERED VEHICLES SUCH lLTERING WILL USUALLY CONSIST OF A SERIES INDUCTOR OR FERRITE BEAD RATHER THAN A SHUNT CAPACITOR )F A CAPACITOR IS USED IT MUST HAVE A VOLTAGE RATING AND LEAKAGE CHARACTERISTICS THAT WILL ALLOW THE END PRODUCT TO MEET APPLICABLE SAFETY REGULATIONS 4HE " AND " IF APPLICABLE WIRES THAT SUPPLY POWER TO A CONTROL PANEL SHOULD BE BUNDLED WITH THE OTHER CONTROL WIRES TO THE PANEL SO THAT ALL THESE WIRES ARE ROUTED TOGETHER )F THE WIRES TO THE CONTROL PANEL ARE ROUTED SEPARATELY

A LARGER LOOP AREA IS FORMED ,ARGER LOOP AREAS PRODUCE MORE EFlCIENT ANTENNAS WHICH WILL RESULT IN DECREASED IMMUNITY PERFORMANCE +EEP ALL LOW POWER ) / SEPARATE FROM THE MOTOR AND BATTERY LEADS 7HEN THIS IS NOT POSSIBLE CROSS THEM AT RIGHT ANGLES

#URTIS 0-# MOTOR CONTROLLERS CONTAIN %3$ SENSITIVE COMPONENTS AND IT IS THEREFORE NECESSARY TO PROTECT THEM FROM %3$ ELECTROSTATIC DISCHARGE DAMAGE -OST OF THESE CONTROL LINES HAVE PROTECTION FOR MODERATE %3$ EVENTS BUT MUST BE PROTECTED FROM DAMAGE IF HIGHER LEVELS EXIST IN A PARTICULAR APPLICATION %3$ IMMUNITY IS ACHIEVED EITHER BY PROVIDING SUFlCIENT DISTANCE BE TWEEN CONDUCTORS AND THE %3$ SOURCE SO THAT A DISCHARGE WILL NOT OCCUR OR BY PROVIDING AN INTENTIONAL PATH FOR THE DISCHARGE CURRENT SUCH THAT THE CIRCUIT IS ISOLATED FROM THE ELECTRIC AND MAGNETIC lELDS PRODUCED BY THE DISCHARGE )N GENERAL THE GUIDELINES PRESENTED ABOVE FOR INCREASING RADIATED IMMUNITY WILL ALSO PROVIDE INCREASED %3$ IMMUNITY )T IS USUALLY EASIER TO PREVENT THE DISCHARGE FROM OCCURRING THAN TO DIVERT THE CURRENT PATH ! FUNDAMENTAL TECHNIQUE FOR %3$ PREVENTION IS TO PROVIDE ADEQUATELY THICK INSULATION BETWEEN ALL METAL CONDUCTORS AND THE OUTSIDE ENVI RONMENT SO THAT THE VOLTAGE GRADIENT DOES NOT EXCEED THE THRESHOLD REQUIRED FOR A DISCHARGE TO OCCUR )F THE CURRENT DIVERSION APPROACH IS USED ALL EXPOSED METAL COMPONENTS MUST BE GROUNDED 4HE SHIELDED ENCLOSURE IF PROPERLY GROUNDED

CAN BE USED TO DIVERT THE DISCHARGE CURRENT IT SHOULD BE NOTED THAT THE LOCA TION OF HOLES AND SEAMS CAN HAVE A SIGNIlCANT IMPACT ON %3$ SUPPRESSION )F THE ENCLOSURE IS NOT GROUNDED THE PATH OF THE DISCHARGE CURRENT BECOMES MORE COMPLEX AND LESS PREDICTABLE ESPECIALLY IF HOLES AND SEAMS ARE INVOLVED 3OME EXPERIMENTATION MAY BE REQUIRED TO OPTIMIZE THE SELECTION AND PLACEMENT OF HOLES WIRES AND GROUNDING PATHS #AREFUL ATTENTION MUST BE PAID TO THE CONTROL PANEL DESIGN SO THAT IT CAN TOLERATE A STATIC DISCHARGE -/6 TRANSORBS OR OTHER DEVICES CAN BE PLACED BETWEEN " AND OFFENDING WIRES PLATES AND TOUCH POINTS IF %3$ SHOCK CANNOT BE OTHERWISE AVOIDED

(10/4/2013)

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80

%,%#42/34!4)# $)3#(!2'% %3$

C38

ELECTRICAL CONTROL AND ADJUSTMENT

!00%.$)8 " #524)3 7%%% 2O(3 34!4%-%.4 -!2#( 7%%% 4HE $IRECTIVE %# ON 7ASTE %LECTRICAL AND %LECTRONIC %QUIPMENT 7%%% WAS ADOPTED BY THE %UROPEAN #OUNCIL AND 0ARLIAMENT AND THE #OUNCIL OF THE %U ROPEAN 5NION ON *ANUARY 4HE AIM OF THE DIRECTIVE WAS TO IMPROVE THE COLLECTION AND RECYCLING OF 7%%% THROUGHOUT THE %5 AND TO REDUCE THE LEVEL OF NON RECYCLED WASTE 4HE DIRECTIVE WAS IMPLEMENTED INTO LAW BY MANY %5 MEMBER STATES DURING AND 4HIS DOCUMENT PROVIDES A GENERAL DESCRIPTION OF #URTIS S APPROACH TO MEETING THE REQUIREMENTS OF THE 7%%% LEGISLATION .OTE THAT THE DIRECTIVE GAVE SOME mEXIBILITY TO THE MEMBER STATES IN IMPLE MENTING THEIR INDIVIDUAL 7%%% REGULATIONS LEADING TO THE DElNITION OF VARYING IMPLEMENTATION REQUIREMENTS BY COUNTRY 4HESE REQUIREMENTS MAY INVOLVE CONSID ERATIONS BEYOND THOSE REmECTED IN THIS DOCUMENT 4HIS STATEMENT IS NOT INTENDED AND SHALL NOT BE INTERPRETED OR CONSTRUED TO BE LEGAL ADVICE OR TO BE LEGALLY BINDING ON #URTIS OR ANY THIRD PARTY #OMMITMENT

#URTIS IS COMMITTED TO A SAFE AND HEALTHY ENVIRONMENT AND HAS BEEN WORKING DILIGENTLY TO ENSURE ITS COMPLIANCE WITH 7%%% LEGISLATION #URTIS WILL COMPLY WITH 7%%% LEGISLATION BY s $ESIGNING ITS EQUIPMENT WITH CONSIDERATION TO FUTURE DISMANTLING

RECOVERY AND RECYCLING REQUIREMENTS s -ARKING ITS PRODUCTS THAT FALL WITHIN THE SCOPE OF THE DIRECTIVE WITH THE REQUIRED SYMBOL AND INFORMING USERS OF THEIR OBLIGATION s 4O SEPARATE 7%%% FROM GENERAL WASTE AND DISPOSE OF IT THROUGH THE PROVIDED RECYCLING SYSTEMS s 2EPORTING INFORMATION AS REQUIRED BY EACH MEMBER STATE

80

s &ACILITATING THE COLLECTION RECYCLING AND DISPOSAL OF 7%%% FROM PRIVATE HOUSEHOLDS AND OTHER THAN PRIVATE HOUSEHOLDS BUSINESSES AS DElNED

BY THE APPLICABLE MEMBER STATE REGULATION s 0ROVIDING INFORMATION TO TREATMENT CENTRES ACCORDING TO THE REQUIRE MENTS DElNED IN THE LOCAL REGULATION 7%%% SYMBOL ON #URTIS PRODUCTS

4HE REQUIREMENT TO MARK EQUIPMENT WITH THE 7%%% SYMBOL THE CROSSED OUT WHEELED BIN WENT INTO EFFECT AS OF !UGUST !S OF THIS DATE #URTIS )N STRUMENTS BEGAN THE PROCESS OF MARKING ALL PRODUCTS THAT FALL WITHIN SCOPE OF THIS DIRECTIVE WITH THE 7%%% SYMBOL AS SHOWN OPPOSITE /BLIGATIONS FOR BUYERS OF ELECTRICAL AND ELECTRONIC EQUIPMENT

!S OF !UGUST IN EACH %5 MEMBER STATE WHERE THE 7%%% DIRECTIVE HAS BEEN IMPLEMENTED DISPOSAL OF %%% WASTE OTHER THAN IN ACCORDANCE WITH THE SCHEME

80-04-M227EN

80-04-M227EN

ELECTRICAL CONTROL AND ADJUSTMENT

C39

IS PROHIBITED 'ENERALLY THE SCHEMES REQUIRE COLLECTION AND RECYCLING OF A BROAD RANGE OF %%% PRODUCTS #ERTAIN #URTIS PRODUCTS FALL WITHIN THE SCOPE OF THE DIREC TIVE AND THE IMPLEMENTED MEMBER STATE REGULATIONS !FFECTED #URTIS PRODUCTS THAT HAVE REACHED END OF LIFE MUST NOT BE DISPOSED AS GENERAL WASTE BUT INSTEAD PUT INTO THE COLLECTION AND RECYCLING SYSTEM PROVIDED IN THE RELEVANT JURISDICTION

&OR SEVERAL YEARS NOW #URTIS HAS BEEN IMPLEMENTING A RIGOROUS PROGRAM WITH THE AIM OF ACHIEVING FULL COMPLIANCE WITH THE 2ESTRICTIONS ON THE USE OF (AZARDOUS 3UBSTANCES 2O(3 $IRECTIVE %# #URTIS HAS TAKEN ALL AVAILABLE STEPS TO ELIMINATE THE USE OF THE SIX RESTRICTED HAZARDOUS SUBSTANCES LISTED IN THE DIRECTIVE WHEREVER POSSIBLE !S A RESULT OF THE #URTIS 2O(3 PROGRAM MANY OF OUR INSTRUMENTATION PRODUCT LINES ARE NOW FULLY 2O(3 COMPLIANT (OWEVER #URTIS S ELECTRONIC MOTOR SPEED CONTROLLER PRODUCTS ARE SAFETY CRITICAL DEVICES SWITCHING VERY LARGE CURRENTS AND DESIGNED FOR USE IN EXTREME ENVIRONMENTAL CONDITIONS &OR THESE PRODUCT LINES WE HAVE SUCCESSFULLY ELIMINATED lVE OUT OF THE SIX RESTRICTED HAZARDOUS SUBSTANCES 4HE SINGLE REMAINING ISSUE PREVENTING FULL 2O(3 COMPLIANCE IS THE UNSUITABILITY OF THE LEAD FREE SOLDERS AVAILABLE TO DATE DUE TO THE WELL DOCUMENTED ISSUES SUCH AS TIN WHISKERS AND PREMATURE FAILURE COMPARED WITH LEADED SOLDER DUE TO SHOCK VIBRATION AND THERMAL CYCLING #URTIS IS CLOSELY MONITORING ALL 2O(3 DEVELOPMENTS GLOBALLY AND IN PAR TICULAR IS FOLLOWING THE AUTOMOTIVE INDUSTRY S ATTEMPTS TO INTRODUCE LEAD FREE SOLDER AS A RESULT OF THE %ND OF ,IFE 6EHICLE %,6 $IRECTIVE %# 4O DATE THE AUTOMOTIVE INDUSTRY HAS REJECTED ALL LEAD FREE SOLDER PASTES DUE TO A SIGNIlCANT REDUCTION IN RELIABILITY COMPARED TO LEADED SOLDERING #URTIS lRMLY BELIEVES THAT THE OPERATING ENVIRONMENTS SAFETY REQUIREMENTS

AND RELIABILITY LEVELS REQUIRED OF AUTOMOTIVE ELECTRONICS ARE DIRECTLY ANALOGOUS TO THAT OF OUR SPEED CONTROLLER PRODUCTS !S SUCH #URTIS WILL NOT BE SWITCHING TO A LEAD FREE SOLDER PROCESS UNTIL LEAD FREE SOLDER PASTES AND TECHNIQUES ARE AVAILABLE THAT MEET THE REQUIREMENTS OF THE 2O(3 STUDY GROUPS AND %,6 !UTOMOTIVE )N DUSTRY BODIES 4HAT IS WHEN ALL KNOWN ISSUES INCLUDING THAT OF TIN WHISKERS ARE SATISFACTORILY RESOLVED !T THIS MOMENT IN TIME ALL #URTIS MOTOR SPEED CONTROLLERS USED ON INDUSTRIAL VEHICLE APPLICATIONS ARE ALSO REGARDED AS EXEMPT UNDER %%% CATEGORY OF THE 2O(3 DIRECTIVE %# 4HIS MEANS THERE IS NO REQUIREMENT AT THIS TIME FOR #URTIS CONTROL SYSTEMS USED ON SUCH EQUIPMENT TO COMPLY WITH THE DIRECTIVE #URTIS WILL WORK CLOSELY WITH ALL KEY CUSTOMERS TO ENSURE THAT WHENEVER POSSIBLE WE ARE IN A POSITION TO CONTINUE THE SUPPLY OF PRODUCTS SHOULD THESE EXEMPTIONS EXPIRE

(10/4/2013)

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80

2O(3

C40

ELECTRICAL CONTROL AND ADJUSTMENT

!00%.$)8 # 02/'2!--).' $%6)#%3 -%.53 #URTIS PROGRAMMERS PROVIDE PROGRAMMING DIAGNOSTIC AND TEST CAPABILITIES FOR THE CONTROLLER 4HE POWER FOR OPERATING THE PROGRAMMER IS SUPPLIED BY THE HOST CONTROLLER VIA A PIN CONNECTOR 7HEN THE PROGRAMMER POWERS UP

IT GATHERS INFORMATION FROM THE CONTROLLER 4WO TYPES OF PROGRAMMING DEVICES ARE AVAILABLE THE 0# 0ROGRAM MING 3TATION AND THE HANDHELD PROGRAMMER 4HE 0ROGRAMMING 3TATION HAS THE ADVANTAGE OF A LARGE EASILY READ SCREEN ON THE OTHER HAND THE HAND HELD PROGRAMMER WITH ITS ¾ MM SCREEN HAS THE ADVANTAGE OF BEING MORE PORTABLE AND HENCE CONVENIENT FOR MAKING ADJUSTMENTS IN THE lELD "OTH PROGRAMMERS ARE AVAILABLE IN 5SER 3ERVICE $EALER AND /%- VER SIONS %ACH PROGRAMMER CAN PERFORM THE ACTIONS AVAILABLE AT ITS OWN LEVEL AND THE LEVELS BELOW THAT A 5SER ACCESS PROGRAMMER CAN OPERATE AT ONLY THE 5SER LEVEL WHEREAS AN /%- PROGRAMMER HAS FULL ACCESS 0# 02/'2!--).' 34!4)/.

4HE 0ROGRAMMING 3TATION IS AN -3 7INDOWS BIT APPLICATION THAT RUNS ON A STANDARD 7INDOWS 0# )NSTRUCTIONS FOR USING THE 0ROGRAMMING 3TATION ARE INCLUDED WITH THE SOFTWARE (!.$(%,$ 02/'2!--%2 4HE HANDHELD PROGRAMMER IS FUNCTIONALLY EQUIVALENT TO THE 0# 0ROGRAM MING 3TATION OPERATING INSTRUCTIONS ARE PROVIDED IN THE MANUAL 4HE PROGRAMMER REPLACES THE AN EARLIER MODEL WITH FEWER FUNCTIONS 02/'2!--%2 &5.#4)/.3

80

0ROGRAMMER FUNCTIONS INCLUDE 0ARAMETER ADJUSTMENT PROVIDES ACCESS TO THE INDIVIDUAL PROGRAMMABLE PA

RAMETERS -ONITORING PRESENTS REAL TIME VALUES DURING VEHICLE OPERATION THESE INCLUDE ALL INPUTS AND OUTPUTS $IAGNOSTICS AND TROUBLESHOOTING PRESENTS DIAGNOSTIC INFORMATION AND ALSO A

MEANS TO CLEAR THE FAULT HISTORY lLE 0ROGRAMMING ALLOWS YOU TO SAVE RESTORE CUSTOM PARAMETER SETTINGS lLES AND

ALSO TO UPDATE THE SYSTEM SOFTWARE NOT AVAILABLE ON THE &AVORITES ALLOWS YOU TO CREATE SHORTCUTS TO YOUR FREQUENTLY USED ADJUSTABLE

PARAMETERS AND MONITOR VARIABLES NOT AVAILABLE ON THE

80-04-M227EN

80-04-M227EN

ELECTRICAL CONTROL AND ADJUSTMENT

C41

4HE 0ROGRAM -ENU AND -ONITOR -ENU ARE PRESENTED HERE &OR &AULTS SEE THE 4ROUBLESHOOTING #HART IN 3ECTION 4HE OTHER PROGRAMMER MENUS ARE SELF EXPLANATORY 0ROGRAM -ENU NOT ALL ITEMS AVAILABLE ON ALL CONTROLLERS

(10/4/2013)

55Ęņ50 ņ

55œņ50 ņ

55ōņ50 ņ

55àņ50 ņ

| 4|!ņ$ ņ50 ņ

$ % $ $ņ50 ņ

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3PEED 3ELECT MAXIMUM SPEED AS 07- 3PEED 3ELECT MAXIMUM SPEED AS 073PEED 3ELECT MAXIMUM SPEED AS 073PEED 3ELECT MAXIMUM SPEED AS 074HROTTLE MAXIMUM SPEED AS 07-INIMUM SPEED AS 07!CCELERATION RATE IN SECONDS 33 SWITCH /N !DD -ODE /FF &IRST /N -ODE &INAL 33 THROTTLE /N !DD -ODE /FF &IRST /N -ODE 4HROTTLE FAULT DETECTION /N /FF 4HROTTLE TYPE n .EUTRAL DEADBAND ADJUSTMENT AS OF ACTIVE RANGE 4HROTTLE INPUT REQUIRED FOR MAX OUTPUT AS OF ACTIVE RANGE 4HROTTLE MAP n ,IFT LOCKOUT OF 33 /N /FF ,IFT LOCKOUT OF 33 /N /FF ,IFT LOCKOUT OF 33 /N /FF ,IFT LOCKOUT OF 33 /N /FF ,IFT LOCKOUT OF THROTTLE /N /FF ,OCKOUT TYPE n 0RECHARGE ENABLE /N /FF 3TARTUP LOCKOUT TYPE n -AIN CONTACTOR CONTROLLED INTERNALLY /N /FF

55àņ ! ņ

$ELAY BETWEEN 33 OPEN AND CORRESPONDING OUTPUT SHUTDOWN IN SECONDS

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5NDERVOLTAGE CUTBACK STARTING POINT IN VOLTS ,OW VOLTAGE CUTBACK RATE n #ONTACTOR PULL IN VOLTAGE #ONTACTOR HOLDING VOLTAGE

80-04-M227EN

80

4HE S PROGRAMMABLE PARAMETERS ARE LISTED HERE IN THE ORDER IN WHICH THEY ARE DISPLAYED BY THE PROGRAMMER

C42

ELECTRICAL CONTROL AND ADJUSTMENT

0ROGRAM -ENU .OTES

4HROTTLE TYPES SEE 4HROTTLE 7IRING IN 3ECTION

4YPE n KΩ, WIRE POT

4YPE KΩn , WIRE POT

4YPE SINGLE ENDED n 6 INPUT

4YPE SINGLE ENDED WIRE POT n KΩ

,IFT LOCKOUT TYPES

SEE 3ECTION 0ROGRAMMABLE 0ARAMETERS PAGE

4YPE %NABLE LOW

$ISABLE HIGH OR OPEN

4YPE %NABLE HIGH OR OPEN $ISABLE LOW

4YPE %NABLE HIGH

4YPE %NABLE LOW OR OPEN $ISABLE HIGH

$ISABLE LOW OR OPEN

0RECHARGE FUNCTION AND FAULT DETECTION DEPEND ON THE COMBINED

SETTING OF TWO PARAMETERS 0RECHARGE AND #ONTACTOR #ONTROL SEE 3ECTION 0ROGRAMMABLE 0ARAMETERS PAGES

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80

80-04-M227EN

3TARTUP LOCKOUT TYPES SEE 3ECTION 0ROGRAMMABLE 0ARAMETERS PAGE

4YPE NO STARTUP LOCKOUT

4YPE STARTUP LOCKOUT UNLESS +3) INPUT IS RECEIVED BEFORE SPEED REQUEST

4YPE STARTUP LOCKOUT UNLESS +3) AND INTERLOCK INPUTS ARE BOTH RECEIVED BEFORE SPEED REQUEST

80-04-M227EN

ELECTRICAL CONTROL AND ADJUSTMENT

C43

-ONITOR -ENU )TEMS ARE LISTED HERE IN THE ORDER IN WHICH THEY APPEAR IN THE -ONITOR -ENU DISPLAYED BY THE PROGRAMMER (EATSINK TEMPERATURE IN #

0ņ '!| 6OLTAGE AT CAPACITOR BANK CONTROLLER " BUS ||ņ '!| 6OLTAGE AT +3) PIN * $'|'4ņ '!| 6OLTAGE ACROSS CONTROLLER S " AND - BUS BARS | 4'||! Ħ 4HROTTLE REQUEST AS OF FULL THROTTLE $ %ņ '%|ņ 4 4 -AIN CONTACTOR OUTPUT ON OFF

| ņ

! ņĦ 07- DUTY CYCLE OF MOTOR DRIVE SECTION 55Ęņ %0 | 3PEED 3ELECT SWITCH ON OFF 55œņ %0 | 3PEED 3ELECT SWITCH ON OFF 55ōņ %0 | 3PEED 3ELECT SWITCH ON OFF 55àņ %0 | 3PEED 3ELECT SWITCH ON OFF ! |!' ņ %0 | ,IFT LOCKOUT ON OFF %| 4! ņ %0 | )NTERLOCK SWITCH ON OFF

80

|5 % ņ| $0

(10/4/2013)

80-04-M227EN

ELECTRICAL CONTROL AND ADJUSTMENT

CI

!00%.$)8 $ 30%#)&)#!4)/.3

.OMINAL INPUT VOLTAGE 07- OPERATING FREQUENCY %LECTRICAL ISOLATION TO HEATSINK

6 AND 6 K(Z 6 AC MINIMUM

+3) INPUT VOLTAGE +3) INPUT CURRENT NO CONTACTORS ENGAGED

6 MINIMUM FOR 6 MODEL 6 MINIMUM FOR 6 MODEL M! WITHOUT PROGRAMMER M! WITH PROGRAMMER

,OGIC INPUT VOLTAGE ,OGIC INPUT CURRENT

SEE BELOW M!

#ONTACTOR DRIVER OUTPUT CURRENT 3TATUS ,%$ OUTPUT CURRENT

! MAXIMUM M! MAXIMUM

/PERATING AMBIENT TEMPERATURE RANGE 3TORAGE AMBIENT TEMPERATURE RANGE

# TO # & TO & # TO # & TO &

(EATSINK OVERTEMPERATURE CUTBACK (EATSINK UNDERTEMPERATURE CUTBACK

LINEAR CUTBACK STARTS AT # & COMPLETE CUTOFF AT # & CURRENT BELOW # &

0ACKAGE ENVIRONMENTAL RATING

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88

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(10/4/2013)

80-04-M227EN

80

4ABLE $ 30%#)&)#!4)/.3 #/.42/,,%2

80

ELECTRICAL TROUBLESHOOTING

(28/10/2013)

80-08-M227EN

2

ELECTRICAL TROUBLESHOOTING

80

Code

Type

Error

Cause

101

Error Application

"ACCEL SWITCH ACTIVE AT KEY ON"

"The acceleration switch is on when key on"

102

Error Application

"DIR. SWITCH ACTIVE AT KEY ON"

"At least one of direction switches is on when key on"

103

Error Application

"DIRECTION SWITCH BOTH ON ERROR"

"Both of the direction switches are on at the same time"

104

Error Application

"TRACT POT VALUE OUT OF RANGE"

"The value of traction pot is out of range(<30 or >2800)"

105

Error Application

"TRACT SWITCH OFF WITH LARGE POT"

"The acceleration switch is off but the value of traction pot is more than 30%"

106

Error Application

"STEER POT VALUE OUT OF RANGE"

"The value of steer pot is out of range(<30 or >2800)"

107

Error Application

"PUMP SPEED1 SWITCH ACTIVE AT KEY ON"

"The pump speed1 switch is on when key on"

108

Error Application

"PUMP SPEED2 SWITCH ACTIVE AT KEY ON"

"The pump speed2 switch is on when key on"

109

Error Application

"PUMP SPEED3 SWITCH ACTIVE AT KEY ON"

"The pump speed3 switch is on when key on"

110

Error Application

"PUMP SPEED4 SWITCH ACTIVE AT KEY ON"

"The pump speed4 switch is on when key on"

111

Error Application

"CAN COMMUNICATION ERROR"

CAN communication error

114

Error Application

BATTERY LOW ERROR

"The battery is low. BDI value<25 warning, <15% slow the truck"

115

Error Application

"START UP ERROR ERROR"

Internal error when start up

116

Error Application

"LIFT SWITCH ACTIVE AT KEY ON"

The lift switch is on when key on

121

Error Application

"PUMP POT VALUE OUT OF RANGE ERROR"

"The value of pump pot is out of range(<10 or >2800)"

122

Error Application

"LIFT SWITCH OFF WITH LARGE POT VALUE"

"The lift switch is off but the value of pump pot is more than 30%"

124

Error Application

DRIVER LEFT WITH DIRECTION

"Driver left the truck but the direction switch is still on, turn off direction switch , the error disappear"

125

Error Application

"MAIN CONTACTOR OFF ERROR"

Main contactor is off

201

Warning Left Traction

LEFT TRACT ACS TEMP LOW

ACS temperature is lower than -20°C

202

Warning Left Traction

"LEFT TRACT ACS TEMP HIGH"

ACS temperature is higher than 85°C

203

Warning Left Traction

"LEFT TRACT ACS TEMP SENSOR"

"ACS temperature sensor not connected or short circuit"

204

Warning Left Traction

"LEFT TRACT MOTOR TEMP LOW"

"Motor temperature is lower than -35°C"

205

Warning Left Traction

"LEFT TRACT MOTOR TEMP HIGH"

"Motor temperature is higher than 145°C"

206

Warning Left Traction

"LEFT TRACT MOTOR TEMP SENSOR"

"Motor temperature sensor not connected or short circuit"

207

Warning Left Traction

LEFT TRACT SPEED SENSOR

"Speed sensor not connected or short circuit"

208

Warning Left Traction

"LEFT TRACT HIGH VOLTAGE"

The ACS voltage is higher than 58V

209

Warning Left Traction

LEFT TRACT LOW VOLTAGE

The ACS voltage is lower than 24V

210

Warning Left Traction

"LEFT TRACT DEFAULT PAR. LOADED"

Default parameters are loaded

211

Warning Left Traction

"LEFT TRACT REDUCED POWER"

"The ACS output power has been reduced"

212

Warning Left Traction

"LEFT TRACT DEFAULT CAL. PAR."

CAL. Use default parameters

216

Warning Left Traction

"LEFT TRACT CURR SENSOR DEFAULT"

Current sensor use default parameters

217

Warning Left Traction

"LEFT TRACT OPEN DRIAN ERROR"

"The open drain output is not connected"

218

Warning Left Traction

LEFT TRACT MISC

Other warnings

251

Error Left Traction

"LEFT TRACT SHORT CIRCUIT"

"There is a short circuit among B+,B-,U,V,W"

252

Error Left Traction

"LEFT TRACT ACS TEMP HIGH"

"ACS temperature is higher than 125°C"

253

Error Left Traction

"LEFT TRACT MOTOR TEMP HIGH"

"Motor temperature is higher than 180°C"

254

Error Left Traction

"LEFT TRACT CURR SENS. ERROR"

Current sensor error

255

Error Left Traction

"LEFT TRACT CAP. NOT CHARGING"

"ACS capacitor is not charged up to 85% in 10s"

256

Error Left Traction

"LEFT TRACT NOT RESPONDING"

ACS is no responde

80-08-M227EN

(28/10/2013)

ELECTRICAL TROUBLESHOOTING

Code

Type

Error

Cause

Error Left Traction

"LEFT SLAVE COMMUNICATION TIMEOUT"

Slave node communication timeout

258

Error Left Traction

LEFT TRACT SDO FAILURE

SDO err in CAN

259

Error Left Traction

"LEFT MASTER COMMUNICATION TIMEOUT"

Master node communication timeout

260

Error Left Traction

LEFT TRACT LOW VOLTAGE

The ACS voltage is lower than 18V

261

Error Left Traction

"LEFT TRACT HIGH VOLTAGE (SW)"

The ACS voltage is higher than 68V

262

Error Left Traction

"LEFT TRACT HIGH VOLTAGE (HW)"

The ACS voltage is higher than 68V

263

Error Left Traction

"LEFT TRACT PCB TEMP HIGH"

"The ACS PCB temperature is higher than 125°C"

264

Error Left Traction

LEFT TRACT MISC.

Other errors

301

Warning Right Traction

"RIGHT TRACT ACS TEMP LOW"

ACS temperature is lower than -20°C

302

Warning Right Traction

"RIGHT TRACT ACS TEMP HIGH"

ACS temperature is higher than 85°C

303

Warning Right Traction

"RIGHT TRACT ACS TEMP SENSOR"

"ACS temperature sensor not connected or short circuit"

304

Warning Right Traction

"RIGHT TRACT MOTOR TEMP LOW"

"Motor temperature is lower than -35°C"

305

Warning Right Traction

"RIGHT TRACT MOTOR TEMP HIGH"

"Motor temperature is higher than 145°C"

306

Warning Right Traction

"RIGHT TRACT MOTOR TEMP SENSOR"

"Motor temperature sensor not connected or short circuit"

307

Warning Right Traction

RIGHT TRACT SPEED SENSOR

"Speed sensor not connected or short circuit"

308

Warning Right Traction

"RIGHT TRACT HIGH VOLTAGE"

The ACS voltage is higher than 58V

309

Warning Right Traction

RIGHT TRACT LOW VOLTAGE

The ACS voltage is lower than 24V

310

Warning Right Traction

"RIGHT TRACT DEFAULT PAR. LOADED"

Default parameters are loaded

311

Warning Right Traction

"RIGHT TRACT REDUCED POWER"

"The ACS output power has been reduced"

312

Warning Right Traction

"RIGHT TRACT DEFAULT CAL. PAR."

CAL. Use default parameters

316

Warning Right Traction

"RIGHT TRACT CURR SENSOR DEFAULT"

Current sensor use default parameters

317

Warning Right Traction

"RIGHT TRACT OPEN DRIAN ERROR"

"The open drain output is not connected"

318

Warning Right Traction

RIGHT TRACT MISC

Other warnings

351

Error Right Traction

"RIGHT TRACT SHORT CIRCUIT"

"There is a short circuit among B+,B-,U,V,W"

352

Error Right Traction

RIGHT TRACT ACS TEMP HIGH

ACS temperature is higher than 125°C

353

Error Right Traction

"RIGHT TRACT MOTOR TEMP HIGH"

"Motor temperature is higher than 180°C"

354

Error Right Traction

"RIGHT TRACT CURR SENS ERROR"

Current sensor error

355

Error Right Traction

"RIGHT TRACT CAP. NOT CHARGING"

"ACS capacitor is not charged up to 85% in 10s"

356

Error Right Traction

"RIGHT TRACT NOT RESPONDING"

ACS is no responde

357

Error Right Traction

"RIGHT SLAVE COMMUNICATION TIMEOUT"

Slave node communication timeout

358

Error Right Traction

RIGHT TRACT SDO FAILURE

SDO err in CAN

359

Error Right Traction

"RIGHT MASTER COMMUNICATION TIMEOUT"

Master node communication timeout

360

Error Right Traction

RIGHT TRACT LOW VOLTAGE

The ACS voltage is lower than 18V

361

Error Right Traction

"RIGHT TRACT HIGH VOLTAGE (SW)"

The ACS voltage is higher than 68V

362

Error Right Traction

"RIGHT TRACT HIGH VOLTAGE (HW)"

The ACS voltage is higher than 68V

363

Error Right Traction

"RIGHT TRACT PCB TEMP HIGH"

"The ACS PCB temperature is higher than 125°C"

364

Error Right Traction

RIGHT TRACT MISC.

Other errors

80

257

(28/10/2013)

3

80-08-M227EN

ELECTRICAL TROUBLESHOOTING

80

4

80-08-M227EN

(28/10/2013)