OM Pimespo Series THESI Series 4519 SERVICE MANUAL - PDF DOWNLOAD

SERVICE MANUAL THESI Series 4519

Part No 60420339 I ED. 02/2001 Rev. 08/2003

THESI - Index

Index General Rules .......................................................................................................... 1 To avoid accidentsi ......................................................................................................................... 1 Safety rulesa.................................................................................................................................... 1 Electronic equipment ...................................................................................................................... 3 Hydraulic equipment ...................................................................................................................... 4 Removal and replacement .............................................................................................................. 4

Section 1 – Introduction ...................................................................................... 1.1 Definitions ................................................................................................................................... 1.1 Removal of covers and guards ..................................................................................................... 1.2 Tightening torques for important nuts and bolts .......................................................................... 1.3 Tightening torques for hydraulic connections ............................................................................. 1.3

Section 8 – Lift Group ......................................................................................... 8.1 Assembling the mast .................................................................................................................... 8.1 Description of the lift group PKG and PKK ................................................................................ 8.2 Maintenance of the lift group PKG and PKK .............................................................................. 8.3 Removal of the primary lift cylinder ......................................................................................... 8.10 Refitting the primary lift cylinder .............................................................................................. 8.11 Removal of the secondary lift cylinder ...................................................................................... 8.11 Refitting the secondary lift cylinder .......................................................................................... 8.12 Dismantling the lift cylinders .................................................................................................... 8.13 Re-assembly of the lift cylinders ............................................................................................... 8.14 Bleeding air from the lift cylinders ............................................................................................ 8.15 Lift chains .................................................................................................................................. 8.16 Reach carriage assembly with side shift .................................................................................... 8.20 Fixing the mast in a safe condition ............................................................................................ 8.21

Section 9 - Hydraulic system .............................................................................. 9.1 Introduction ................................................................................................................................. 9.1 Hydraulic functional diagram ...................................................................................................... 9.2 Hydraulic functional diagram with Overcenter Valve ................................................................. 9.4 Hydraulic assembly diagram ....................................................................................................... 9.7 Modification to improve functioning of Overcenter Valve ......................................................... 9.9 Overcenter Valve assembly instruction diagram for production Thesi Trucks .......................... 9.10 Electrical denomination of the valves ....................................................................................... 9.11 Description of the electrovalve group........................................................................................ 9.11 Relief valve adjustment ............................................................................................................. 9.12 Location of the hydraulic distributor ......................................................................................... 9.12 Main components of the hydraulic system ................................................................................ 9.13

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Page 3

THESI - Index

Sezione 10 -Electric motor ................................................................................ 10.1 Electric motor specifications ..................................................................................................... 10.1

Section 11 - Electrical system ........................................................................... 11.1 Electronic control ...................................................................................................................... 11.1 Electronic control ...................................................................................................................... 11.2 Display ....................................................................................................................................... 11.3 X1 connector.............................................................................................................................. 11.7 X2 connector............................................................................................................................ 11.10 Connection of motors to the power control ............................................................................. 11.17 Power control for traction and lift ........................................................................................... 11.17 Power control for power steering ............................................................................................ 11.17 PMOS logic unit for Traction/Lift ........................................................................................... 11.18 Limit stop sensors for mast carriage control ............................................................................ 11.19

Section 12 – Power steering .............................................................................. 12.1 Hydraulic diagram for the steering system ................................................................................ 12.1 Power steer pump motor ............................................................................................................ 12.2

Sezione 14 - Optionals ....................................................................................... 14.1 Table of Optional Kits ............................................................................................................... 14.1 Assembly instructions for the preselector/height meter kit ....................................................... 14.2 Entering the stocking heights ................................................................................................. 14.8 Automatic mode ..................................................................................................................... 14.9 Picking up the load ................................................................................................................. 14.9 Depositing the load ................................................................................................................. 14.9 Power steering control, part number 45198201506 ................................................................. 14.10 List of options that can be operated from the console ............................................................. 14.13

Section 15 – Programming ................................................................................ 15.1 Adjustment of parameters and diagnostics via console or PC................................................... 15.1 Programming via the console .................................................................................................... 15.1 List of the available menus ........................................................................................................ 15.2 The console ................................................................................................................................ 15.3 Menus ........................................................................................................................................ 15.3 Parameter Change ................................................................................................................. 15.3 Tester ..................................................................................................................................... 15.5 Program Vacc ........................................................................................................................ 15.6 Alarms ................................................................................................................................... 15.7 Config Menu’ ............................................................................................................................ 15.7 Adjustments ......................................................................................................................... 15.7 Set Options ........................................................................................................................... 15.9 ALARMS................................................................................................................................. 15.11 Console .............................................................................................................................. 15.11 Rev. 08/03

Page 4

THESI - Index

DISPLAY ALARMS ............................................................................................................... 15.15 FORK SYNCHRONIZER ....................................................................................................... 15.16 Safety .................................................................................................................................... 15.16 CARRIAGE RETRACTION LOCK-OUT WHEN FORKS ARE LOWERING ................... 15.16

Section 16 - Accelerator pedal autosensing ..................................................... 16.1 Section 17 - THESI from serial number F24519P00001.................................. 1.1 1 Introduction ............................................................................................................................ 17.2 1.1 Table of improvements.................................................................................................. 17.2 2 Modifications to the power steering system ........................................................................... 17.3 2.1 Main features ................................................................................................................ 17.3 2.2 New electronic steering control .................................................................................... 17.4 2.3 Power steering system features ..................................................................................... 17.6 2.4 Connections................................................................................................................... 17.6 2.5 Functions ....................................................................................................................... 17.8 2.6 Composition of the power steering system ................................................................. 17.10 3 Modifications to the electrical system .................................................................................. 17.11 3.1 Electronic control ........................................................................................................ 17.11 3.2 New fan dissipator ...................................................................................................... 17.11 4 Modifications to the dashboard and controls ........................................................................ 17.12 4.1 New layout for the controls ......................................................................................... 17.13 4.2 New dashboard covers ................................................................................................ 17.13 5 Modifications to the optional equipment .............................................................................. 17.13 5.1 Preselector ................................................................................................................... 17.13 5.2 Fork synchronizer with frame plate L = 980 mm ....................................................... 17.13 5.3 Movable platform (optional) ....................................................................................... 17.14 6 New hydraulic distributor ..................................................................................................... 17.15

Appendix A – Electrical diagrams .................................................................... A.1

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Page 5

THESI - General Rules

General rules To avoid the accidents The majority of accidents that occur in the workshop are caused by lack of observance of a few simple and fundamental rules of prudence and safety. For this reason the majority of the cases can be avoided: all it takes is to forsee the possible causes and to act accordingly with the necessary caution and prudence.

With any type of machine, however well developed and constructed, it is not possible to absolutely exclude every eventuality of an accident.

A careful and prudent mechanic is the best guarantee against accidents. The scrupulous observance of only one elementary safety rule would be more than sufficient to avoid many serious accidents.

Safety rules Generally To carefully follow the procedures laid down for maintenance and repair.

Attention!

Never carry out cleaning, lubrication or maintenance with the battery connected, except in the cases prescribed.

Do not wear rings, wrist watches, loose or untied articles of clothing or dangling items such as, ties, torn garments, scarves, waistcoats or blouses with opened zip fasteners which could get entangled in moving parts. It is recommended instead to use approved protective clothing such as helmets, anti-slip shoes, gloves, safety glasses.

Do not perform any repair or maintenance work on the machines with people on the seat, except the usual operator to provide assistance to carry out the work.

Do not operate the truck in any other position than seated in the driver’s seat. Verify that there is no pressure in the hydraulic circuits before removing plugs and covers. Refer to the instructions provided on the subject in the present publication.

All maintenance work must be carried out with the maximum care and attention. The stepladders and platforms used in the workshop or in the field must be of construction conforming to the current safety rules and regulations.

Label all the controls to signal that an intervention is in progress. Use blocks or straps constructed of suitable material to support the truck should the truck or any parts of it be required to be raised up.

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Page 1

THESI - General Rules

Do not check electrolyte levels or refill the battery whilst smoking, since there are explosive gasses present.

If the brakes need to be released manually whilst working on the truck, wheels must be held in position by suitable blocks or similar equipment.

For the transport of forklifts under repair use a suitable trailer or if possible a low loader. To load or unload the truck from the transport vehicle choose a level area that offers a solid support to the wheels of the transport vehicle. Firmly anchor the truck to the trailer bed and block the wheels.

For electric heaters, battery chargers and similar equipment, employ sources of auxiliary electric supply with suitable earth connections to avoid the possibility of electric shock.

If the lifting or carrying of the heavy parts is required, use hoists or similar equipment of suitable capacity and ability and ensure anyone in the vicinity keeps clear. Be aware of the presence of people working in your vicinity.

Never use petrol, diesel or other inflammable liquids as detergents: always use inflammable, non-toxic commercial solvents.

If using compressed air for cleaning always wear safety glasses with side screen protectors.

Compressed air pressure should never exceed the maximum permitted value according to local or national safety standards.

Don’t smoke or use naked flames or cause sparks when handling, or in the proximity of, flammable materials.

Do not use naked flames as means of illumination when working on the truck or checking for leaks.

Ensure all guards and protectors are in place when the machine is in operation. Do not leave the machine unattended whilst in use. Do not get down from the driving position unless the truck is stopped and the handbrake is on. If something gets jammed in the truck do not attempt to free it unless the engine is switched off and the key is removed.

Proceed with extreme caution when required to do work under or in the vicinity of the truck. Always wear the recommended safety equipment: helmets, safety glasses and safety shoes.

In the case of interventions outside the workshop, if possible bring the machine to level ground and block it.

In cases where it is not possible to move the truck to a suitable work area, before starting the work, mark out an area around the truck with special stakes and chain/tape that signals the job is in progress.

If the breakdown should occur on a ramp or a sloping area, block the truck to prevent any movement and move the machine in the safest possible way.

Do not use damaged chains or frayed cables for lifting or towing. Always use safety gloves when handling chains or cables.

Lifting chains must be securely anchored at all points of connection. Ensure the anchors are rated and strong enough to carry the load being lifted. Keep clear of lifting points during the lifting or towing operation.

Working areas must always be kept clean and dry.

Any oil or water spillage must be cleaned up immediately.

Never allow any accumulation of oil or grease contaminated rags on the floor as this will present a serious fire risk. Always dispose of such rags in an appropriate metallic container with a metal lid or cover.

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Page 2

THESI - General Rules

Before operating the truck ensure that the driver’s seat is adjusted correctly and locked in position.

Ensure also that there are no persons in the vicinity of the truck or the attachment. Do not carry items in your pockets that could fall out and enter the compartments of the truck.

If there is a risk of being struck by metal particles or similar always wear safety glasses with side protection, a safety helmet, safety shoes and appropriate gloves.

When carrying out welding operations it is essential to wear protective clothing, welding glasses, safety helmet, overalls, gloves and socks. Other persons in the vicinity should also wear welding glasses whether involved in the work or not.

When handling frayed cables always wear adequate protection.

Attention!

Never look at the welding ark without adequate eye protection (gloves, spectacles etc). Use extreme care when handling. Keep hands and fingers well clear of moving or rotating machinery. Always use approved available safety protection, such as safety glasses and safety shoes.

When carrying out repairs under the truck, position the truck on a pit or suitable hoist.

On the completion of any work remove all tools from the truck and ensure all parts removed have been refitted and all fixing screws etc. re-tightened.

Electrical Installation Always be aware when connecting batteries that the supply cables must be connected in the prescribed method (+) to (+) and (-) to (-).

Avoid short circuits and sparks on the battery terminals, the gas from the seals is extremely flammable.

During recharging leave the battery cover open for more effective ventilation. Never check the charge level with a bridge using metallic connectors on the terminals. Avoid sparks or naked flames in the vicinity of the battery. To avoid explosions do not smoke.

Prior to any maintenance operation check for any loss of fuel or electrolyte: clean up any leakage before proceeding with the work.

Prior to any maintenance operations: check if any elements are short-circuited: rectify any short-circuits before proceeding with the work.

Do not recharge the battery in a closed environment: ensure that the ventilation is adequate to avoid the possibility of accidental explosion caused by the accumulation of the gas eliminated during charging.

Always disconnect the battery before carrying out any work on the electrical system.

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Page 3

THESI - General Rules

Hydraulic Installation Fluid sprayed out from small holes can be almost invisible and yet can have sufficient force to penetrate the skin: To check for this type of leakage use a piece of card or wood. Never put your hand over the hole.

If fluid is sprayed into the skin contact your first aid attendant immediately. Without prompt medical attention there could be a risk of serious infection or dermatitis.

Hydraulic pressures must always be checked with appropriate equipment.

Lifting And Handling When lifting and handling heavy objects always use suitable equipment with adequate capacity. Ensure the load is supported with adequate hooks and slings. If required use eyebolts provided for lifting operations.

Be aware of any persons in the vicinity of the raised load. Handle all parts with great care. Do not put hands or fingers between parts. Always wear certified safety equipment such as safety glasses, gloves and safety shoes.

Avoid twists or kinks in the lifting chain or steel ropes. Always wear safety gloves when handling ropes, chains or slings.

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Page 4

THESI – Section 1 – Introduction

Introduction Conventions

The terms FORWARD/REVERSE/RIGHT/LEFT which appear in the manual refer to the sides of the forklift indicated as follows: A B C D

= = = =

FORWARD REVERSE LEFT RIGHT

C

A

B

D

Rev. 05/00

Page 1.1

THESI – Section 1 – Introduction

Removal of the covers Access to the motor compartment

To gain access to the motor compartment open cover 1.

Before opening cover 1, switch the truck off and slide the seat forward, using lever D. Remove the securing bolt A from the cover.

N.B. Lower the operator footplate, if fitted, using the footplate lowering button.

Attention The securing bolt A must be tightened to a torque of 85Nm B

C

D COVER 3 COVER 1

COVER 2

A

Removal of cover 2 Removal of this cover will give access to the master unit, slave and power steel modul.

Remove as follows: • switch off the truck • remove the “red mushroom” emergency button; • remove the 4 screws from the external quadrant of the display; • using the specialised screwdriver, remove the 3 securing screws from points B.

Removal of cover 3

Removal of this cover will give access to the Steering linkages.

Remove as follows: • switch off the truck • remove the steering wheel as illustrated in illustration E • remove the 3 securing bolts at point Ctando le viti di bloccaggio cofano. with specialised screwdriver PART. E

Attention Retighten the fixing screws on covers 1,2 and 3 when work is complete.

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Page 1.2

THESI – Section 1 – Introduction

Tightening torque for the principal screws/nuts In the following table the tightening torques for the principal screws/nuts are listed.

These values are relative to screws with classification 8.8.

DESCRIPTION

Nm

DRIVE WHEEL NUTS TRACTION GROUP PLATE SCREWS FIXING SCREWS REDUCER TO PLATE FIXING SCREWS MOTOR TO PLATE LIFT CYLINDER FIXING SCREW FIXING SCREWS LIFT CYLINDER TO TRUCK FIXING SCREWS OIL PUMP WITH POWER STEER MOTOR FIXING BOLTS WITH SPACERS FOR POWER STEER MOTOR FIXING SCREWS ELECTRO-PUMP TO PLATE FIXING SCREWS MOTOR COMPARTMENT COVERS Tolerance

140 205 85 25 80 400 50 25 85 85 ± 5%

Torque setting for nuts/terminals on hydraulic pipe connections T oleran ce: + 20 % C O N N E C TIO N N U T S O N H Y D R A U LIC P IP IN G : IS O M E T RIC T H R E A D S M 10 x 1 M 14 x 1 ,5 M 16 x 1 ,5 M 18 x 1 ,5 M 22 x 1 ,5 M 33 x 2

T a ble ta ke n fro m hyd rau lic d iag ram - N m ta k en fro m P a rk er c atalo gu e.

Nm 25 50 80 90 16 0 42 5

T oleran ce: + 20 % TE R M IN A L C O N N E C T IO N S O N H Y D R A U L IC P IP IN G : IS O M E T RIC T H R E A D S M 10 X 1 M 12 X 1 ,5 M 14 X 1 ,5 M 22 X 1 ,5 M 30 X 2

T a ble ta ke n fro m hyd rau lic d iag ram - N m ta k en fro m P a rk er c atalo gu e.

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Nm 25 30 50 16 0 ?

Page 1.3

THESI – Section 8 – Lift Group

Lift Group Assembly of the Mast The number of shims ( 1 ) fitted during manufacturing is stamped on the reach carriage. This quantity must always be kept the same if the mast is removed and refitted.

The hexagonal headed M20 ( 2 ) must be tightened to a torque of 400Nm. The position of the pins ( 3 ) for the attachment of the mast to the reach carriage are marked. The marks on the end of the pins must be aligned with the marks on the reach carriage. On one pin there is one punch mark which must be aligned with the single punch mark on the reach carriage. On the other pin there are two punch marks which again must be aligned with the two punch marks on the other side of the reach carriage. The tightening torque of the socket headed screws ( 4 ), which fasten the pins to the mast is 80Nm.

Attention After assembly check the inclination of the mast towards the operators position.

The angle a must be set at the following values: • = 0,5° 0,1° for h3 < 9655 • = 0,25° 0,1° for h3 > 9955 Lateral inclination must be 0° + 0,1°.

Clearance between the mast sides and the reach carriage must be 1mm + 0.5mm

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Page 8.1

THESI – Section 8 – Lift Group

Description of the lift groups PKG and PKK THESI models A-B-C are fitted with the same type of triplex mast, with excellent central visibility. The mast is fitted onto the reach carriage with two pins located on each side of the outer mast section.

There are two types of mast available, both of similar conception and both fitted with a tilting and side shift carriage.

183 or PKG masts are for lift heights up to 6.3 m 186 or PKK masts are for lift heights over 6.3 m The masts are developed to give trouble free operation with minimal maintenance requirements. The angular support rollers run inside the mast profiles for precise operation. During maintenance operations roller positions can be adjusted with shims.

There are two hydraulic cylinders employed for lifting the fork carriage and extending the inner mast sections. The inverted primary lift cylinder, is extended by hydraulic oil pressure fed through the distributor and the secondary lift cylinder and raises the fork carriage. When the primary lift cylinder reaches the end of its stroke, the oil pressure in the secondary cylinder increases and the inner mast sections are smoothly and softly extended.

The fork carriage assembly is manufactured to the FEM standard and all models are of the double plate type. Fork carriages are fully welded on these models and have five principal guide rollers. The guide rollers can be shimmed to compensate for wear.

Two tilt cylinders are mounted on the fork carriage assembly. These cylinders can move the fork carriage 2° forward and 4° back from vertical.

BL800 type lift chains are strategically arranged with chain anchors which give autoalignment.

The forks on THESI A trucks have a profile of 80mm x 40mm x 1150mm, while on the THESI B –C trucks they have a profile of 100mm x 45mm x 1150mm.

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Page 8.2

THESI – Section 8 – Lift Group

Maintenance of the lift group PKG and PKK Removing the forks -

Put the hand brake on – extend the reach fully forward, raise the fork carriage to approx. 150mm from the ground. Switch OFF the truck.

-

Unscrew the central holding screw on the fork carriage.

-

Release the fork latch pin and slide the fork to the central position on the carriage.

-

Lower the fork onto wooden blocks situated at the heel and the toe of the fork until the fork is released from the upper rail of the carriage.

-

Switch on the truck, release the hand brake and reverse the truck slowly until the fork is clear of the carriage.

-

Repeat the procedure for the other fork.

NOTE: To ease the process of sliding the forks, lightly lubricate the top and bottom faces of the carriage.

Refitting the forks -

Drive the truck up to the fork positioning it centrally on the carriage.

-

Drive the truck slowly forward until the fork is located on the center of the carriage.

-

Apply the hand brake and lift slowly with fork located on the carriage.

-

Ensure the fork is sitting correctly on the carriage and then slide to one side.

-

Repeat the operation with the other fork and refit the central holding screw.

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Page 8.3

THESI – Section 8 – Lift Group

Maintenance of the forks Remove any rust, scale or paint from the forks and examine them for wear or damage. Forks must be withdrawn from use if the heel is worn to less than 90% of the original thickness.

NOTE The vertical section of the fork can be used as a reference for the original thickness.

-

Check the central fork holding screw is installed and not damaged.

Fork latch pins -

Lubricate the fork latch pins with oil and manipulate them a few times to ensure the oil penetrates well.

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Page 8.4

THESI – Section 8 – Lift Group Removal of the mast -

Position the truck under an appropriate lifting device (with capacity of at least 3000 kg).

-

Apply the hand brake, block the load wheels.

-

Reach the mast out fully, lowering the fork carriage. Switch off the truck and disconnect the battery.

-

SRelease any hydraulic pressure from all cylinders by pressing the red emergency lowering push button mounted in the reach carriage.

NOTE When removing the mast for dismantling, it will be beneficial to first remove the tilt and side shift assembly as described in the paragraph “Remove of the Tilt and Side Shift assembly”.

-

Disconnect the hydraulic hoses below the level of the support bracket, situated on the right side between the mast and the reach carriage. These are the connectors for the tilt and side shift group.

-

Connect a sling, of adequate capacity, to the top of the mast, passing it through the internal and intermediate sections and with a suitable lifting device, lift these two sections sufficiently to gain access to the base of the secondary lift cylinder and the fixing bolts. Block the mast sections in this position.

-

Disconnect the hydraulic supply hose to the secondary lift cylinder.

-

Temporarily clamp the mast to the reach carriage with a suitable clamp.

-

Remove the two hexagonal headed (M20) bolts at the base of the mast.

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Page 8.5

THESI – Section 8 – Lift Group -

Fully lower the internal and intermediate mast sections and reposition the sling to lift all sections of the mast together. Gently lift the complete mast assembly, just enough to hold the weight.

-

Unscrew the four (M12) socket headed shrews, which hold the mounting pins to the mast section, on both sides of the reach carriage.

-

Using two extractor bolts M8 x 50mm, extract both mounting pins from the reach carriage. Take note of the number if shims fitted between the spacer ring and the mast.

SHIM

SPACER RING

-

Using an adequate lifting device, lift out the mast from the reach carriage.

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Page 8.6

THESI – Section 8 – Lift Group

Refitting the mast -

This operation must only be carried out using a lifting device with a capacity no less than 3000kg.

-

Ensure that the reach carriage is reached fully out, apply the hand brake, switch OFF the truck, disconnect the battery and firmly block the wheels.

-

Using an adequate lifting device, lift the complete mast, with all sections, into position in the centre of the carriage.

-

Align the outer mast sections with the mounting pins in position in each side of the carriage. Replace the shims originally fitted between the mast and the spacer ring.

-

Use the long (M12) bolts to assist with the insertion of the mounting pins.

-

Insert the four original (M12) screws to fix the mounting pins in their locations. Remove the two long (M12) bolts which were used to guide the mounting pins into position.

-

Repeat the operation for the other side of the mast. Finally tighten all eight fixing screws on the mounting pins

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Page 8.7

THESI – Section 8 – Lift Group

-

Clamp the mast against the reach carriage, with a suitable clamp and sling together the top cross members of the inner and intermediate mast sections.

-

Using the sling, lift the two mast sections sufficiently to gain access to fit the two (M20) fixing bolts at the base of the mast.

NOTE: Ensure that the lower section of the lift cylinder is clear of the lower cross member on the internal mast section and the two do not touch when the mast is raised.

-

Connect the hydraulic hose for the supply to the lift cylinder.

-

Mount the two (M20) hexagonal headed fixing screws at the base of the mast, with the original shims between the mast and the reach carriage.

-

Lower the two inner mast sections into position and remove the slings.

-

Reconnect the unions for tilt and side shift, located on the support bracket clamped to the lift cylinder behind the mast.

-

Adjust the lift chains.

-

Vent any trapped air from both lift cylinders.

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Page 8.8

THESI – Section 8 – Lift Group

Regolazione della posizione verticale del montante -

Park the truck on a plane surface. Using an inclinometer set the angle of inclination of the fixed mast.

1) For lift heights h3 < 9655mm incline 0,5° (30’) back.

2) For lift heights h3 > 9955mm incline 0,25° (15’) back.

Add or remove the shims between the mast and reach carriage to obtain the desired angle of inclination.

Tighten the (M20) bolts to a torque of 400Nm.

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Page 8.9

THESI – Section 8 – Lift Group

Removal of the primary lift cylinder The following procedures are valid for forklift trucks with lift heights up to 7.6m. For trucks with lift heights above 7.6m the complete mast must be removed from the truck to enable removal of the primary and secondary lift cylinders.

NOTE: It is recommended that two qualified persons carry out the following procedures.

-

Park the truck under a lifting device of adequate capacity ( safe working load of 1000kg ) with the mast fully reached out and the fork carriage lowered to the ground.

Lift the fork carriage ( with the lifting device ) until the primary lift chain is slack and block into position. Ensure that the primary lift cylinder is fully closed.

Mount a wooden block of adequate size “1” between the top of the reach carriage and the primary lift cylinder.

Remove the securing ring on the hose pulley and remove the pulley.

Secure the piston rod of the primary lift cylinder to the cylinder body with suitable straps to prevent it extending.

Using a raising platform of adequate capacity, disconnect the hydraulic supply line to the primary lift cylinder “4” A 41mm spanner will be required. To ensure minimum oil loss cap both the supply line and the fitting on the lift cylinder.

Loosen the clamp in the cylinder body “5”. On the higher lift height masts the cylinder can be slid down, onto the wooden block positioned previously.

Connect a sling around the body of the cylinder, fixed with a clamp “10”, to prevent the sling from sliding up the body of the cylinder.

Carefully remove the cylinder from its support on the intermediate mast.

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Page 8.10

THESI – Section 8 – Lift Group

Refitting the primary lift cylinder -

To refit the primary lift cylinder, follow the removal procedure in the reverse order.

Ensure that the locating boss at the supply end of the cylinder is correctly located in the hole in the intermediate mast section.

Check the condition of the ‘O’ ring on the supply connector. Replace if necessary.

Tighten the supply line connector “4” ( in the figure on the preceding page ), to a torque of 120-150 Nm. Do not over-tighten.

Check the oil level in the reservoir. Refill if necessary with the recommended type of hydraulic oil.

Vent any air from the hydraulic system, as described in the paragraph “Venting air from the lift cylinders”.

Removal of the secondary lift cylinder NOTE: It is recommended that the following procedures are carried out with two qualified persons.

-

-

Park the truck under a lifting device of adequate capacity (safe working load 1000kg). Reach the mast fully forward and lower the forks to the ground. Block the load wheels.

Using a suitable raising platform, disconnect the hydraulic supply line to the top of the secondary lift cylinder, see figure 11. A 41mm open ended spanner will be required. Cap the supply line and the fitting in the lift cylinder.

Using a suitable sling around the upper cross member of the internal and intermediate mast sections, lift these two sections sufficiently to allow the removal of the cylinder. Safely block the mast sections in this position.

Remove the clamp on the cylinder body, (see figure on preceding page).

Remove the upper bracket for the connection of the hydraulic hose and move away from the cylinder , (see figure on preceding page) Remove the lower bracket, located on the outer mast section, for the connection of the hydraulic hoses for the tilt and side shift.

Access the bracket between the right hand side if the reach carriage and the right outer mast section.

Move the bracket “1” away from the cylinder “2”.

Continue on following page

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Page 8.11

THESI – Section 8 – Lift Group

Removal of the secondary lift cylinder - continued from preceding page -

-

-

Place a drain tray below the mast assembly to contain any oil spillage.

Using a 41mm open ended spanner disconnect the connection to the lower hydraulic hose. Cap the hydraulic line and the fitting on the cylinder.

Remove the upper support bolts for the lift cylinder.

Put a suitable sling “3” around the cylinder “1” and secure it in position on the cylinder body with a clamp “2” and connect the sling to the lifting device.

Carefully lift the cylinder sufficiently to clear the top of the reach carriage and swing it away from the mast.

Refitting the secondary lift cylinder -

To refit the secondary lift cylinder, follow removal procedure in reverse order.

Take extreme care during the refitting procedure to avoid any damage to the cylinder.

Check the condition of the “O” ring in the supply connector. Replace if necessary.

Tighten the hydraulic connections to a torque of 120-150Nm. Do not over tighten.

Check the oil level in the reservoir, refill if necessary with the recommended type of hydraulic oil, consult section 10.

Vent any air from the hydraulic system, as described in the paragraph “Venting air from the lift cylinders”.

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Page 8.12

THESI – Section 8 – Lift Group

Dismantling the cylinders

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Piston rod Cylinder Spacer Seal carrier Support plate ‘O’ ring Lock ring Pressure seal Bush Wiper seal Hexagon headed bolt M4 x 6 Spiral pin Safety valve – burst Flow control valve Rev. 05/00

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

Sealing washer Piston rod Cylinder Seal carrier ‘O’ ring Lock ring Pressure seal Bush Wiper seal Heagon headed bolt M4 x 6 Sealing washer Safety valve - burst Pulley bracket Continue on following page

Page 8.13

THESI – Section 8 – Lift Group

Dismantling the cylinders – continued from preceding page -

The lift cylinder must be held in a vice with soft jaws.

Remove the safety valve (burst) “13” or “26” using a slotted profile socket.

On the primary lift cylinder, remove the chain pulley and the bracket, which must be extracted from its seat using firm blows from a hide faced or copper mallet. While being rotated anticlockwise.

On the secondary lift cylinder, punch down the lock pin to allow removal of the seal carrier”4”.

Remove the spiral pin “12” positioned at the extreme end of the rod.

Remove the seal carrier “4”, using a chain spanner or a “C” spanner.

Remove the piston “1” and the seal carrier “4”from the cylinder body “2” Extract the seal carrier “4”, from the piston rod “1”.

Replace the wiper seal “10” the bush “9”, the pressure seal “8”, the ‘O’ ring “6” and the lock ring “7” on the secondary cylinder.

Replace the same components in the primary cylinder.

Assembling the cylinders -

To re-assemble the primary and secondary lift cylinders follow the procedure for dismantling in reverse order.

-

On the secondary lift cylinder, ensure that the spacer “3” is replaced before fitting the piston rod “1” into the cylinder body “2”.

-

Refit the seal holders “4” or “18” on cylinders “2” or “17”, using loctite 242 uniformly applied around the threads of the cylinder and tighten to a torque of 160-180 Nm

Rev. 02/01

Page 8.14

THESI – Section 8 – Lift Group

Venting the air from the lift cylinders Air can be expelled from the hydraulic system by lifting the mast to the maximum lift height and lowering several times. Alternatively proceed as follows: -

To vent the air from the primary lift cylinder, loosen the bleed screw “1” with an M7 spanner.

Operate the lift lever until the air is expelled i.e. oil flows from the vent screw without any air bubbles. Retighten the bleed screw “1”.

-

Repeat the procedure for the bleed screw “2” on the secondary lift cylinder.

-

Ensure that the operation of lift, tilt and side shift is not “spongy” after venting the air. If the lift function continues to be “spongy” repeat the procedure to vent the air from the cylinders.

Attention!

As the primary lift cylinder is extended it should position itself smoothly into the seat of the chain pulley at the base of the intermediate mast section. If it is necessary to replace the primary lift cylinder ensure that the piston rod is aligned with the chain pulley in such a way as to permit the insertion of the two locking pins for the pulley.

Rev. 05/00

Page 8.15

THESI – Section 8 – Lift Group

Lift chain Check -

Clean the guide on the mast and the lift chain.

Examine the wear, particularly around the rollers.

Check, if applicable, rotating pins for play or wear.

Check, if applicable, link plates for elongation, rust or missing.

Check the chain anchors.

Replace any damaged chain.

Check the condition of the rollers and the surface on the mast guide, make sure they are secure.

In particular check for the presence of: (a) Missing or damaged link plates. (b) Link pins loose or damaged, damage on the end of the pin. (c) Evidence of pitting due to heat or corrosion, particularly on the external face of the link plate. (d) Link pins rotating in the link plates. (e) Loss of free movement ( chain rigid ). (f) Wear of the edges of the link plates, caused by sliding on the pulleys. (g) Damage to the lock mechanism on the anchor pins. (h) Wear or corrosion on the anchor pins ( including the integral anchor ). (i) Wear or fatigue between the pin and the plate and/or the associated components.

If any of the previously mentioned defects are evident the chain must be replaced.

Measuring the wear Measure the depth of the plate (A), it should not be more than 5% less than the original dimension. If any link plates are worn beyond this limit replace the chain.

The original dimension can be measured on a part of the chain that does not pass over the pulley.

continued on following page

Rev. 05/00

Page 8.16

THESI – Section 8 – Lift Group

Measuring the wear – continued from previous page Before measuring for any elongation of the chain it must be taut. If the chain is measured while still fitted to the truck, the weight of the fork carriage or the mast section is sufficient to tension the chain enough to give accurate measurement. If on the other hand the chain has been removed, it must be held taut while the measurements for elongation are taken.

The sections of chain which pass over the pulleys will have a greater wear rate.

Since the wear rate is not uniform along the entire length, take measurements for elongation on a number of sections of the chain (minimum three), measure the elongation over 10 pitches. If the maximum elongation is found to be above 2% replace the chain.

P

10P

Note • It is more important to observe that elongation is not always an indication that the chain is about to fail, also a chain may fail without any signs if elongation. This is particularly applicable for the trucks that operate on uneven ground. It is extremely important to examine chain anchor combs and threads. If the chains are replaced ensure also that the chain anchors, with associated nuts and washers are also replaced.

• Never lengthen a chain by joining two lengths together (this will invalidate the certification of the chain) • If the mast is fitted with two chains, both chains must be replaced together. When refitting ensure that both chains are adjusted to the same tension.

Rev. 05/00

Page 8.17

THESI – Section 8 – Lift Group Adjustment of the lift chain In all lift groups it is extremely important that the vertical cylinders reach their mechanical stops at full extension, ensuring that the lifting force is available for the full extent of the stroke of the cylinder. If the chain is adjusted too short it will not allow the lift cylinder to reach its full extension and the lifting force from the cylinder will be transmitted to the chain and the mast. This will cause excessive tension on the chain and mast and could result in damage to either/or both units. There will also be a tendency for the lift cylinder to bend.

If the chain is too slack, it could be damaged by coming into contact with the load carried on the forks, also the maximum lift height will not be obtainable.

Lift groups using inverted lift cylinders rely on correct adjustment of the lift chain to guarantee full extension of the cylinders.

Procedure to adjust the lift chain • • •

•

Park the truck on a level surface, apply the hand brake and block the load wheels.

Switch off the truck and disconnect the battery.

Check the associated components: - Relieve the weight of the chain from the chain pulleys and check the pulleys and bearings for wear. Make sure that the pulley turns freely and the chain runs centrally between the flanges of the pulley.

- Check the tension of the chain for the fork carriage.

Adjustment of the chain for the mast sections The figure shows the anchor points of the lift chain for the mast sections “1”and the fork carriage “2” with the fork carriage raised.

These anchors are used to adjust the length of the lift chains for the fork carriage and mast sections.Proceed as follows to carry out any adjustment.

- With the mast in the vertical position fasten the lift/lower lever in the lower position (it can be tied to the hand brake lever).

Pull on each chain to ensure both lift cylinders are fully closed.

- Adjust the chain anchor “1”, until all mast sections are in line at the top, see figure “21” - Attention After adjustment is completed retighten the lock nuts “3” on the chain anchors.

Continued on following page

Rev. 05/00

Page 8.18

THESI – Section 8 – Lift Group

Adjustment of the lift chain – continued from previous page •

Adjustment of the lift chain for the fork carriage - Position the fork carriage with the rollers protruding below the inner mast section, approx. 24mm, before proceeding with the chain adjustment, this will position the base of the forks 5-7mm above the ground. Adjust the chain anchor “2”to a suitable position for the correct tension on the lift chain for the fork carriage.

- After adjustment is completed tighten the chain anchor lock nut “4”. The clearance between the fork carriage and the upper cross member of the internal mast should be 5-10mm.

- If during adjustment the chain is found to be dry, apply lubrication before returning the truck into service.

- Make sure that the mast sections and fork carriage are operating correctly.

- Remove the blocks from the wheels and return the truck into service.

Note If the procedure is not carried out, the pulley in the primary lift cylinder could be damaged, by coming into contact with the intermediate chain anchor, at maximum extension if the mast.

-

Adjust the anchor “1”on the mast so that at least two threads are visible after the locknut.

Only make adjustments to the chain for the fork carriage with anchor “4”.

Tighten both chain anchors with lock nuts (3) and (6)

This procedure ensures that when the chain anchor for the intermediate chain “7” is in its highest position, with respect to the pulley on the primary lift cylinder, there will be a clearance maintained between the pulley and the chain anchor at the full extension if the mast.

Rev. 05/00

Page 8.19

THESI – Section 8 – Lift Group

Tilt and side shift assembly The tilt and sideshift assembly is comprised of two comprehensive principal welded steel assembles, that is the support located in the inner mast on rollers and the fork plate attached to the sideshift piston rod.

Two tilt cylinders are mounted at the base of the support and push forward to give 4º back tilt or withdraw to give 2º forward tilt. The standard sideshift has a total movement of 160mm, 80mm each side of centre.

It is ideally positioned to work between the extension legs on a model with a large frame.

Various heights of load backrests are available.

Attention Never work below a raised fork carriage unless the carriage has been blocked into position and the pressure in the hydraulic system has been relieved.

Removal of the tilt and sideshift assembly -

Park the truck below a suitable lifting device of adequate capacity to lift the internal mast section.

Firmly block the load wheels. Apply the handbrake, switch OFF the truck and disconnect the battery.

Place a drain tray beneath the mast assembly to collect any oil spillage.

Lift the fork carriage sufficiently to gain access to the tilt and sideshift hoses.

Position adequate blocks between the chain pulley of the lift cylinder and the fork carriage.

Disconnect the hoses from the tilt and sideshift cylinders.

Remove the clamps from the sideshift hoses on the right hand side of the support.

Remove the cover of the support, which protects the tilt hoses.

Remove the hose clamps located between the tilt cylinders and remove the tubing, position them out of the way.

Lower the forks onto a pallet and fix them onto a bracket “G” with strong rope or a counter weight.

Remove the chain anchor pin from the chain anchor and secure the chain to one side.

Using the hydraulic system, raise the mast sufficiently to release tilt and side shift assembly.

Reconnect the battery and carefully reverse the truck away from the tilt and side shift assembly.

Refitting the tilt and side shift assembly -

To refit the tilt and side shift assembly, follow the removal procedure in the reverse order.

Ensure that the carriage rollers and shims are replaced in their original positions.

Rev. 05/00

Page 8.20

THESI – Section 8 – Lift Group

Fixing the mast in a safe condition If it is necessary to work with the mast raised, it must be secured in a safe condition, described as follows.

Attention Ensure a chain of adequate capacity and length is used, which will hold the mast in the full lift height position.

-

Lift the forks Secure the chain around the cross member “1”of the external mast section and cross member “2” of the intermediate mast section.

Take the weight of the mast on the chain.

Lower the forks completely .

Rev. 05/00

Page 8.21

THESI - Section 9 – Hydraulic System

Hydraulic Installation Introduction

Considered in the following table, are the functions of the fork lifting/lowering, tilt and side shift.

The power steering has a dedicated motor and pump with separate adjustment.

The speed of the hydraulic functions are regulated as follows: Fork lowering Proportional valve Fork lifting speed of the pump motor Tilt speed of the pump motor Reach speed of the pump motor Fork synchroniser speed of the pump motor

(OPTIONAL)

Only one hydraulic function may be operated at a time. Except during fork lowering, the auxiliary function can be activated.

The pump motor has two rotation speeds, one for lifting and one for the auxiliary functions.

Rev. 05/00

Page 9.1

THESI - Section 9 – Hydraulic System

SIDE SHIFT

OUT

LIFTING FORKS

REACH

IN

BACK

TILT

FORWARD

SEAT SIDE

STEERING WEEL SIDE

Hydraulic function diagram

continued on following page Rev. 05/00

Page 9.2

THESI - Section 9 – Hydraulic System Hydraulic function diagram – continued from previous page 1.

Motor

2.

Gear pump

3.

4.

Filter on return line to tank Relief valve set to 250 bar

5.

EV1 electrovalve for fork lifting; fork lifting speed is controlled by the speed of the pump motor.

6.

7.

EVP proportional electrovalve for fork lowering; oil flow is adjustable by a regulating screw Safety button for lowering; when activated allows lowering of the forks, lowering stops immediately the button is released

8.

Free lift cylinder (primary cylinder) with solid lift ram, in series with secondary cylinder, it is the first cylinder to operate when oil pressure arrives from the oil pump

9. Lift cylinder (secondary) with hollow ram; operates after the primary lift cylinder 10. Blocking valve; fitted in the lift cylinder and activated if a hydraulic hose bursts 11. Flow regulation valve inside lift cylinder 12. Proportional electrovalve; in operation when carriage is reached in 13. Proportional electrovalve; in operation when carriage is reached out 14. Relief valve set at 130 bar; for carriage reach in 15. Relief valve set at 80 bar; for carriage reach out 16. Electrovalve EV4; in operation when tilting back 17. Electrovalve EV5; in operation when tilting forward 18. Valve set at 90 bar (preloaded) 19. Electrovalve EV6; in operation when sideshifting towards the seat side 20. Electrovalve EV7; in operation when sideshifting towards the steering wheel 21. Point of attachment for the 5th hydraulic element for fork synchronisation The element for fork synchronisation is the same as the element for the side shift functions.

There are two hydraulic groups available from spare parts, one for four levers and one for five levers.

Rev. 05/00

Page 9.3

LIFT (FORKS)

Rev. 08/03 REACH (MAST)

OUT

IN

FORKS UP

OVERCENTER VALVE

TILT

FORKS DOWN SEAT SIDE SIDE SHIFT (FORKS)

STEERING WHEEL SIDE

POWER STEERING

HYDRAULIC MOTOR

THESI - Section 9 – Hydraulic System

Hydraulic functional diagram with Overcenter Valve

Continued on following page

Page 9.4

THESI - Section 9 – Hydraulic System Hydraulic functional diagram whit Overcenter valve continued from previous page 1.

2.

Motor Gear pump

3.

4.

Filter on return line to tank Relief valve set to 250 bar

5.

EV1 electrovalve for fork lifting; fork lifting speed is controlled by the speed of the pump

6.

motor.

EVP proportional electrovalve for fork lowering; oil flow is adjustable by a regulating screw

7.

Safety button for lowering; when activated allows lowering of the forks, lowering stops immediately the button is released

8.

Free lift cylinder (primary cylinder) with solid lift ram, in series with secondary cylinder, it is the first cylinder to operate when oil pressure arrives from the oil pump

9.

Lift cylinder (secondary) with hollow ram; operates after the primary lift cylinder

10. Blocking valve; fitted in the lift cylinder and activated if a hydraulic hose bursts 11. Flow regulation valve inside lift cylinder 12. Proportional electrovalve; in operation when carriage is reached in 13. Proportional electrovalve; in operation when carriage is reached out 14. Relief valve set at 130 bar; for carriage reach in 15. Relief valve set at 80 bar; for carriage reach out 16. Electrovalve EV4; in operation when tilting back 17. Electrovalve EV5; in operation when tilting forward 18. Overcenter Valve 19. Electrovalve EV6; in operation when sideshifting towards the seat side 20. Electrovalve EV7; in operation when sideshifting towards the steering wheel 21. Point of attachment for the 5th hydraulic element for fork synchronisation The element for fork synchronisation is the same as the element for the side shift functions.

There are two hydraulic groups available from spare parts, one for four levers and one for five levers.

22. Power steering pump motor 23. Power steering hydraulic motor

Rev. 08/03

Page 9.5

THESI - Section 9 – Hydraulic System

Hydraulic assembly diagram 56 Valve group 55 Carriage reach cylinder 54 Carriage reach cylinder 53 Power steering 52 Hydraulic motor 51 Power steering pump 50 Lift pump 49 Reservoir assembly 48 EGE08LREDA3C connector 47 A T T08ZLA3C T connector 46 Overcenter valve 45 GEO8LRE3/8DOMDA3C connector 44 Copper 3/8” washer 43 M14X1.5 pipe union 42 Cap 41 Valve group / mast pipe 40 Return pipe (1’ section) 39 Delivery pipe 38 14 rqrb14b bonded washer 37 Right power steering pipe / right hydraulic motor 36 Left power steering pipe / left hydraulic motor 35 Power steering delivery pipe 34 Special connector 33 Special connector 32 EW22L0MDA3C 90° connector 31 Power steering pump suction pipe 30 Valve group / tilt down pipe Brandeggio forche verso il basso/l’alto Cilindro carro traslatore Cilindro colonna Gruppo valvole Idroguida Modello colonna Motore idraulico Pompa idroguida Pompa sollevamento Questa disposizione vale anche per la colonna da 25Q.li Schema di collegamento tubi secondo il modello di colonna Serbatoio olio Sollevamento forche Traslatore laterale (lato sedile/volante) Rev. 08/03

29 Valve group / tilt up pipe 28 Valve group / side shift left pipe 27 Valve group / side shift right pipe 26 GE08LRED0MDA 3C connector 25 Valve group / mast pipe 24 121 O-ring 23 M14x1.5/10-3RSN02-2 pipe union 22 Valve group / carriage back cylinder pipe 21 Valve group / carriage forward cylinder pipe 20 GE10LREDOMDA3C connector 19 18 GE12ZLM 18x1.5EDA3C connector 17 Copper ½” washer 16 IBM 08 T 12 connector 15 20-32/9/C6/W2 clamp 14 Return pipe (2’ section) 13 Valve group / Overcenter pipe (F) 12 Valve group / Overcenter pipe (S) 11 10 9 ½” gas pipe union 8 Return pipe (1’ section) 7 1/2” rqrb08 ½” pipe union 6 RQRB08 ½” bonded washer 5 Delivery pipe 4 KWFV-15L/35 delivery flange 3 KWFV-28L/40suction flange 2 Lift pump suction pipe 1 EW28LOMDA3C 90° connector Fork tilt down/up Carriage reach cylinder Mast cylinder Valve group Power steering Mast model Hydraulic motor Power steering pump Lift pump This layout is also applicable for the 25 Q.li mast Pipe connection diagram in accordance with type of mast Oil reservoir Fork lift Side shifter (seat/steering wheel side) Page 9.6

Rev. 08/03

Hydraulic assembly diagram

THESI - Section 9 – Hydraulic Installation

Page 9.7

THESI - Section 9 – Hydraulic System

Modification to improve functioning of the Overcenter Valve We have created a kit of parts for installation on THESI trucks that have a problem with the tilt function (the forks do not maintain their position when they are tilted up).

We recommend that this kit be installed only if the retention valve for the tilt function does not hold correctly after shimming the spring to eliminate the problem.

List of parts to order for the modification Description Quantity Overcenter valve 1 Valve support 1 Pipe 1 Pipe 1 T connector 1 Connector 1 Connector 2 M5 hexagon head screws 2 Washer diameter 5 2 Screw 1 Washer 1

Location of the Overcenter Valve

Rev. 08/03

Page 9.9

Rev. 08/03

T Connector

2 spring washers diameter 6 2 M6x40 hexagon head screws

Connector

Overcenter Valve

Connector

Connector

Page 9.10

Per colonna 186 il tubo in questione è l’ultimo a destra come visualizzazione sulla foto

Tubazione cod.88805034 da valvola overcenter ad attacco su colonna per brandeggio verso il basso (3 pallini) per colonna 183 e 25 Q.li.

Tubazione da valv. overcenter ad attacco su colonna per brandeg-gio verso l’alto (2 pallini)

Overcenter Valve

Pipe connected to the A1 of the valve group (3 balls)

Insert 1 collar - 1 M6x65 hexagon head screw 1 flat washer diameter 6

Pipe connected to the B1 of the valve group (2 balls)

THESI - Section 9 – Hydraulic System

Overcenter Valve assembly instruction diagram

THESI - Section 9 – Hydraulic System

Electrical denomination of the valves

D eHydraulic nominazione Denomination Idraulica

D eElectrical nominazione Denomination Ele ttrica

EV1

sollevlift amento

EVP

2Y11 pin 2/4: EV1 pin 1/3: EVP

EV2

1Y2

riereach ntro cin arro

EV3

1Y3

ureach scita cout arro

EV4

1Y4

brandeggtilt io back forche in alto

EV5

1Y5

brandegtilt gioforward forche in basso

EV6

1Y6

trassideshift lazione fotowards rche latoseat sedile

EV7

1Y7

sideshift traslaziotowards ne forchesteering lato volwheel ante

Function Funzione

dlower iscesa

Description of the electrovalve group ( view from above )

2Y11

Rev. 05/00

1Y2

1Y4

1Y6

1Y3 1Y5

1Y7

Page 9.11

THESI - Section 9 – Hydraulic System

Relief valve adjustment The adjustment of the relief valve, must be carried out, with a load on the forks which is 100 kg greater than the nominal load. This will ensure that the relief valve will not intervene, until the rated capacity is reached.

It also ensures that all the oil flow provided by the pump, is fed to the cylinder in operation, with the normal load on the forks.

Relief valve

Location of the hydraulic distributor The distributor is located on the reach carriage behind the steering wheel, as shown in the figure.

Rev. 05/00

Page 9.12

THESI - Section 9 – Hydraulic System

The main components of the hydraulic system are: Pump motor Power steering motor Hydraulic motor

Power steering motor Pump motor

Hydraulic motor

Rev. 08/03

Page 9.13

THESI - Section 10 - Electrical Motors

Electric motors Electric motor specifications Traction motor:

Type of excitation Voltage Power output Maximum speed Nominal armature current Running field current Acceleration field current Insulation class Number of brushes Brush wear rate IP

Separate + 48V 5.2 KW 4000 rpm 131 A 15 A 35 A F 4 3mm / 1000 h 20

Pump motor:

Type of motor Voltage Power output Nominal current Maximum speed Insulation class Number of brushes Brush wear rate

Series excitation + 48 V 11.5 KW 330 A 4000 rpm F 4 3mm / 1000h

Power steering motor:

Type of motor Voltage Power output Nominal current Maximum speed Insulation class Number of brushes Brush wear rate

Rev. 08/03

Series excitation +48 V 0.9 KW 20 A 4800 rpm F 4 5 mm / 1000 h

Page 10.1

THESI - Section 11 - Electrical Installation

Electrical system Electronic control Introduction The truck is controlled by the following three logic units: 1. slave 2. display 3. power steering The first logic unit checks and controls the functions of the truck and also controls the Console (or PC_Console); the second logic unit acts as the interface with the operator and displays the state of the truck and malfunctions, if any; the third logic unit controls the power steering.

The block diagram below shows the hardware of the machine.

BATTERY

HSFC SLAVE SYSTEM LOGIC UNIT POWER SUPPLY 1

PC-CONSOLE CONSOLE

TRACTION MOTOR DISPLAY CARD LIFT MOTOR

LCD DISPLAY

2

LEVER POTENTIOMETER GROUP Lift and auxiliary functions

MOTOR AND USES SENSOR GROUP ENCODER FOR HEIGHT METER AND PRESELECTOR

TRACTION CONTROL GROUP

STEER WHEEL POSITION INDICATOR

ELECTROVALVE GROUP

POWER STEERING MOTOR

POWER SUPPLY

POWER STEERING LOGIC UNIT

STEERING SENSOR

3 Diagram below shows the hardware of the system

Rev. 08/03

Page 11.1

THESI - Section 11 - Electrical Installation Electronic control The electronic control system controls the traction motor by setting the field and armature current parameters.

Rev. 08/03

Page 11.2

THESI - Section 11 - Electrical Installation Display The display serves as the interface between the system and the operator and displays the state of the machine as well as any abnormal alarm situations.

It receives signals from the various truck component monitoring sensors and transmits them to the slave logic unit (see the list of I/Os received from the X2 connector on page 11.10).

The display also manages the height meter and preselector functions for the stocking heights (see the appropriate chapter for further information).

Description of the graphic display:

Display Steer wheel position indicator (optional):

L

R

Indicatore sterzo: Steering todithe left ruota a sinistra

L

R

ruotaPositioned in posizione centrale in the middle

L

R

Steering the right ruota atodestra

This is an optional function that may or may not be enabled. If the steer wheel position indicator function is not enabled, it will not appear on the display.

Rev. 08/03

Page 11.3

THESI - Section 11 - Electrical Installation Current mode of operation indicator:

MAN indicates that the mode of operation is manual, during which all the controls are available to the operator at his/her discretion.

AUTO indicates that the mode of operation is automatic, during which the stocking heights are preselected automatically.

The current function is shown in the “b” field:

LIFT/LOWER MAST

CARRIAGE REACH FORWARD/ BACKWARD

TILT UP/DOWN

SIDE SHIFT

SYNCHRONIZE FORKS WIDE/NARROW

Auxiliary function indicator in the CHECK LIST window: This window displays the following symbols when checking specific conditions of the truck:

HAND BRAKE ON

BATTERY OUT OF POSITION (FUNCTION NOT AVAILABLE) BRAKE FLUID LOW OIL FILTER CLOGGED PUMP MOTOR BRUSH WEAR TRACTION MOTOR BRUSH WEAR

Rev. 08/03

Page 11.4

THESI - Section 11 - Electrical Installation Speed entered indicator:

LOW SPEED

HIGH SPEED

Low speed may be enabled as follows: 1) By means of the selector: CUTBACK SPEED 2 is enabled and can be calibrated from the console. See the appropriate chapter for instructions on the calibration range.

2) When the forks are higher than 8500 mm: a microswitch enables CUTBACK SPEED 1.

3) When the reach carriage is out of position: CUTBACK SPEED 2 is enabled. This function can be enabled from the console to increase operator safety.

4) When curving: the CURVE CUTBACK parameter can also be enabled from the console, with the ability to choose the angle at which the truck slows down (ANGLE CUTBACK, LEVELS 1-9 = 10 - 90 ).

5) When the auxiliary functions are selected: CUTBACK SPEED is enabled.

Direction of travel indicator: FORWARD TRAVEL (carriage base side)

BACKWARD TRAVEL (fork side)

Fork height indicator (optional):

Indicates the height reached by the forks in mm (height meter and preselector only)

Rev. 08/03

Indicates the sector entered (preselector only)

Page 11.5

THESI - Section 11 - Electrical Installation Battery-state-of-charge indicator:

Indicates the battery-stateof-charge: battery charged

Battery discharged (density < 1.14g/cm3) Only one section appears together with the low battery symbol. If set from the console, the lift function will be locked out immediately (or within three minutes).

Hours of operation indicator:

Hour Meter

The number indicates the number of hours the truck has been operating. The counting mode can be selected from the console: - running: counting is activated when a pump or traction function is operated (default setting) - key on: counting is activated when the truck is switched on (key on). See the appropriate chapter for instructions on how to set the mode.

Alarms display:

Alarms

When the truck is switched on, no message will be displayed in the “Alarms” field if the main remote switch closed properly. The operator will be alerted of any abnormal condition by the appearance of an alarm symbol. See the appropriate chapter for the list of alarms and corrective actions.

Rev. 08/03

Page 11.6

THESI - Section 11 - Electrical Installation

Connector X1

The connector is located on the slave logic and carries the inputs and outputs to the logic. It is a SAAB 55 pin connector

Continued on following page

Rev. 08/00

Page 11.7

THESI - Section 11 - Electrical Installation Connector X1 - continued fro preceding page

Continued on following page

Rev. 08/03

Page 11.8

THESI - Section 11 - Electrical Installation

Connector X1 - continued from preceding page

Rev. 05/00

Page 11.9

THESI - Section 11 - Electrical Installation

Connector X2

The X2 connector is located under the display. This is a 55-pin SAAB connector as shown in the photograph.

Continued page continuaona following pag. seguente

Rev. 08/03

Page 11.10

THESI - Section 11 - Electrical Installation

Connector X2 - continued from preceding page

Connector X2 I/O diagram

Rev. 08/03

Page 11.11

THESI - Section 11 - Electrical Installation How to change the contrast on the L.C.D. display: - Turn the key switch OFF - Turn the key switch ON, and press the ENTER key for a few seconds

- Increase or decrease the contrast by using the UP and DOWN keys respectively

- Turn the key switch OFF - Press the OUT key to exit the menu and save the contrast setting

- Press the ROLL key to exit the menu without saving the contrast setting

Rev. 08/03

Page 11.12

THESI - Section 11 - Electrical Installation How to change the free lift height of the mast (for the optional Height Meter and Preselector): - Turn the key switch OFF - Turn the key switch ON, and press the ROLL key for a few seconds

- Scroll the different mast heights by using the UP and DOWN keys

- Press the OUT key to exit the menu and save the height setting

- Press the ROLL key to exit the menu without saving the height setting

Rev. 08/00

Page 11.13

THESI - Section 11 - Electrical Installation Table of heights to program: Mast

Height

Mast

Height

Mast

Height

Mast

Height

Mast

Height

How to change the mast height in the slow speed zone (for the Height Meter and Preselector with the H1/H2 CUTBACK option):

- Turn the key switch OFF - Remove the cover to access the X4 connector as shown in the figure

- Connect the console - Remove the connector and connect it to the console

Rev. 08/03

Page 11.14

THESI - Section 11 - Electrical Installation -

Turn the key switch ON Select the SET OPTION menu on the console Turn H1 / H2 CUTBACK ON and confirm Turn the key switch ON Press the UP key for a few seconds

- Use the UP and DOWN keys to select height H1 or H2 and confirm by pressing the ENTER key to change the value, or press the OUT key to return to the normal screen

- When the ENTER key is pressed, the x1 message will appear indicating the multiplier currently used

- Use the UP and DOWN keys to add or subtract the value indicated by the multiplier from the actual value of the height selected

Rev. 08/03

Page 11.15

THESI - Section 11 - Electrical Installation - Change the multiplier by pressing the ROLL key (the values available are 1, 10, 100, 1000)

- When the desired height is displayed, press the ENTER key to save and return to the previous level, or press the OUT key to return to the previous level without saving

- Repeat the sequence to set the other height and press the OUT key to return to the normal screen

Rev. 08/03

Page 11.16

THESI - Section 11 - Electrical Installation

Connections between the cables and power control Power control for traction and lift

Characteristics of the motors Traction Motor

Rev. 08/03

Page 11.17

THESI - Section 11 - Electrical Installation

PMOS Logic board EPROM “ SUPER_VISOR “ ( identified with letter “S”) EPROM “COMBI” ( identified with letter “C” )

Rev. 08/03

Page 11.18

THESI - Section 11 - Electrical Installation

Limit stop sensors for mast carriage control The purpose of the limit stop sensors is to prevent the carriage from stopping abruptly and bumping when it moves forward/backward. The limit stop sensors are located as shown in the figure below.

Forward and Backward limit stop

Rev. 08/03

Page 11.19

THESI - Section 12 - Power Steering

Power Steering Electrical installation – Power Steering 1.

2.

3.

4.

5.

Dedicated power steering motor Vain pump Pump delivery non return valve Pre-adjusted relief valve Spool valve At rest, in the central position: oil flow from the pump is returned to the reservoir. When the operator turns the steering wheel, the spool moves to one of the extreme positions off centre, distributing the oil flow in the requested direction.

Power steering pump is activated via a pressurestat, by the rotation of the steering wheel.

6. Distribution valve 7. Hydraulic motor 8. Antishock valve 9. Anticavitation valve 10. Non return valve 11. Pressure retaining valve 12. Filter

P O W E R STEERING

HYDRAULIC MOTOR

Rev. 05/00

Page 12.1

THESI - Section 12 - Power Steering

Power Steering Motor Specifications of the power steer motor Type of Type ofexcitation motor Rated voltage Power rating Nominal current Maximum rpm Class of insulation Number of brushes Brush wear

Series series excitation

+ 48 V 0.9 KW 20 A 4800 rpm F 4 5 mm / 1000 h

Power steer motor assembly diagram

When refitting, the two fixing bolts (1) must be tightened to a torque of 85 Nm

Rev. 05/00

Page 12.2

THESI - Section 14 - Optionals

Optionals Table of Optional Kits The table below lists the optional electrical system kits available for standard trucks to allow installation of the various optionals.

The list also contains two standard parts: the standard Display and the engine temperature indicator kit.

888.06.010 Display std 820.55.500 * Height meter kit for 183 mast 820.55.550 * Height meter kit for 186 mast 820.55.501 * Height meter kit for 183 -30 mast 820.55.551 * Height meter kit for 186 -30 mast 888.18.200 Movable platform kit 888.18.300 Clogged oil filter kit 888.18.301 * Carriage retract lock-out kit when forks are loweringer 888.18.313 * Fifth Lever electrical kit 888.18.350 Radio transmission kit 888.18.400 Brake fluid level kit / * Preselector kit 888.18.500 Revolving beacon kit 888.18.502 * Steer indicator kit 888.18.503 Motor temperature indicator kit 888.18.020 Reverse alarm kit

888.06.000 GR. EL/CO STD Standard (for Cold Stores also) OPT

OPT OPT OPT OPT OPT OPT OPT OPT OPT SERIE OPT

COMMENTS: 1. OPT/STD indicates whether the kit is optional or standard 2. The * symbol indicates whether the option can be operated from the console

Rev. 08/03

Page 14.1

THESI - Section 14 - Optionals

Assembly instructions for the preselector/height meter kit There are 4 different kits available depending upon the type of mast. References 41-44 provide the part number for each type of mast.

Each part in the kit is listed in the Spare Parts catalog on page 08/110.

The following table provides a description of each part.

Rev. 08/03

Page 14.2

THESI - Section 14 - Optionals

1. Assemble all the subassemblies first before installing the kit on the truck: Winder Unit (parts 23-26, 3, 27-28, 7, 21-22), Encoder (parts 4, 6). Holes do not need to be drilled for any of the operations described below because the truck has already been prepared for installation of the kit.

Rev. 08/03

Page 14.3

THESI - Section 14 - Optionals

2. Install the Winder Unit and Encoder using the specially shaped metal plate (parts 23-26).

Place both units together on the plate and fasten them onto the upper spacer on the outer (fixed) mast, using the pre-drilled holes.

Winder Unit (view from the operator side)

Encoder

Rev. 08/03

Page 14.4

THESI - Section 14 - Optionals

Proximity sensor facing the forks

Winder Unit (view from the operator side) 3. Fasten the belt (parts 39-40) with the knurled side facing the forks. Both ends of the belt must be fastened to the inner movable mast section, which will start to extend once the forks have reached free lift. Start by fastening the bottom end of the belt onto the mast on the operator side using the clips (parts 1, 9) and the pre-drilled holes.

The bottom end of the belt fastened to the mast (view from the operator side) 4. Wind the belt around the large pulley (part 3) and outside the two small pulleys (parts 27-28).

Knurled side

Rev. 08/03

Page 14.5

THESI - Section 14 - Optionals

5. Fasten the top end of the belt to the other end of the same mast section to which the bottom end is attached, using the clips (part 9). Adjust the tension before tightening the screws, making sure that the belt adheres properly around the toothed pulley. Lower the forks until the mast sections are completely collapsed and fasten the metal strap onto the belt (part 5) at the same height as the Proximity Sensor, which will serve as the starting point for the Encoder. Adjust the distance between the Proximity Sensor and the belt to approximately 1-2 mm, using the nut-lock nut.

6. Using the holes in the Winder unit (parts 2326) support plate, connect the Sensor and Encoder cables to cable 37-38. Pass the latter cable along the right piston (seen from the operator side) of the mast to the bottom of the reach carriage and connect it to the X55 connector (already present).

X55 connector

Rev. 08/03

Page 14.6

THESI - Section 14 - Optionals 7. Connect the UCB97 Console to the X4 connector (shown in the figure) located under the steering wheel. Turn the key switch ON and access the SET OPTION menu by pressing the Roll Up and Set Up keys together. Scroll through the options until AUX FUNCTION #5 is visible. This parameter enables the Preselector function, which has 3 values available: (Level = 0) => No Function, (Level = 1) => Height Meter Function Only, (Level = 2) => Height Meter + Preselector Function. Select the desired function and confirm.

8. Turn the key switch OFF and then ON, pressing the ROLL key on the display for a few seconds.

The display will show several Free Lift values that are available for the type of truck being used.

Using the UP and DOWN keys, move the arrow until it reaches the Free Lift value for the mast on the truck. (N.B. this value is contained on the serial number plate of the mast.) Press the OUT key to confirm, or the ROLL key to exit without saving the changes.

Rev. 08/03

Page 14.7

THESI - Section 14 - Optionals

Acquisition of the pre-set stacking heights Press the ENTER button on the display, to access the program to acquire the stacking heights.

On the display will be shown the menu: AUTOTEACHING 1 and AUTOTEACHING 2 relating to the two areas A and B. With the UP and DOWN buttons on the display, move the cursor to the required selection on the menu and press ENTER to confirm the selection.

At this point, the list of stacking heights will be displayed for the area selected, with the indication of the first level (corresponding to the free lift).

Block1=2565 Block2=2565 Block3=2565 Block4=2565 Block5=2565 Block6=2565 Block7=2565 H=2565

While raising the forks to the required level, the actual fork height is displayed in real time in the field H = xxxx.

When the required level is reached, press the numbered button you wish to assign to this level and press ENTER to memorise.

During the operation of height selection, MEMO will appear in the display until the operation is complete.

To return to the standard display press OUT. Turn the key switch OFF to save the data entered.

L

0

R

M A N

0

H=1671

OK

Rev. 08/03

SECT.A

1/2

1

00001 P IM

E S P O

Page 14.8

THESI - Section 14 - Optionals

Operation with preselect programmed The default area active at switch on is always A; if a change of area is required, press the OUT button before the selected height is reached.

If a change of area is required, press in sequence, the OUT button, the height selection button 1 to 7 and the button relative to the forks loaded or unloaded.

DOWN button UP button

forks unloaded orks loaded

At the end of this sequence, the truck has been switched from manual to automatic (AUTO will be shown in the display).

In the case of an incorrect selection, it is possible to exit from the automatic mode at any time by pressing the ENTER button.

The functions available (lift, reach, tilt or side shift) will be shown in the field on the display where PIMESPO normally appears.

N.B. It is important that the carriage is fully reached in, otherwise the request to reach in will appear in the display (please reach in…)

Picking up the load from a selected rack position After selection of the area (with the OUT button), the stacking height (button 1 to 7) and the DOWN button (no load on the forks), lifting or lowering will be available from the existing position of the forks.

When the operator activates the lift function, the load will be lifted to the selected lift height.

At this point only auxiliary functions are enabled (reach, tilt and side shift), to permit fork entry into the pallet, and slow lift speed to raise the pallet.

The lifting will be automatically terminated after 150mm, at which point the operator must retract the mast fully and proceed with the next operation.

Each phase of the operation will be visible on the display during the procedure.

Depositing the load into a selected rack position After selection of the area (with the OUT button), the stacking height (button 1 to 7) and the UP button (load on the forks), lifting or lowering will be available from the existing position of the forks.

When the operator activates the lift function the load will be raised to a position 150mm higher than the programmed lift height.

At this point only auxiliary functions are enabled (reach, tilt and side shift), to permit the alignment of the pallet with the stacking position and slow speed lowering to position the pallet on the racking.

The lowering will be automatically terminated after 120mm at which point the operator must retract the mast fully and proceed with the next operation.

Each phase of the operation will be visible on the display during the procedure.

Rev. 06/00

Page 14.9

THESI - Section 14 - Optionals

Power steering control, part number 45198201506 From serial number F24519K0001 to serial number F24519P00168 The new power steering control kit, part number 45198201506, is operated via the deadman button with a delay upon release of the button, and is installed to maintain the power steering active until the machine comes to a complete stop.

List of kit parts, part number 45198201506: The kit consists of the following: 1 DIN relay support bar (35 mm L = 80 mm) 2 M5x8 TCCE screws 2 flat washers diameter 5 2 grower washers diameter 5 1 programmable timer relay wired with a 3-connector sheath consisting of 1 2-pin connector and 2 10-pin male and female connectors Installation instructions: 1. Fasten the relay support in the area under the platform under the deadman button as shown in the photo by drilling 2 M5 threaded holes, using the relay support as a drilling jig.

2. Fasten the relay onto the support.

3. Disconnect the X22 connector from the accelerator and insert the sheath from the Kit, using the 2 10-pin connectors.

4. Disconnect the S3 connector from the power steering sensor and connect it to the 2-pin connector in the new kit.

5. Adjust the setting of the relay timer and potentiometer as shown in the diagram.

Rev. 08/03

Page 14.10

THESI - Section 14 - Optionals

SETTAGGIO TEMPORIZZATORE TIMER SETTING

Gli switch devono essere Set the switches as follows: predisposti come segue: - 1 OFF - 2 ON - 3 OFF - 4 ON - 5 ON - 6 OFF

ON - OFF

Predisporre gli Set the come switches as switch shown in the photo indicato nella foto.

the potentiometer IlAdjust potenziometro regolatotoalthe maximum (completely turned in a in massimo (ruotato completamente clockwise direction) senso orario)

.

Ruotare il Turn the relay potenziometro del relè potentiometer to fino al valore massimo the MAX value as MAX come indicato shown in the photo nella foto.

Rev. 08/03

Page 14.11

THESI - Section 14 - Optionals

- Drill 2 M5 holes in the middle of the 2 slots on the relay support

Rev. 08/03

Page 14.12

THESI - Section 14 - Optionals

List of options that can be operated from the console Table 1 shows a list of available options that can be operated only from the console when set appropriately.

Table 1: List of options that can be operated from the console OPTIONS Reverse buzzer Steer wheel position indicator Curving speed reduction Low speed when carriage is out Height meter Preselector Immediate lift lock-out when battery is low Lift lock-out after 3 minutes when battery is low Carriage retract lock-out when forks are lowering Fork synchronizer 5 th lever 360° steering Programmable speed reduction when forks are lifting and lowering

Rev. 08/03

FUNCTION NAME AUX FUNCTION 3 = ON STEER DISPLAY = ON CURVE CUTBACK = ON CUTBACK SPEED = ON AUX FUNCTION 5 = 1 Lansing / 3 Elecar AUX FUNCTION 5 = 2 Lansing / 4 Elecar AUX FUNCTION 4 = 0 AUX FUNCTION 4 = 1 BLOCK REACH = PRESENT SINC FORKS = PRESENT STEER CONFIG = OPTION#2 H1/H2 CUTBACK = ON

Page 14.13

THESI - Section 15 - Programming via the console

Programming Adjustment of parameters and diagnostic checks through Consul or PC It is possible to adjust the parameters of the truck or display values or alarms through consul or PC.

For programming you will need: • consul UCB • connection cable or • diskette for the first installation of the software on the PC • PC • interface cable

Programming with the consul Connect the cable from consul to the connector X4 which is positioned on a bracket at the side of the steering column. The cable has a SAAB female connector connected to a SAAB male connector which also provides support.

This operation can be carried out with the truck switched on.

Version of software

THESI 48V

PIMESPO 350A

the

V0.58 00332 Hours worked

The list of available functions will be displayed when the consul is connected and the truck is switched on.

The available functions for the various Menus are described in the pages that follow.

The operation of the console keys is explained below: 1.

ROLL UP selects the following screen 2.

ROLL DOWN selects the preceding screen 3.

ENTER confirms the value set by the up/down keys 4.

OUT exits the selected function 5.

SET UP increases the parameter 6.

SET DOWN reduces the parameter

Rev. 08/00

Page 15.1

THESI - Section 15 - Programming via the console

Description of the available menus TABLE 1 MENU'

Press ENTER MENU' to access

MENU ITEMS PARAMETER CHANGE

Provi des access to the parameters that can be modi fi ed to optimize the functi oning of the machine

TESTER

Monitors the parameters of the machi ne (voltage l evels, for exampl e)

PROGRAM VACC

Permits cali bration of the accelerator pedal

MOTOR DATA

NOT AVAILABLE

ALARM

CONFIG MENU’ CO NFIG Press ENU' UP ROLLM UP+SET to access

Rev. 08/03

Functionality

Displ ays the last four alarms

SAVE PARAMETER

NOT AVAILABLE

RESTORE PARAMETER

NOT AVAILABLE

SET MODEL

NOT AVAILABLE

SET OPTIONS

Permi ts selecti on of the optional functi ons

ADJUSTMENTS

Permi ts cali bration of the steering functi on and potenti ometri c l evers

Page 15.2

THESI - Section 15 - Programming via the console

The Console The 1st level menu is accessed by connecting the console to the X4 connector, which is located on the bracket next to the steering wheel. This menu contains the following submenus: - PARAMETER CHANGE - TESTER - PROGRAM VACC - MOTOR DATA (not available) - ALARM - SAVE PARAMETER - RESTORE PARAMETER A protected menu (level 2) with several inaccessible pages also becomes available.

Menus Parameter Change: When opened, the PARAMETER CHANGE menu displays a list of parameters that can be modified to optimize the performance of the truck.

Name ACC. DELAY DEC. DELAY RELEASE BRAKING PEDAL BRAKING INVERS. BRAKING MAX SPEED FORW. MAX SPEED BACK CUTBACK SPEED CUTBACK SPEED 1 CUTBACK SPEED 2

Rev. 08/03

Meaning Traction acceleration delay Traction deceleration delay upon release of the accelerator Braking upon release of travel Braking with the pedal (not applicable: brake sensor not available) Braking when reversing Maximum forward traction speed Maximum backward traction speed Speed reduction for auxiliary outputs (programmable IN/OUT) Speed reduction 1 (8500 mm microswitch) Speed reduction 2 (Low Speed button)

Comments Up to 9 levels of slower values Up to 9 levels of slower values Up to 9 levels of more braking power Up to 9 levels of more braking power Up to 9 levels of more braking power Up to 9 levels of increasingly weaker fields Up to 9 levels of increasingly weaker fields Determines the percentage of pwm to apply to the motor Determines the percentage of pwm to apply to the motor Determines the percentage of pwm to apply to the motor

Page 15.3

THESI - Section 15 - Programming via the console MAX 1 TRACT. CREEP SPEED TR. ANGLE CURVE CUT. CUTBACK 3 1ST SPEED COARSE 2nd SPEED COARSE

Maximum traction current Voltage applied to traction motor upon minimum pressure on accelerator pedal Steering angle at which CUTBACK 3 speed is enabled Speed reduction 3 (curving speed reduction) Lift speed

REACH FWD SPEED

Speed reduction for auxiliary outputs Carriage forward speed

REACH BACK SPEED

Carriage backward speed

L-SHIFT SPEED

TILT UP SPEED

Forks shift left speed (also spread widening speed of forks if 5 th lever is available) Forks shift right speed (also spread narrowing speed of forks if 5 th lever is available) Tilting up speed

TILT DOWN SPEED

Tilting down speed

REACH FWD SLOW

Speed reduction when carriage reaches forward Speed reduction when carriage reaches backward Maximum current on pump Voltage applied to pump at minimum request of potentiometer Delay between pump switching off and closing of lift electrovalve Pump acceleration delay Pump deceleration delay Auxiliary function acceleration delay (carriage shift, tilt, side shift) Auxiliary function deceleration delay Lower proportional electrovalve (EVP) opening delay EVP closing delay Minimum voltage (current) of EVP

R-SHIFT SPEED

REACH BACK SLOW MAX I PUMP CREEP SPEED PUMP LIFT EV. DEL. PU. ACC. DEL. PU. DEC. DEL. AUX ACC. DEL. AUX DEC. DEL. EV. ACC. DEL. EV. DEC. DEL. EVP MIN

Rev. 08/03

Imax to level 9 = 380A Up to 9 levels of higher voltages

Determines the percentage of pwm to apply to the pump Determines the percentage of pwm to apply to the pump Determines the percentage of pwm to apply to the pump Determines the percentage of pwm to apply to the pump Determines the percentage of pwm to apply to the pump Determines the percentage of pwm to apply to the pump Determines the percentage of pwm to apply to the pump Determines the percentage of pwm to apply to the pump Determines the percentage of pwm to apply to the pump Determines the percentage of pwm to apply to the pump

Up to 9 levels of delay increments Up to 9 levels of slower values Up to 9 levels of slower values Up to 9 levels of slower values Up to 9 levels of slower values Up to 9 levels of slower values Up to 9 levels of slower values

Page 15.4

THESI - Section 15 - Programming via the console Tester The table below shows the parameters that are monitored and their ON/OFF status.

Name BATTERY VOLTAGE TR V MOTOR PU TR I MOTOR PU

Description Indicates the battery voltage Value of traction and Vpump armature voltages Value of armature and pump currents

FIELD CURRENT

Value of field current

VMN

Value of VMN

EVP VOLTAGE TR. ACCELERATOR

TEMPERATURE #1 TEMPERATURE #2 FORWARD SWITCH

Voltage on EVP Value of accelerator pedal voltage and % with respect to maximum value Value of lift lever voltage and % with respect to maximum value Value of lower lever voltage and % with respect to maximum value Value of steering angle in degrees Value of height of encoder in mm.

Increases when first mast section extends.

Traction chopper temperature Pump chopper temperature Forward travel microswitch

BACKWARD SWITCH

Micro selector (reversing)

DEADMAN SWITCH

Deadman microswitch

CUTBACK SWITCH 1

Speed reduction 1

CUTBACK SWITCH 2

Speed reduction 2 (low speed button)

ENABLE SWITCH

Accelerator pedal microswitch

BRAKE SWITCH

Pedal brake contact (sensor)

LIFT SWITCH

Lift microswitch

DESCENT SWITCH

Lower microswitch

REACH SWITCH TILT SWITCH

Carriage reach forward/backward microswitch Tilt up/down microswitch

SIDESHIFT SWITCH

Sideshift left/right microswitch

LIFT BLOCK

Lift limit stop sensor

ZERO ENCODER

HANDBRAKE

Encoder reset sensor (transition from free lift to mast) Speed reduction of carriage reach backward (carriage side) Handbrake (sensor)

HPS INPUT

Power steering control status

LIFT ACCELERATOR DESCENT CONTROL STEER ANGLE HEIGHT

REACH RED. BACK

Rev. 08/03

Actual Status 44V – 53V At rest 0 V At rest 48 V At maximum operation 0A At rest 380AAt maximum operation 0A At rest 5A – 35 ADuring traction V batt At rest 0V During traction

At rest: 4.82V (f.c.) lever : 9.99V At rest: 4.82V (f.c.) lever : .0.027V -90° ÷ +90°

ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF

°C °C 0.022V 29.26V 0.022V 29.26V 0.027V 29.26V 0.027V 29.26V 0.027V 29.26V 0.029V 29.26V 29.26V 0.027V (sensor read-out) 0.35V 29.26V 0.35V 29.26V 0.35V 29.26V 0.35V 29.26V 0.35V 29.26V 0.35V 29.26V 0.019V 13.63V ON status of two sensors as per the OFF Table below 13.37V 0.022V (sensor read-out) 0.02V 29.43V

Page 15.5

THESI - Section 15 - Programming via the console

PALLET SENSOR

Load detection sensor

TR. BRUSHES KO

Status of traction brushes

PUMP BRUSHES KO

Status of lift motor brushes

HYDRO BRUSHES KO

Status of power steering motor brushes

BRAKE OIL LEVEL

Status of brake fluid level

OIL FILTER

Status of oil filter

BATTERY OUT

Battery detection sensor Not applicable Maximum permissible temperature for traction motor Maximum permissible temperature for pump motor Hours of operation of traction motor Hours of operation of lift motor Debug input (diagnostics)

TR TEMP SWITCH PU TEMP SWITCH HCOUNT TRACTION HCOUNT LIFTING DEBUG

ON OFF OFF ON OFF ON ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF

0.019V 13.35V 0.023V 13.76V 0.024V 13.74V 0.023V 13.50V 0.024V 13.75V 0.023V 13.75V 13.51V (should not appear) 0.023V (sensor read-out) 0Ω Open (traction locked out) 0Ω Open (pump locked out)

Logical combination of the states of the carriage speed reduction sensors: S1 (low)

S2 (high)

ON ON OFF OFF

ON O FF ON OFF

Speed reduction forw ard OFF OFF OFF ON

Speed red uction backw ard ON OF F OFF OFF

CO M M EN TS if the carriage is retracting If the carriage is extending

Program Vacc: This menu is where the accelerator pedal is calibrated. The procedure for calibrating the pedal is described below.

- Select the PROGRAM VACC page on the console and press ENTER. - A window will appear indicating the default minimum and maximum pedal voltage values. Press ENTER to enable the data entry mode.

- Depress the accelerator pedal to the end of its stroke. The changed minimum value will appear on the console display.

- Press OUT and then ENTER to confirm, keeping the pedal depressed at the same time.

- If the pedal has been calibrated correctly, the system will automatically exit the data entry mode, at which point the pedal may be released.

Rev. 08/03

Page 15.6

THESI - Section 15 - Programming via the console Alarms The Alarms menu displays the last four alarms stored by the truck. Next to the alarm message is the number of consecutive times the alarm has occurred, the number of hours that the system was operating when the alarm occurred, and the temperature of the system at that time. If the temperature recorded is 0° C, this means that the alarm occurred when the machine was being switched on.

Example: CAN BUS KO #2 122h 0°C

Config Menu The pages contained within the protected CONFIG menu of system configurations can be viewed from the first page as follows: - Press the ROLL UP and SET UP keys together on the console for a few seconds until the first page appears.

1. SET MODEL (not available) 2. SET OPTIONS 3. ADJUSTMENT

Adjustment - Use the UP and DOWN keys on the console to scroll through the pages until ADJUSTMENT appears.

- Press ENTER to confirm.

- The following calibrations will be displayed: SET STEER MIN SET STEER MAX ADJ MAX LIFT DW ADJ MAX LIFT UP ADJ MAX TILT DW ADJ MAX TILT UP ADJ MAX L-SHIFT ADJ MAX R-SHIFT ADJ MAX REACH F ADJ MAX REACH B ADJ MAX SINC DW ADJ MAX SINC UP

Rev. 08/03

Page 15.7

THESI - Section 15 - Programming via the console Steering calibration (available only if STEER DISPLAY is enabled): - Select STEER MIN and press ENTER to enable the data entry mode.

- The value of the actual position of the steer wheel will appear. The steer wheel position indicator arrow will also move to the actual position.

- Turn the steering wheel in an anticlockwise direction until it stops. The arrow on the display will move to the far left (L), while the console will display the value 0.

- Press OUT and then ENTER to confirm.

Repeat the operations above to calibrate the steering on the right side (STEER MAX).

Potentiometric lever calibration: - Select LIFT UP and press ENTER to enable the data entry mode.

- The value of the actual voltage on the potentiometric lever will appear (the rest value is approximately 2.5V).

- Move the lever in the direction of the operator until it reaches the end of its stroke. The console should display a voltage value of approximately 5V. - Keeping the lever in this position, press OUT and then ENTER to confirm. If this operation has been performed correctly, the console will return to the main page (ADJUSTMENT menu).

Repeat the operations above to calibrate the lower function (LIFT DW), but move the lever in the opposite direction away from the operator. The value displayed will be approximately 0V.

Follow the procedure above to calibrate the other levers, observing the following correlations:

REACH FORW REACH BACK TILT DOWN TILT UP L-SHIFT R-SHIFT SINK DW SINK UP

Rev. 08/03

Carriage reach forward Carriage reach backward Tilt down Tilt up Sideshift left Sideshift right Widen fork spread Narrow fork spread

2nd lever away from operator 2 nd lever toward operator 3rd lever away from operator 3rd lever toward operator 4th lever away from operator 4th lever toward operator 5th lever away from operator 5th lever toward operator

∼0V ∼ 5V ∼0V ∼ 5V ∼0V ∼ 5V ∼0V ∼ 5V

Page 15.8

THESI - Section 15 - Programming via the console Set Options This menu contains the options that can be enabled from the console.

1. HOUR COUNTER: - running (enables counting when a pump or traction function is operated) - key on (enables counting when the truck is switched on) 2. AUX FUNCTION 1: - OPTION 1 = HAWE unit - OPTION 2 = TECNORD unit 3. CURVE CUTBACK: (if the steering potentiometer is available) - ON = enables speed reduction when curving - OFF = disables speed reduction when curving 4. STEER DISPLAY: (if the steering potentiometer is available) - ON = enables steering display - OFF = disables steering display 5. AUX FUNCTION 2 : - normal = handbrake: lever - digital = handbrake: button 6. AUX FUNCTION 3: - ON = enables reversing buzzer - OFF = disables reversing buzzer 7. AUX FUNCTION 4: - LEVEL 0 = enables lift lock-out immediately when battery is low - LEVEL 1 = enables lift lock-out after 3 minutes when battery is low - LEVEL 2 = no lift lock-out when battery is low 8. AUX FUNCTION 5: (enabled with height meter/preselector only) - LEVEL 0 = no function - LEVEL 1 = height meter function for Lansing mast - LEVEL 2 = height meter and preselector function for Lansing mast - LEVEL 3 = height meter function for Elecar mast - LEVEL 4 = height meter function and preselector for Elecar mast 9. SINC_FORK: - PRESENT = enables fork synchronizer (5th potentiometric lever) - ABSENT = disables fork synchronizer (5th potentiometric lever) 10. CUTBACK SPEED: - ON = enables low speed when carriage is out - OFF = disables low speed when carriage is out

Rev. 08/03

Page 15.9

THESI - Section 15 - Programming via the console 11. BLOCK REACH: - PRESENT = enables carriage retraction lock-out when forks are lowering - ABSENT = disables carriage retraction lock-out when forks are lowering 12. H1/H2 CUTBACK: (enabled with height meter/preselector only) - ON = enables speed reduction when forks are lifting and lowering between 2 programmable heights - OFF = disables speed reduction on mast 13. STEER CONFIG: (enabled with height meter/preselector only) - OPTION #1 = steering restricted to a rotation angle of +/- 90 - OPTION #2 = 360 steering allowed

Rev. 08/03

Page 15.10

THESI - Section 15 - Programming via the console

Alarms Console NOTA: The letter “B” next to the alarm indicates that this is a lock-out alarm. If it occurs while the truck is being started, the main remote control switch will not close; if it occurs while the truck is operating, the main remote control switch will open. These alarm indications appear only on the console, whereas graphic symbols will appear on the display (see page 15.15).

ALARMS 1 BATTERY LOW The lift function is locked out due to low battery.

2 CAN BUS KO B Communication problems between the system microprocessors on the can bus.

• • • •

• 3 CAPACITOR CHARGE B The power unit capacitors cannot be charged.

•

4 CONTACTOR CLOSED B The main remote control switch is already closed when the truck is started.

5 CONTACTOR DRIVER B The main remote control switch does not close after synchronization.

6 EEPROM KO B There are problems communicating with the EEPROM or reading the parameters during initialization.

7 EV COIL SHORTED B The output safety for the ON/OFF electrovalves is tripped when running.

8 EVP NOT OK B Abnormal behavior of the lower function proportional valve coil.

•

•

9 HIGH I PU. ST. BY B The pump is high when the truck is started or the lift function switched off.

Rev. 08/03

There may be an electricity leak on one of the accessories.

The traction motor armature is not connected.

The main remote control switch is broken.

• • •

Replace the display if the usual symbol does not appear.

•

Replace the power system if the display is functioning correctly.

Check the insulation on the truck frame and the motors.

Check that cables 11 and 12 are connected correctly.

Check that the main remote control switch is functioning correctly.

Replace the power system Check that the main remote control switch is functioning correctly.

Switch the machine off and on once or twice and re-enter the parameters for the lever ADJUSTMENT, ADJ.BATT, PROGRAM VACC. Replace the electrovalve coil.

• • • • •

The main remote control switch control circuit is broken.

•

The EEPROM may have been erased.

•

•

There may be a shortcircuit on one or more of the ON/OFF electrovalve coils or with the

•

•

The EVP positive is high (the proportional is driven on the positive) or at rest when the truck is switched on.

The EVP malfunctions during the lower function (the EVP does not observe the pwm entered with the voltage).

The Forward and Backward Travel inputs are active at the same time.

•

The current sensors give a false reading.

The current is flowing in error to the pump.

•

•

• •

R

15

CORRECTIVE ACTION Recharge the battery.

Check the plug-system connection.

Check that X1, X2, X9 are connected correctly.

•

•

•

8a FUSE BROKEN B The F1 COMBI fuse is burned out.

PROBABLE CAUSES The battery is discharged.

The voltage on the power cables has dropped.

If the "CAN BUS KO" + console are connected but there is no signal ∼ problems on the SLAVE. If the "CAN BUS KO" + console are connected but there is a signal ∼ problems on the power steering control.

If the "CAN BUS KO" ∼ problems on the master.

•

• •

Check that the EVP power supply is correct.

Replace the Proportional.

Replace the F1 fuse on the COMBI (2A).

Check the sheath and travel selector button.

Replace the power system.

Page 15.11

THESI - Section 15 - Programming via the console 10 HIGH I TR. ST. BY B The rotor (driving or braking) is high when the truck is started or is at rest.

11 HIGH FIELD CURRENT B The field current is high when the truck is started or is at rest.

•

12 INCORRECT START The truck starting sequence is not correct, or the activation sequence of a function is not correct.

•

• • •

•

• • • • 13 INPUT ERROR # 1 B Inconsistency between inputs.

14 I PUMP=0 (EVER) B The chopper drives the motor but there is no current when the pump is invoked.

15 I TR.=0 (EVER) B The chopper drives the motor but there is no current during traction.

• • • • • • • •

16 LOGIC FAILURE #1 B The safety flip-flop on the main remote control switch does not reset when the truck is switched on.

17 LOGIC FAILURE #2 B The safety flip-flop on the general purpose outputs does not reset when the truck is switched on.

18 LOGIC FAILURE #3 B The safety flip-flop on the electrovalves does not reset when the truck is switched on.

19 MICRO C164 KO B Inconsistent data between the microswitch.

MICRO CONTROL KO B The microprocessor functions inconsistently.

Rev. 08/03

• • • • • • • •

The current sensors give a false reading.

The current is flowing in error to the traction motor.

The current sensors give a false reading.

The current is flowing in error to the traction motor.

If this occurs when starting the truck, in which case the main remote control switch does not close, the sequence may not be correct.

If this occurs when a function is invoked, the sequence may not be correct, in which case the main remote control switch does not open, check for problems on the following: Deadman sensor Accelerator card Travel selector switch Potentiometric levers

•

Replace the power system.

•

Replace the power system.

•

Check that the following have been released: Deadman Accelerator pedal Potentiometric levers Repeat the operating sequence for the function: Deadman depressed before operating the potentiometric levers.

Deadman and travel before operating the accelerator pedal.

Handbrake disabled before traction.

Replace the defective part.

Replace the power system.

The motor is disconnected.

The pump connection is reversed with the traction motor.

The current read-out circuit on the slave logic unit is broken.

The nuts are loose.

The motor is disconnected.

The pump motor connection is reversed with the traction motor armature.

The current read-out circuit on the power logic unit is broken.

The nuts are loose on the power unit.

The main remote control switch may be malfunctioning.

There may be a shortcircuit on the main remote control switch coil.

There may be a short circuit on the following: Flashing beacon Buzzer OUT1 (optional) OUT2 (optional) There may be a shortcircuit on the ON/OFF electrovalve coils.

• •

• • • • • • • • •

• • • •

Tighten the nuts.

Check the power connections.

Check the traction and pump motor connections.

•

Replace the power system.

•

Tighten the nuts.

•

Check that the main remote control switch is functioning correctly and replace the power system.

If there is a shortcircuit, check that the part is functioning correctly and replace it if necessary, otherwise replace the power system.

•

•

• •

The logic unit enables the field or armature without completing synchronization when the truck is switched on.

Check the power connections.

Check the traction and pump motor connections.

Replace the power system.

•

If there is a shortcircuit, check the electrovalve and replace the magnet if necessary, otherwise replace the power system.

Switch the machine off and on and replace the power system if necessary.

Switch the machine off and on.

If the alarm persists, replace the power system.

Page 15.12

THESI - Section 15 - Programming via the console 21 NO FIELD CUR. B There is no field current during traction or the check phase.

•

22 OUT COIL SHORTED B Accessories absorption control.

•

23 PEDAL FAILURE B The accelerator pedal value is not calibrated correctly.

•

• • • • • •

The main remote control switch coil is not connected The field is not connected.

•

There may be a shortcircuit on the accessories: Flashing beacon Buzzer OUT1 (optional) OUT2 (optional) With the start microswitch OFF, the accelerator voltage exceeds the set minimum by at least 1.5V. Accelerates without the start microswitch.

•

•

•

Calibrate the accelerator pedal as described in the previous chapter.

•

Replace the entire accelerator card.

If the pedal has been calibrated correctly, replace the power system.

Recalibrate the levers. If the alarm persists, replace the power system.

Check that the accelerator pedal is functioning correctly.

Recalibrate the lift lever. If the alarm persists, replace the power system.

• 24 POT OUT OF RANGE B The potentiometric levers are out of range.

•

25 PUMP ACC. NOT OK B The lift lever is out of range.

•

26 SHORT CIR COIL B Alarm on the main remote control switch.

•

28 STEER SENSOR KO B High signal from the HPS card.

•

29 TH. PROTECTION B Thermal protection on the traction chopper.

•

30 THERMIC LEVEL #2 B Thermal protection on the pump chopper.

•

31 MOTOR TEMPERAT The thermal protection on the motor has reached the temperature limit and traction is locked out.

32 PUMP TEMPERATURE The thermal protection on the pump has reached the temperature limit and all pump functions are locked out.

33 TR. ACC NOT OK B The accelerator voltage is not correct.

•

Rev. 08/03

•

• •

Check that the main remote control switch coil is connected.

Check that the field cables BK9 and BK10 are connected.

If there is a shortcircuit, check that the part is functioning correctly and replace it if necessary, otherwise replace the power system.

A lever potentiometer is at rest (with the microswitch OFF) at a V∼ 5V (tester on the lever).

•

The generic value of the lift potentiometer is out of range from the 1.5V-3.5V window on the tester at rest, with the microswitch OFF. The safety flip-flop on the main remote control switch trips when the machine is running: there may be a shortcircuit on one of the coils.

There are problems on the power steering control (or electric steering). This alarm only locks out traction. The main remote control switch does not open.

The temperature of the traction chopper is below 77° C (loss of performance) or above 90° C (machine is stopped).

The temperature of the traction chopper is below 77° C (loss of performance) or above 90° C (machine is stopped).

The temperature of the traction motor has reached the permissible limit (the main remote control switch does not open).

The temperature of the lift motor has reached the permissible limit (the main remote control switch does not open).

The direction of travel has not been selected.

The traction accelerator voltage is 1V higher than the programmed minimum resting value.

•

•

•

Check the main remote control switch coil (R>10-) and all the other coils.

•

Check the control power cable connections.

Replace the power steering control.

• •

•

•

Switch off the machine and allow it to rest until the temperature falls below the limit.

Switch off the machine and allow it to rest until the temperature falls below the limit.

Switch off the machine and allow the motor to cool down.

•

Switch off the machine and allow the motor to cool down.

• • •

Select a direction of travel.

Replace the accelerator pedal.

Replace the power system.

Page 15.13

THESI - Section 15 - Programming via the console

34 VFIELD NOT OK B The field voltage is not correct.

• •

35 VMN NOT OK B The armature voltage is not correct.

•

Rev. 08/03

•

The field voltage is close to 0.

The field voltage differs greatly from the 1/2 battery voltage value when traction is at rest.

The VMN voltage at rest is different to the battery voltage.

The VMN voltage does not decrease with an increase of the pwm on the motor when the truck is traveling.

• • • • •

Check the BK9-BK10 cable connections.

Replace the power system.

Check the motor field.

Replace the SLAVE system.

Check that the motor is functioning correctly.

Page 15.14

THESI - Section 15 - Programming via the console

Alarms on the Display TH PROTECTION Nº 29 THERMIC LEVEL 2 Nº 30 MOTOR TEMPERAT Nº 31 PUMP TEMPERATURE. Nº 32

1 2 3 4

INCORRECT START Nº 12 BATTERY LOW Nº 1 ALL OTHER ALARMS

Rev. 08/03

Page 15.15

THESI - Section 15 - Programming via the console Fork synchronizer (5 th lever) The 5th lever is identical to the other 4 levers and allows the operator to widen or narrow the spread between the forks.

This option is enabled in the console in the SET OPTIONS menu.

When the 5th lever is mounted, it should be adjusted in the same way as the other levers in accordance with the table below: SINK DW SINK UP

Widen fork spread Narrow fork spread

5th lever away from operator ∼ 0 V 5 th lever toward operator ∼ 5V

Safety To ensure that the function is used correctly, a safety height of 600 mm has been imposed below which only certain maneuvers are available and others are locked out, as shown in the table below: HEIGHT

MANEUVER

STARTING

H>600mm

Lower Carriage forward Carriage backward Widen fork spread Narrow fork spread Lower Carriage forward Carriage backward Widen fork spread Narrow fork spread

TRUCK IN YES YES / YES YES NO / / / /

H≤600mm

POSITION OF TRUCK PARTIALLY OUT YES YES YES YES YES NO / / / /

THE TRUCK TRUCK OUT YES / YES YES YES YES / NO YES YES

Table of permitted maneuvers NOTE: 1. Lifting, tilting, and sideshifting the forks is permitted in any situation.

Carriage retraction lock-out when forks are lowering This is an optional function which is also enabled from the console (SET OPTIONS menu), and locks out certain movements of the carriage and the lower function if wide forks have been mounted onto the truck. This function is operated with the 5th lever in the same way as the fork synchronizer.

Please refer to the table above for further information.

Rev. 08/03

Page 15.16

THESI - Section 16 - Accelerator pedal autosensing

Accelerator pedal autosensing The accelerator pedal autosensing function is used in situations when the pedal loses its sensitivity.

Calibration procedure 1. Remove the platform.

2. Leave the accelerator pedal in the neutral position.

3. Connect a switch A so that it is able to shortcircuit the two wires located on connector B.

B

4. Depress the pedal for the minimum distance (output signal).

Operate the switch for at least 2 seconds (to memorize the value when traction is triggered).

Release the switch.

5. Wait a few seconds then depress the accelerator pedal to the end of its stroke. Operate the switch for at least 2 seconds (to memorize the maximum value).

Release the switch and release the pedal.

Note: - Perform the autosensing function without pressing the Deadman to avoid unexpected movements from the truck.

- Only one autosensing operation is allowed each time the truck is switched on.

- The maximum amount of time available to perform the calibration is 90 seconds from the moment that the autosensing button is first pressed.

Rev. 08/03

Page 16.1

THESI - Section 17 - From Serial Number F24519P00001

THESI Series 4519 From Serial Number F24519P00001

Rev. 08/03

Page 17.1

THESI - Section 17 - From Serial Number F24519P00001

1 Introduction

1.1 Table of improvements

The THESI 4519 series trucks have undergone several improvements as described in the table below:

Main Parts

Power steering system

Mechanical traction transmission system

Electrical system

Dashboard and controls

Optional equipment

New hydraulic distributor

Rev. 08/03

Improvements • New power steering (hydraulic components).

• New proprietary electronic steering control system to handle more power than the previous system.

• New 1.5 kW motor (previously 0.9 kW).

• New adjustment to optimize the number of steering turns and reduce force on the steering wheel.

• New magnetic steering sensor to replace the pressure switch enabling power steering.

• New reducer with transmission ratio of 1:17.57 (previously 1.12.40) to optimize energy management and thus allow the traction motor and electronic system to run cooler.

• Updated electronic control with new software to manage the traction motor and a greater number of preselected stocking levels (Preselector).

• Improved appearance of the cooling system for the electrical parts by the introduction of a heat dissipator for the electronic control (replacing the fan in the chopper compartment) and optimizing the location of the fan that cools the motor compartment.

• New layout for the controls together with new, non-scratch graphics.

• New, more ergonomic travel direction selector switch.

• New potentiometric levers.

• New ignition key switch with two positions and aluminum switch plate.

• New covers (new controls layout, air vents, and more space under the steering wheel for the operator's legs).

Version with preselector: • Increase in the number of stocking levels from 14 to 56.

Version with fork synchronizer with frame plate L=980 mm: • Introduction of a new lower function release button which, when depressed, allows the forks to descend to approximately 200 mm from the ground with the carriage all the way in (not possible with the previous version).

• Version that allows the forks to be lowered manually in case the electronic system malfunctions.

Page 17.2

THESI - Section 17 - From Serial Number F24519P00001

2 Modifications to the hydraulic steering system

2.1 Main features

The system is composed of the following main components: = Electrical connection = Hydraulic connection 6

1

4

2 5

7 8

3

1. Steering wheel 2. Magnetic steering sensor 3. Electronic control unit 4. Electric power steering motor 5. Hydraulic steering motor 6. Pump 7. Deadman pedal button Increasing the power steering (5) cylinder capacity from 50 cc to 70 cc and the power of the electric motor (4) from 0.9 to 1.5 kW, allowed us to reduce the number of steering wheel turns required to turn the drive wheel 180°, as shown in the table below: Previous Thesi Series No. of steering Rotation of drive wheel turns wheel 6.5 180

Thesi from Serial Number F24519P00001 No. of steering Rotation of drive wheel turns wheel 4 180

The new magnetic sensor (2) generates two different electrical signals when the steering wheel is turned. The first is a digital On/Off signal upon the slightest turn of the steering wheel. The second is an analog signal, which is proportional to the speed of rotation of the steering wheel.

These signals are controlled by the new electronic control system whose special software optimizes the number of revolutions of the electric pump motor. This has resulted in a looser, more precise, and responsive steering which is similar to electric steering but still maintains all the advantages of hydraulic steering: - Reliability - Precision - Ability to steer (albeit with more difficulty) if there is an electrical fault Rev. 08/03

Page 17.3

THESI - Section 17 - From Serial Number F24519P00001 Attention DO NOT press the Deadman button before turning the key switch ON to prevent the occurrence of an alarm.

1. Turn the key switch ON. 2. Press the deadman pedal button A (enables the pump motor with a low number of revolutions, approximately 350 rpm).

3. Turn the steering wheel (the number of revolutions will suddenly increase to 1000 rpm; it will increase to the maximum of 2200 rpm in accordance with the speed of rotation).

A

The pump motor remains enabled for 7 seconds after the deadman pedal button A has been released.

This allows the truck to be steered even though it might still be moving after release of the deadman button.

2.2 New electronic steering control

The new electronic steering control is a proprietary system with the following specifications:

X 81

Nominal power voltage: 48V d.c.

Maximum pump motor current: 6 d.c.

MOS power technology + microprocessor Real time control of the internal and external parts that may affect the behavior of the steering system, with self-diagnosis of the control circuits.

The electronic unit controls the pump motor and the safety of the system by transmitting an electric signal to the COMBI control system.

If there is an electrical fault in the steering system, the truck will be automatically locked out by electric braking (STEER SENSOR KO alarm on the COMBI system). The chopper can be used even on the previous Thesi versions, and automatically selects the input and output control program.

This has been programmed with the wiring and consists of negatively polarizing or not the X81:9 input.

25-pin X81 Connector

Pin 9 Not connected Connected to B-

Rev. 08/03

Model

Thesi Thesi from Serial Number F24519P00001

Page 17.4

THESI - Section 17 - From Serial Number F24519P00001 The table below shows the control inputs and outputs used on the X81 connector:

Pin 1 2 3 4 5 6 7 8 9 10-25

Inputs Outputs

Rev. 08/03

o o o o o

o o o

Description B+ 48 V power supply after ignition Traction lock-out (STEER SENSOR KO) Analog steering sensor signal B power supply + 5V (preset) Digital steering sensor signal Deadman pedal button signal Not connected

Digital operating mode selection signal Free

Page 17.5

THESI - Section 17 - From Serial Number F24519P00001 2.3 Power steering system features The electronic power steering control system is capable of supplying a nominal current of 60A at a battery voltage of 48V. The system should be controlled by a deadman sensor together with a digital control (such as a pressure switch), or by a sensor that provides a digital and/or analog control signal (such as a Hall sensor).

2.4. Connections

+ 4

3

1

2

3 8

1

2

7 15

13

Power and control cable connections

Rev. 08/03

+ 4

8 15 13 7 Power cable connections only

Page 17.6

Rev. 08/03

Power supply system

BK 15

BK 7

BK 13

BK 8

Logic unit connections (25-pin connector)

Power steering motor

4+

1-

2

B+ 48V after ignition

Steer sensor KO

Steering sensor analog input

B- power supply sensors

+5V power supply sensors

Digital steering sensor input

Deadman input

Selector input Current version

Power steering system

Power supply connections (eye terminals diameter 6)

Power supply safety fuse

THESI - Section 17 - From Serial Number F24519P00001

Connect the power steering system by following the instructions in the diagram below:

Page 17.7

THESI - Section 17 - From Serial Number F24519P00001 Make the following connections: 48V power steering motor with a maximum power of 1.5 kW to terminals 4+ and 2 using 6 mm diameter eye terminals Negative battery post to terminal 148V B+ positive post behind the fuse-protected main remote control switch to terminal 4+ Make the following logic unit connections: Pressure switch (low operation by means of simple contact or NPN transistor) between pins 6 and 4 of the 25-pin connector, or Steering sensor as follows: Positive: if +48V to pin 1, or if +5V to pin 5 of the 25-pin connector Negative: to pin 4 of the 25-pin connector‘ Digital signal (low operation by means of simple contact or NPN transistor) to pin 6 of the 25-pin connector Analog signal to pin 3 of the 25-pin connector (with output signal proportional to the speed of rotation of steering equal to approximately 5V when steering is not operated and 0V at maximum speed) Deadman sensor to input 7 of the 25-pin connector If there is no Deadman connector (for example on the Thesi with a first generation Rexroth power steering system), bridge pins 4 and 9 of the 25-pin connector. If there is no analog signal, bridge pins 3 and 4 of the 25-pin connector.

2.6 Functions With the IDRO11 software, the output specifications are as follows: With Deadman input

With Deadman + digital input

%PWM

%PWM

With Deadman + input + digital + analog %PWM 100% 50%

50%

25% t

t

t

Each time the power steering motor is enabled, a control output with a delay reaching the level indicated in the figure is established. On the logic card is an LED that shows the status of the operation: LED ON: the operation is correct LED OFF: the STEER SENSOR KO alarm occurs Press the Deadman button to enable the power steering motor in one of the 3 configurations shown above. The power steering motor is enabled for 7 seconds after the Deadman button is released to allow the truck to be steered while it is moving, even at top speed.

Rev. 08/03

Page 17.8

THESI - Section 17 - From Serial Number F24519P00001 Output table: In pu t

PW M

900W m oto r + pressu re sw itch

m oto re 1500W + senso re H all

(%)

Vo ltag e (V )

Cu rren t (A)

Vo ltag e (V )

Cu rren t (A)

Deadm en

25

/

/

12

10

Dead men + D igital *

50

48

30

24

25

Deadm en+ digital + analog<3V (high rotation)

100

/

/

48

55

* It is not necessary to press the Deadman buttons if pins 4 and 9 of the logic connector are bridged.

NOTE: The system limits the current to below 60A; if more current is required, the percentage of PWM (and thus the voltage on the power steering motor) is reduced to keep the current within the limits.

5. Allarms With the IDRO13 software, the following alarms may appear on the console:

Condition Current > 0A when truck is switched on*

Allarm CAPACITOR CHARGE

Cause • •

Current > 60 A

Reduced voltage on motor

•

Power supply not connected correctly.

Shortcircuit in MOS. Excessive power steering motor absorption.

Solution • •

• •

• System temperature > 70° C

STEER SENSOR KO

•

Excessive motor absorption.

• •

Reconnect the power supply.

Replace the system.

Check and/or replace the motor.

Check the hydraulic system and mechanical movements of the wheel.

Replace the system.

Check and/or replace the motor.

Check the hydraulic system and mechanical movements of the wheel.

* This alarm is relieved by using the electronic system, which detects the consumption of current when the truck is switched on (not possible if it is functioning correctly).

Rev. 08/03

Page 17.9

THESI - Section 17 - From Serial Number F24519P00001 2.7 Composition of the power steering system The system consists of the following parts: · COD.PIM. 888.06.192: Logic card with software version IDRO13; · COD.PIM. 888.06.194: Power card; · COD.PIM. 888.06.195: MOS lock bar (no. 2); · MOS lock spring: Omicron A/2666 with outside diameter = 8mm, length = 20mm, 450 gr/m (no.6); · Hardware to fasten the cards and close the boxes (see list and drawing COD.PIM.888.06.190)

Below is an overall view of the system:

IDRO13

Rev. 08/03

Page 17.10

THESI - Section 17 - From Serial Number F24519P00001

3 Modifications to the electrical system 3.1 Electronic control The electronic control now has new software (new EPROM) that is capable of managing the traction motor with new field and armature current parameters. This was necessary in order to maintain the same traction speeds after modifying the transmission ratio to 1:17.57.

This has resulted in the following: Increased number of revolutions of the motor but with the same speed performance Reduced current on the motor upon acceleration but with the same acceleration performance The motor and electronic control run cooler with the same performance (speed and acceleration)

3.2 New dissipator and fan

Two new features have been introduced to improve heat dissipation and prevent the operating temperature inside the motor compartment and the COMBI chopper compartment from rising:

Electronic control

Dissipator

Fan

Rev. 08/03

Page 17.11

THESI - Section 17 - From Serial Number F24519P00001

4 Modifications to the dashboard and controls

4.1 New layout for the controls

The new layout for the controls is as follows: 8 3

2

1 7

5

4

6

1.

2.

3.

4.

5.

6.

7.

8.

New non-scratch graphics New 2-position ignition key switch New aluminum switch plate for the key New travel direction switch New location for the slow speed switch New location for the acoustic warning button Steering wheel height adjustment has been eliminated New trim for the handbrake lever

The travel direction switch is now bigger and easier to use. The potentiometric levers have also been changed (new supplier) and no longer display the function graphics but they still look the same as the previous ones and are easier to assemble. The new graphics are indelible, and oiland scratch-proof. The old 3-position ignition switch has been replaced with a new 2-position switch. A new rubber trim has been added between the cover and the handbrake to improve the appearance.

Although not by choice, we had to eliminate the steering wheel height adjustment because the steering column supplier is currently unable to deliver the necessary parts. However, eliminating the adjustable steering column has created more space for the operator’s legs under the steering wheel.

Rev. 08/03

Page 17.12

THESI - Section 17 - From Serial Number F24519P00001 4.2 New dashboard cover

All the dashboard covers have been changed due to the new layout of some of the controls (as described above).

The COMBI chopper compartment cover (with the clip) has also been modified at the side in the area where the battery plug and socket are located to accommodate two air vents A and B, replacing the old ones as shown in the figure below:

B

A

5 Modifications to the optional equipment 5.1 Preselector

The preselector function allows the operator to fully or partially automate the stocking operations inside the warehouse.

Instead of 2 sectors (A and B) there are now 8 (A, B, C, D, E, F, G, H), but the 7 different heights per sector remain unchanged (Block 1 to Block 7). The total number of levels that can be stored and selected has now increased from 14 to 56. The stocking height data entry controls remain the same.

5.2 Fork synchronizer with frame plate L = 980 mm

This feature allows the operator to widen or narrow the spread of the forks by means of a 5th lever, which is identical to the 4 levers already existing on the truck.

A button A has been added, and when depressed, lowers the forks to approximately 200 mm from the ground with the carriage all the way in.

This operation could not be performed on the previous Thesi trucks because the forks were restricted to approximately 600 mm from the ground.

A

ATTENTION: this maneuver may be dangerous!

If the operator does not control the lower function, the synchronizer frame plate will bump against the legs of the truck body.

Rev. 08/03

Page 17.13

THESI - Section 17 - From Serial Number F24519P00001

5.3 Movable platform (optional) This platform is used to change the position of the pedals to the needs of the operator.

In this configuration, the location of the platform lift and lower buttons has been changed.

The new location of the buttons is shown in the figure at the side: A. Platform lift button B. Platform lower button

A B

Rev. 08/03

Page 17.14

THESI - Section 17 - From Serial Number F24519P00001

6 New hydraulic distributor Located as shown in the figure below, the new hydraulic distributor contains a manual valve to lower the forks and which can be operated if the electronic system fails.

If this occurs, the manual lower valve 1 shown below should be turned in a clockwise direction using an Allen wrench.

The valve should be returned to the original position once the forks have been lowered.

NOTE: Access the valve by bringing the carriage all the way out and removing the distributor compartment cover.

1

2

1. Manual lower valve 2. New Overcenter Valve location

1 Rev. 08/03

Page 17.15

THESI - Appendix A – Electrical diagrams

Electrical Diagrams The table lists the electrical diagrams: Part number

Description

88806041

Master sheat diagram

88806043

Carriage shift extension sheath

88806070

Electrical connections diagrams (part 1) version I - 09/07/02 - Applicable up to serial number F24519N00503

88806070

Electrical connections diagram (part 2) version I - 09/07/02 - Applicable rom serial number F24519N00503

88806070

Electrical connections diagram (part 1) version N - 22/04/03 - Applicable rom serial number F24519P00001

88806070

Electrical connections diagram (part 2) version N - 22/04/03 - Applicable from serial number F24519P00001

88806078

Carriage shift sheath

88806115

Parameter setting table

88806151

Slave sheath diagram

Rev. 08/03

Page A.1

THESI - Appendix A – Electrical diagrams

88806041 Master sheat diagram Italian

Allungato ramo X11 Codice grezzo Colore Cont.

Data Denominazione Documento riservato Foglio (..) di (..)

Guaine DIN 72551-FLRY-B Isolamento guaina DIN40621-sw Contrassegnare il gruppo guaine con il numero del disegno, il codice del fornitore, data costruzione: sett./anno.

Sui connettori deve essere segnato in modo indelebile il codice es. X1.

Tutti i connettori devono essere forniti cablati.

I conduttori (X, Y) sono collegati tra di loro con una saldatura a ultrasuoni.

Isolare la saldatura.

La distanza minima tra le due saldature è 60mm.

La direzione dei conduttori è definita con un trattino (Vedi dis.)

Lingua Materiale Modifica Nome Numero disegno Peso Protezione secondo DIN34 Quote ausiliarie Quote di verifica Scala Schema guaina Master Thesi 2 Sost.

Conn. AMP 55 poli nero P.F. COD. CON PROT. IN GOMMA Prot. Faston femm. AMP Contatto maschio ...

Cappuccio per SAAB 42 poli nero Gommino passacavo ...

Contatto femmina Junior ...

Tappo in gomma per ...

Gommino passacavo per microtimer Guarnizione Guarnizione per SAAB 6 poli Rev. 08/03

English X11 copper wire extension Raw material part number Color Checked Date Description Confidential document Sheet (..) of (..)

DIN 72551-FLRY – B SHEATHS SHEATHS INSULATED TO DIN 40621 – SW MARK THE SHEATH WITH THE DRAWING NUMBER, THE MODIFICATION, THE SUPPLIER ITEM NUMBER, THE DATE OF MANUFACTURE WEEK/YEAR.

The part number should be indelibly marked on the connectors, for example X1 ALL THE CONNECTORS SHOULD BE SUPPLIED ALREADY WIRED.

Wires (X, Y) are connected to each other by ultrasound welding.

Insulate the welding.

The minimum distance between each weld is 60 mm.

The direction of the wires is indicated by a dash (see drawing) Language Material Alteration Name Drawing number Weight Protected to DIN34 Auxiliary dimensions Test dimensions Scale MASTER sheath diagram Thesi 2 Supercedes Black 55-pin AMP connector P.F. COD. With rubber protection AMP female faston protection Male contact ...

Cap for black 42-pin SAAB connector Rubber fairlead ring ...

Junior female contact ...

Rubber cap for ...

Rubber fairlead ring for microtimer gasket ...

Gasket for 6-pin SAAB connector Page 1

THESI - Appendix A – Electrical diagrams

88806041 Master sheat diagram (continued from preceding page) Conn. ... poli ... grigio ...

Dis. Approv.

Manuf.

Stds.

Toler Orig Sens. motore Temp. soll.

Temp. traz.

Usura trazione Spz. Usura pompa Usura idroguida Prolunga master Filtro olio intasato Ventola vano motori Potenz. Sterzo Sens. Pres. Batteria Freno a mano Sens. Olio freni Tolleranza lunghezza conduttori in mm Fino a 300 Da 300 a 600 Da 600 un poi Se si sommano delle singole misure la tolleranza da considerare è quella della quota totale Codice Colore base BK WH BU OG BN A GN YE GY

PK

Rev. 08/03

...-pin connector ... gray ...

Drawing Approved Manufactured Standards Tolerances Original Motor sensor Lift temperature Traction temperature Traction wear Brushes Pump wear Power steering wear Master extension sheath Clogged oil filter Motor compartment fan Steering potentiometer Battery detection sensor Hand brake Brake fluid sensor WIRE LENGTH TOLERANCES in mm UP TO 300 BETWEEN 300 AND 600 FROM 600 AND UP If the individual measurements are added together, the tolerance should be for the total length Part number Standard Colour Black White Blue Orange Brown Azure Green Yellow Grey Pink

Page 2

THESI - Appendix A – Electrical diagrams

88806043 Carriage shift extension sheath Italian

Colore Data Denominazione Contrassegnare la guaina con il numero del disegno e della modifica, il codice del fornitore, la data di costruzione: sett./anno.

Posizionare l’etichetta di contrassegno dove indicato.

Sui connettori deve essere segnato in modo indelebile il codice; es. X1.

Tutti i connettori devono essere forniti cablati Mod. 300349 del 12.07.2000: allungato guaina ventola Mod. 300139 del 31.03.2000: Eliminazione guaina cicalino, ventola con cavo 2x0.5, diram. X33-X34 + 50mm, colleg. Cavo 4 su X34.4 Mod. 300045 del 26.10.99: Miglioria Thesi 2 Emesso per produzione con Mod. 990069 Contatto maschio ...

Gommino passacavo ...

Contatto femmina faston ...

Tappo in gomma per ...

Coprifaston ...

Guarnizione per 16 poli Conn. ... poli ... nero ...

Etichetta per contrassegno guaina Tipo Matr.

Schema Guaina prolunga - Carro traslatore Tolleranza lunghezza conduttori in mm Fino a 300 Da 300 a 600 Da 600 un poi Se si sommano delle singole misure la tolleranza da considerare è quella della quota totale Codice Colore base

Rev. 08/03

English Color Date Description MARK THE SHEATH WITH THE DRAWING NUMBER, THE MODIFICATION, THE SUPPLIER ITEM NUMBER, THE DATE OF MANUFACTURE WEEK/YEAR.

The part number should be indelibly marked on the connectors, for example X1 ALL THE CONNECTORS SHOULD BE SUPPLIED ALREADY WIRED.

Modification 300349 dated 12.07.2000: fan sheath extension Modification 300139 dated 31.03.2000: Elimination of buzzer sheath, fan with cable 2x0.5, diram. X33-X34 + 50mm, colleg. cavo 4 su X34.4 Modification 300045 dated 26.10.99: Improvements to Thesi 2 Issued for production with Mod. 990069 Male contact ...

Rubber fairlead ring ...

Faston female contact ...

Rubber cap for ...

Faston cover ...

16-pin gasket ... ...-pin connector ... black ...

Label for marking the sheath Type Serial number Diagram Carriage shift extension sheath WIRE LENGTH TOLERANCES IN MM UP TO 300 BETWEEN 300 AND 600 FROM 600 AND UP IF THE INDIVIDUAL MEASUREMENTS ARE ADDED TOGETHER, THE TOLERANCE SHOULD BE FOR THE TOTAL LENGTH PART NUMBER STANDARD COLOUR

Page 1

THESI - Appendix A – Electrical diagrams

88806043 Carriage shift extension sheath (continued from preceding page) BK WH BU OG BN A GN YE GY

BLACK WHITE BLUE ORANGE BROWN AZURE GREEN YELLOW GREY PINK

PK

Rev. 08/03

Page 2

J

I

H

G

F

E

D

C

B

1

1

1

:37

2

:L-

:L+

:54

F7*

X60

2

2

OG 1X0.22 PK 1X0.22 X22

Z[54]

:9

WH

RD

3

A1

:18

:22

X1

F8

3

3

1X0.5

2

2

OG-GN 1X1.0

Z[22]

1

1

1X0.5

Z[9]

G D

4

1V24-25

D G

G

G

F1

5 S

D

D

S

:17 :42

S

1V22-23

2C1-9

X41*

F3 :13

:24

S

D

S

5

5

1X0.5

4

4

1X0.5

BU

RD

G

6

6

1X0.5

BU

RD

YE GN OG PK

BU BK

6

1V28-29

1V2 6-27

2V1-14

2D1-6

F2

K1

+B

S1

G

G

1X1.0

S

D

D

S

:41

OG

BK

Z[41]

1X0.5

:1

7

1V10-21

1B 20

8

3R2*

9

X72

X70 BK13

X71

X69

F2

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X68 BK12

X67

V3*

F1

+T

:2

BK9

10

BK11

BK10

8

8

35

BK12 35

M

1X0.5

BU

:1

:7 :6

:4 :3 :2

11

11

1M1

MG

2M1

1X0.5

GY-RD

1X0.5

RD

2R4

3S2*

BN 1X1.5

OG-BK 1X0.5

:5

BN 1X0.5

1X0.5

BU

10

3M3*

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BU 1X1.5

:23

Z[44]

X6

Z[23]

2B4

X66 BU 35

X63BK 35

-B

X65 RD 35

-S

+P

-P

X64 BK 35

1X0.5

BU

9

+S

B-

1C1 -7

1

3S1*

1X0.5

1X0.5

BU

1S3

:7

A1

GY

Z[7]

X14

BN-WH 1X1.0

:3

1X0.5

1X1.0

8

YE-BK 1X1.0

1 V1-9

2B 19

:5

:7

1X0.5

1S2

GN

Z[5]

1S1

3F1*

VT-BK 1X1.0

BU

1X1.0

7

BN 1X0.52

6

X24:2

5

X24:1

X21

X21 :53

6

X13

BK

1B3*

7

7

1X0.5

OG

Z[24]

BN BU BN

7B2

8

8

1X0.5

RD

1B1

1X1.5

5

GY

4

BN

Z[53]

3

1

1X1.0 1

X22

F6

X60

S2A

G1

1X1.5

1 RD-BU 1X1.5 1X1.5

Z[13]

2

1X1.0 2

BU

2

2

X80

1

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BK4 50 2

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Z[55]

9

9

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1X1.0

3

BK

/S1

RD BK2 50

BK1 50

1X1.5 1X1.5

10

10

WH-BK 1X0.5

Z[42]

Z[17] BU 1X1.5

1X1.0

RD-GY 1X1.5

4

1X0.5 3

7

10

A

VT-BK 1X1.5

50

1 BK

1GY

2

1X1.5

5

1X0.5 5

1X0.5 4

BN

2

8

7

10

1

BK3

2

BN

1BN-BK 1X1.5

2

BU

1 2 BN 1X1.0 3

1PK

2

X61

6

1X0.5 6

BU

RD

1

9

9

1X0.5 8

RD

BN 1X0.5

O

BK 35

O

+ +

BK3 35

NO

I NO

I

M

Z[43]

:43

1X0.5

X7

VT

:7

12

3M1

F5

13

S3

2

BN

14

X23a

X23a

2Y12*

X33

X33

X32

15

X9

X9

16

X74

X75

X73

0.75

VT 1X0.5 OG 1X0.5 WH-VT 1X0.5 BU-RD 1X0.5

0.75

1Y2

2

2

1

1

1

OUT2

2

1X0.5

YE-RD

1X0.5

BN-BK GY-WH

3

BN

4

1X0.5 1X0.5 1X0.5 1X0.5 1X0.5 1X0.5 1X0.5

RD-GN 1X0.5

:5

:3

:4

1X0.5

:2

1X0.5

:7 :6

Z[52] Z[48] Z[11] Z[29] Z[31] Z[19] Z[51] Z[49] Z[14]

17

0.75

Z[50]

GY-YE 1X0.5

Z[45]

BU VT-WH

Z[4]

RD BU

BK-VT

Z[28]

BU

:5

1X0.5

:4

1X0.5

:3

1X0.5

:2

1X0.5 1X0.5

:5

1X0.5

:4

GN-WH 1X0.5

Z[40] Z[47]

WH-OG

1X1

RD

2Y4

:3

1X0.5

:2

1X0.5

:7

18

A6

19

A3

X00

X23b

1Y6

RD-GY

X23b

1X0.5

3B1

1X0.5

1X0.5

BU

:5

RD

:4 :3 :2

20

1Y7

:18

X36*

:35

X12

X12

X39

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X55

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21

6B15*

:12

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22

X82:1

3

3

2 BU 0.5

2

1 BN 0.5

1

3

3

2

2

1

1

1

2

BK

22

:33

4

4

1Y9*

5

5

21

6

6

1X1.0 1X1.0

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23

23

:1

2B14*

X27

X82:2

M

X38

:2

10

9M2

X38

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7B4

1Y8*

1

9 OUT4

9 WH-OG 1X1.0 10

X36*

1X1.0

0.75

:16

1X0.5

RD

OG

7

1X1.5 1X1.0

BN-BK

BN

8

RD-GY 1X1.5 7 1X0.5

20

RD-YE

1X1.0

PK BN-BK

YE-BU

2R5*

WH-VT 1X0.5 BU-RD 1X0.5 YE 1X0.5

0.75

:25 :6

2Y5

:6

YE

Z[12] Z[30] Z[33]

Z[34]

2B5*

0.75

BU Z[25] Z[6]

:7 :6

:40 :47

1Y3

1X1.0 1X1.0 1X1.0 1X1.0 1X0.5 1X0.5

X50*

BN-BK RD-BK YE-BK

2R1

BN-BK BU 1X1.0

13 14 15 16

1X0.5

WH-RD 1X0.5

BU

BU

1 2 3 4

BU-BK GY-GN WH-BK VT

:28

RD-GY 1X1.5

2Y11

3

3

WH-BU

5

RD

6

OG

7 8 9 10 11 12

:52 :48 :11 :29 :31:19 :51 :49 :14 :50

4

4

5 6 7 8 9 10 11 12

:4

5

5

11

13 14

:45

6

6

8

8

10 12

11

13 14

15 16

X10

7

7

9

9 10 12

X32

1X0.75

WH-BU 1X1.0 YE-BK 1X1.0 RD-GN 1X1.0 OG-BU 1X1.0 1X1.0

YE-RD 1X1.0

BU 1.5

13 14

15 16

0.5

2B1

2

WH

BN 1.5

2

BN1.5 BU1.5

15

2

2

0.5

GY

1X1.0 8

BU

0.5

RD

2R3

X44:2

0.5

BU

2B3

X47:2

RD

1X0.75

BN

1X0.75

GY-WH 1X1.0 3 2

OG-GN 1X1.0

X46:2 X49:2

X42:2

2

BN-GN 1X1 X48:2

X43:2

2

16 X47:1

X44:1

BN

BU

1

X8

2Y13*

X52:2

X51:2

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X46:4 X49:1

X42:1

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W1

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X52:1

X51:1

X46:1

4

1

1

1

1X0.5

1

RD-BU 1X0.5 Z[8]

0.5

YE-GN 0.5

2R2

1X1.0

RD-GY

WH

2 3 4

24

X34

X40

YE-GY

1X1.0

25

1B16

X35

X35

Z[15]

:15

1

RD 1X0.5

BU 1X0.5

26

1B17

1X0.5

GN

Z[10] Z[32]

:10 :32

1X0.5

GN-WH

1X0.5

PK-BK

1X1.0

Z[38] OG-WH

1X0.5

Z[20] BN-WH

1X0.5

Z[36] BN

Z[2]

Z[1]

WH-RD

1X1.0 1

1

2

2

3

3

4

4

5

1X1.0

26

OUT3

:2

RD-BU BU 1X1.0 RD 1X0.5

:36 :20 :38 :1

3 4 5 6 7

5

6

6

RD 1X0.5

27

Z[26]

:26

1X1.0

:21 :39

GY-PK

1X1.0

YE-RD

1X1.0

Z[21] YE-GN Z[39]

27

BU 1X0.5

10

X15

8 9

X4

OUT1

1

2

3 4 5 6 7 8 9 10

A6

1

1

2

3

8

8

28

7B3*

X56

X56

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X25:1

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4S1

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28

1X0.5

4H2*

1X0.5

BU

1X0.5

V2

BN

25

2

2 3

4 5 6 7 9

9

X40

X34

24

7

7

4H3*

1

1

2 3 4

8

8

1RD 0.5

1

19

2

2

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5

PK-BK 0.5

6

9

9

2BU 0.5

2

4 5 6 7

29

X25:2

+ 29

1RD 0.5

1

18

3

3

5 6

10

10

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3

2BU 0.5

2

17

4

4

1

1

1

3

3

3

4

4

BN

PK BU

4RD 0.5

4

10

10

BU

3RD-GY 0.5

3

:1

30

4H1

:2

30

X57

X57

V1

31

7S1

1 GY-PK 0.5

31

1

16

6

6

2

2

5

5

GN

1

1

5BU 0.5

5

RD 1.5

BU

2

15

10

10

5

5

1

1

6

6

YE GY

2

2

6BK 0.5

6

VT 0.75

BK BU

4RD 0.5

4

RD-GY 1X1.0

1

14

1

9

9

4

4 3 2

GN

BN

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O

3

3

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O

Z[3]

BK15 10

10

1

2

2

8

8

BU

X9.3

WH-RD

X9.2

1

1

1

7

7 WH

X9.4

X00.5 X00.4 X00.3 X00.2

2 1RD-GY

RD-BK 1

X9.1

X00.1

An YE Dig WH B-

Vcc BN

WH

ch B ch A BVcc

GN YE

BN

+

I

BU

-

NO

4

4 BN

+

I

BU

-

NO

BN

+

I

BU

-

NO

BN

+ O

-

NO

5BU 0.5

5

13

10

BK8

X00.6

5 GY-BU 4 GY 3 GY-PK 2 GY-RD

1

X20

X20

GY

Y[33]

32 33

OG A WH BU YE GY BN BK PK RD GR VT

:31 :6

1X0.5

YE-GN

X2

Y[34]

1X0.5

:33 :34 :4

Y[4]

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OG

BU BU BU BU

1X0.5 1X0.5 1X0.5 1X0.5

34

:8

ARANCIO AZZURRO BIANCO BLU GIALLO GRIGIO MARRONE NERO ROSA ROSSO VERDE VIOLA

6B4*

:5

:24 :25 :39

1X0.5

WH

X19

:22 :23 :36 :37 :35

Y[31]

1X0.5

BK-RD

GN

1X1.0

1X0.5

WH

RD 1X1.5

1

1

2

2

3

3

9M1

M

4

4

35

:9 :10

5

5

6B5

:7

A2

36

BU 1X0.5

36

6B8

1X0.5

Y[13]

:13

GY-RD BU

1X0.5

37

6B10

1X0.5

RD-GY

1X0.5

RD-YE

38

6B11

1X0.5

Y[32] Y[3]

Y[29]

:29

YE

:32 :3

1X0.5

BU

38

1X0.5

BU

37

Tu tti i simboli, i relativ i contrassegni e le a bbr ev iazio ne dei colori dei cavi, in trodotti nel present e s chema, fanno riferimanto alle seguen ti norme: EN 6061 7- x x ; CEI 44-6; VDE 0293 I EC 757

X5

X5

6

6

35

1X0.5

X19

1

1

BN

1X1.5

2

2

Y[6]

1X0.5

WH

BU 1X1.5

VT 1X0.5 BK

1X1.5

3

3

1X0.5

Y[5] Y[8]

Y[7]

1X1.5

4

4

YE-BK BU 1X0.5

1X0.5 1X0.5

1X1.5

5

5

PK-BK WH-BK

1X0.5

1X1.0

6

6

I4

WH 1X1.0

WH 1X1.5

BU 1X0.5 WH-YE

RD

7

7

1

1

1X1.0

8

8

2

2

BU

9

9

BU 1X1.0

10

3

3

RD-GY

1X0.5

BN

10

4

4

YE-RD

1X1.0

BN

1X0.5

BU

5

5

7

7

34

2

1

6

6

8

8

33

1X1.0

BU

YE 1X0.5

2

1

9

9

32

1

X26:2

2

1

10

10

YE-GN

2BU 0.5

2

OG 1X0.5

2

X26:1

2

1

X16

BN

12

6 5 4 3 2

1 GY-BK

X00[1:6]

I

6OG 0.5

6

2B2

:6

BK7

35

BK13

6 GY-WH

B[1:3]

X9[1:4]

39

39

X11

X11

40

OG

1X1.0

PK

1X1.0

OG-GN

1X1.0

1X0.5

Y[30] Y[15] Y[2]

Y[12] Y[27]

42

:19

6B7

:28

:20

0 9.07.02

1

1

43

MF

:21

Y[42]

44 45

Sost.

S :A :

Thesi 2

46

888.06.070

Orig.

47

47

Schema di collegamento elettrico

46

Denominazione

45

Modifica guaina slave Modifica Materiale : Codice grezzo :

:41

:26 :11

6B6*

:40

Y[26] Y[28]

:42

1X0.5 1X0.5

:38

WH-BU

GY-WH 1X0.5

44

Data Cont.

Quote di verifica Quote ausiliarie Data Nome Dis. DS 16.05.01 Cont.

Approv.

Manuf.

Stds.

I

2

2

RD 0.5 BN-WH

Y[28]

RD 0.5 YE-BU BU 0.5

16

43

Protezione secondo DIN34

41

1B8*

3

3

BU 0.5 1X0.5

RD-WH 1X0.5 BU 0.5

42

Lingua : Italiano Documento riservato

3R1*

4

4

RD-GN

:12 :27

5

5

8

:30 :15 :2

6

6

9

8

:18

7

7 9

11 13

13

:17

I1

10

10 11

14

14

:16

BN

BN

I2

12

12

15

15 16

:14

BK

O

+

BK

O

+

I3

41

BU

-

BU

-

BU 1X1.0

40

BU YE-GN

I NO

I NO

1BN 1X1.0

2

:1

BN

Numero disegno

48

48

301377

CID

di :2

49 50

Foglio: 1

50

fit Toler.

Scala :

Status :

Peso in Kg

49

J

I

H

G

F

E

D

C

B

A

THESI - Appendix A – Electrical diagrams

88806070 Electrical connections diagrams (part 1) (version I - 09/07/02 - Applicable up to serial number F24519N00503) Tutti I simboli, I relativi contrassegni e le abbreviazioni dei colori dei cavi , introdotti nel presente schema, fanno riferimento alle seguenti norme EN 60617-xx; CEI 44+6; VDE 0293 IEC 757 BK WH BU OG BN A GN YE GY

PK

All the symbols, markings, and abbreviations for the colors of the wires used in this diagram are in accordance with standard EN 60617-xx; CEI 44+6; VDE 0293 IEC 757 Black White Blue Orange Brown Azure Green Yellow Grey Pink

16.05.01

888.06.070

Rev. 08/03

Page 1

J

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A

1

1

4

5

6

Lampeggiante

4H3*

3

Buzzer

4H2*

Fusibile 4A

F8

Clacson

Fusibile 4A

F7*

Batteria 48V

Fusibile 2A

F6

4H1

Fusibile 40A

F5

G1

...

...

Disgiuntore con reset manuale

Fusibile 4A

F3

3F1*

Fusibile 300A

7

Condensatori 2200uF 100WV

1C1-7

F2

...

...

Fusibile 4A

...

...

F1

Pulsante sblocco discesa sincr. forche

7B4*

...

Sensore blocca discesa

7B3*

Diodi 30CPF04

Uomo morto

7B2

..

Encoder

6B15*

2D1-6

Sensore usura spazzole sollevamento

6B11

Condensatori 1000uF 100WV

Sensore usura spazzole trazione

6B10

2C1-9

Sensore temperatura motore trazione

6B8

Sensore olio freni

6B6*

Sensore freno a mano

Sensore temperatura motore sollevamento

6B5

6B7

...

Sensore filtro olio

...

8

Sensore di sterzo

3B1

6B4*

I-20

Shunt sollevamento

13

14

15

9

A-20

E-29

A-30

I-2

F-7

F-3

F-3

F-2

H-13

...

F-4

H-5

F-5

...

I-5

I-4

J-8

...

...

E-23

I-28

A-4

I-22

F-39

F-38

F-37

F-43

F-45

F-36

MOS W60N10357711

MOV GE V68ZA10

MOV GE V68ZA10

MOV GE V68ZA10

...

...

...

Micro marcia lenta 8500 mm

Pulsante clacson

Pulsante discesa pedana

Pulsante sollevamento pedana

Pulsante marcia lenta

Pulsante marcia indietro

Pulsante marcia avanti

11

12

13

14

Prolunga carro traslatore

MOS IRFP3710

15

1V28-29 MOS (campo F2) IRFP3710

1V26-27 MOS (campo F2) IRFP 3710

16

Pulsante autoapprendimento pedaliera

Pressostato idroguida

17

18

19

19

E-14/F-35

I-5

J-5

I-5

J-4

I-4

J-7

I-7

F-9

A-28

A-31

...

...

...

H-31

A-28

F-11

F-8

A-9

A-8

A-7

A-1

H-14

H-2

Pulsante di emergenza

...

G-8

F-40

A-19

A-11

A-15

A-13

A-17

...

B-23

E-26

E-14

E-25

...

A-23

F-34

E-10

I-13

H-11

I-11

H-5

...

E-35

F-44

F-43

F-43

F-6

18

Interruttore chiave

...

Resistenza 10 Ohm/50W

Potenziometro di sterzo

1V24-25 MOS (campo F1) IRFP3710

W1

17

Potenziometro 5^ leva/sincronizzatore forche

1V22-23 MOS (campo F1) IRFP3710

2V1-14

16

Potenziometro sollevamento/discesa colonna

1V10-21 MOS W60N10397675

1V1-9

V3*

V2

V1

...

...

...

7S1

4S1

3S2*

3S1*

1S3

1S2

1S1

/S1

S3

S2

S1

...

3R2*

3R1*

2R5*

2R4

2R3

Potenziometro carro traslatore

Potenziometro brandeggio

2R2

F-34

...

Uscita programmabile

Uscita programmabile

Uscita programmabile

Uscita programmabile

...

Vantola impianto SLAVE

Ventola vano motore

Attuatore pedana

Motore idroguida

Motore pompa

Motore trazione

Teleruttore generale

...

Ingresso programmabile

Ingresso programmabile

Ingresso programmabile

Ingresso programmabile

12

...

...

OUT4

OUT3

OUT2

OUT1

...

9M2

9M1

3M3*

3M1

2M1

1M1

K1

...

I4

I3

I2

I1

11

Potenziometro traslatore forche

10

10

2R1

H-7

I-24

A-18

A-10

A-14

2B19

2

A-16

A-12

Sensore di zero

Micro traslatore forche

2B1

I-7

2B14*

Shunt trazione

1B20

I-27

I-25

Micro 5^leva/sincronizzatore forche

Sensore rallentamento carro dentro

1B17

Micro sollevamento/discesa colonna

Sensore rallentamento carro fuori

1B16

F-41

2B5*

Sensore presenza batteria

1B8*

A-6

2B4

Pedale freno

1B3*

A-2/4

...

J-17 + A-25

I-16/18

Micro carro traslatore

Pedale acceleratore

1B1

C-2/D-27

9

C-32/D-44

2B3

...

...

8

Micro brandeggio

Consolle di programmazione

A6

7

2B2

Controllo elettronico IDROGUIDA

A3

6

Controllo elettronico MASTER

5

Controllo elettronico SLAVE

4

A2

3

A1

2

20

20

24

25

26

X55

...

X52*

X51*

X50*

X49

X48

X47

X46

X44

22

23

Conn. SAAB 10 poli

...

24

25

26

Conn. EV DIN 43650C18209W23MPM

Conn. EV DIN 43650C18209W23MPM

Conn. Dupont Dubox 7 poli

Conn. EV DIN 43650C18209W23MPM

Conn. EV DIN 43650C18209W23MPM

Conn. EV DIN 43650C18209W23MPM

Conn. EV DIN 43650C18209W23MPM

Conn. EV DIN 43650C18209W23MPM

Conn. EV DIN 43650C18209W23MPM

Conn. EV DIN 43650C18209W23MPM

...

...

Conn. SAAB 10 poli

Conn. SAAB 6 poli

Conn. SAAB 4 poli

Conn. JPT 3 poli

Conn. SAAB 6 poli

Conn. SAAB 10 poli

Conn. SAAB 16 poli

Conn. SAAB 16 poli

Faston femmina 110 con protezione

Faston femmina 110 con protezione

Faston femmina con protezione

Faston femmina con protezione

Conn. JPT 2 poli + SAAB 4 poli

Conn. SSAb 10 poli

Conn. SAAB 10 poli

Conn. SAAB 10 poli

Conn. SAAB 6 poli

Faston femnmina con protezione

Terminale a punta

Faston femmina con protezione

Faston femmina con protezione

Conn. SAAB 10 poli

Conn. SAAB 16 poli

Conn. Dupont Dubox 7 poli

27

29

28

G-21/23

...

G-14

G-14

A-18/19

G-16

G-18

G-19

G-15

G-20

G-18

G-17

G-4

...

...

E-25/27

H-21/23

H-24

A-20/21

G-26/27

F-25/27

F-14/18

E-14/18

A-23

F-35

E-29

F-5

29

H-15 + H-20

B-3/5

E-5/7

E-32/34

B-33/34

A-30/31

A-28

A-9

A-7/8

B-21/23

E-40/44

A-17

H-16/18

A-15

Conn. SAAB 10 poli

A-12

A-10

E-36/38

B-25/26

D-32/45

D-2/27

J17-18

...

...

28

Conn. Dupont Dubox 7 poli

X42 X43

27

Conn. Dupont Dubox 7 poli

Conn. Dupont Dubox 7 poli

Conn. SAAB 10 poli

Conn. SAAB 6 poli (consolle SLAVE)

Conn. SAAB 42 poli (impianto MASTER)

Conn. AMP 55 poli (impianto SLAVE)

Conn. JPT 3 poli (predisp. trasm. dati)

21

23

Conn. SAAB 6 poli (consolle idroguida)

...

...

22

X41*

...

...

X40

X39*

X38*

X36*

X35

X34

X33

X32

X27

X26

X25

X24

X23

X22

X21

X20

X19

X16

X15

X14

X13

X12

X11

X10

X9

X8

X7

X6

X5

X4

X2

X1

X00

...

...

21

30

2Y12*

2Y11

2Y5

2Y4

1Y9*

1Y8*

1Y7

1Y6

1Y3

1Y2

...

...

...

...

...

...

...

...

...

X82

...

X80

...

X75

X74

X73

X72

X71

X70

X69

X68

X67

X66

X65

X64

X63

X61

X60

X57

X56

30

32

33

34

...

I-16

I-16

I-16

J-9

J-9

J-9

I-9

I-9

I-9

H-9

H-9

H-9

H-9

H-5

I-2

G-31

31

32

33

34

35

G-14

I

09. 07.0 2

39

...

...

...

...

...

...

...

...

...

2Y13*

37

41

42

...

...

...

...

...

...

...

...

...

Ev. chiusura forche

38

39

40

Protezione secondo DIN34

Lingua : Italiano Documento riservato 36

40

43

44

45

46

41

42

43

Sost.

S :A :

44

45

46

Orig.

888.06.070

MF Modifica guaina slave Data Cont.

Modifica Quote di verifica Materiale : Quote ausiliarie Codice grezzo : Data Nome Denominazione Dis. DS 16.05.01 Cont.

Schema di collegamento elettrico Approv.

THESI2 Manuf.

Stds.

G-15 Ev. apertura forche

G-19

G-18

A-22

A-22

G-20

G-19

G-17

Ev. sollevamento (2-4) + discesa (1-3) forche

Ev. brandeggio basso

Ev. brandeggio alto

Ev. blocco freno negativo

Ev. sblocco freno negativo

Ev. traslazione laterale volante

Ev. traslazione laterale sedile

Ev. traslazione carro fuori

G-16

...

Ev. traslazione carro dentro

... ...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

E-23/24

...

Faston femmina con protezione

38

G-28/29

37

...

36

B-1

35

Conn. JPT 2 poli

...

Morsetto A3: VMN idroguida

Morsetto A3: - batteria

Morsetto A3: + batteria

Morsetto A1: campo F2 trazione

Morsetto A1: campo F1 trazione

Morsetto A1: - batteria

Morsetto A1: VMN trazione

Morsetto A1:+ dopo teleruttore

Morsetto A1: - batteria

Morsetto A1: VMN pompa

Morsetto A1: + dopo shunt

Morsetto A1: + dopo teleruttore

Morsetto A1: + dopo teleruttore

Morsetto A1: + diretto batteria

Spina-presa batteria (RAVIOLI)

Conn. SAAB 2 poli

Conn. SAAB 6 poli

31

Numero disegno

...

...

...

...

...

...

...

...

...

47

G-13

47

CID

48

301377

48

Foglio: 2

Scala :

49

di :2

50

50

fit Toler.

Status :

Peso in Kg

49

J

I

H

G

F

E

D

C

B

A

THESI - Appendix A – Electrical diagrams

88806070 Electrical connections diagrams (part 2) (version I - 09/07/02 - Applicable up to serial number F24519N00503)

Rev. 08/03

Page 1

THESI - Appendix A – Electrical diagrams

88806070 Electrical connections diagrams (part 2) (version I - 09/07/02 - Applicable up to serial number F24519N00503) (continued from preceding page)

Rev. 08/03

Page 2

THESI - Appendix A – Electrical diagrams

88806070 Electrical connections diagrams (part 2) (version I - 09/07/02 - Applicable up to serial number F24519N00503) (continued from preceding page)

16.05.01

888.06.070

Rev. 08/03

Page 3

J

I

H

G

F

E

D

C

B

A

1

1

2

X60

X60

S2A

G1

X80

1

X80

BK4 50 2

2

2

1

1

:L-

3

:L+

OG 1X0.22

RD

3

PK 1X0.22

1X1.5

VT-BK 1X1.5

/S1

BK2 50

BK1 50

A1

4

F7*

F6

:37 4

1 RD-BU 1X1.5

2

2

BK3 50

1 BK

2

G

G

1X1.5

S

D

S

D

Z[54]

:54

BK

:9

5

1V 24-25

1V 22-23

F8

2C 1-9

:55

Z[55]

:22

G

G

G

6

S

D

S

D

S

D

1V28-29

1V26-27

2V1-14

2D1 -6

F2

K1

:13

:24

F1

7

:17 :42

G

G

S

D

D

S

6

8

1V10-21

1B20

1V1-9

Z[53]

WH

OG-GN 1X1.0

Z[22]

1X0.5

Z[9]

RD

3

3

2

2

1

1

10

10

WH-BK 1X0.5

Z[42]

9

9

1X0.5

BU

Z[17] BU 1X1.5

8

8

1X0.5

7

7

1X0.5

RD

OG

6

6

1X0.5

BU

5

5

1X0.5

RD

4

4

1X0.5

BU

1X0.5

RD

Z[24]

BU BK BN BU

YE GN OG PK

BN

BK

X13

2B19

S1

X24:2

5

X24:1

X21

X21

1X1.5

:53

GY

1X1.0

BK

Z[41]

1X0.5

9

B-

10

X70 BK13

X72

1C 1-7

X71

F2

X69

X68 BK12

X67

F1

-T

+T

-B

BK9

BK10

BK11

X63 BK 35

1

X66 BU 35

X65 RD 35

-P

X64 BK 35

-S

3R2*

3S1*

YE-BK 1X1.0

BN-WH 1X1.0

+S

1X0.5 1X0.5

1X0.5

:2

:1

11

8

8

35

BK12 35

12

M

1M1

MG

2M1

V3* 3M3*

1X1.5

BN 1X1.5

BU

3S2*

M

:4 :3

2R4

:23

1X0.5

BU

:5

12

:44

1X0.5

BU

:2

13

M

:43

1X0.5 Z[43]

X7

3M1

F5

13

1X0.5

X6

:7

1X0.5

BU

RD

2B4

:6

OG-BK 1X0.5

1X0.5

GY-RD

1X0.5

BU

11

Z[44]

1S3

:7

A1

GY

Z[7]

Z[23]

X14

+P

:5

GN

Z[5]

BU

1S2

BN 1X0.52

:41

3F1*

VT-BK 1X1.0 OG

1X1.0 1X1.0

10

4

1S1

1

1X1.0 1

BN

5

1X0.5 4

1B3*

2

1X1.0 2

BU

6

1X0.5 5 1X0.5 6

BU

RD BK

9

14

10

15

10

16

X74

X75

X73

2Y12*

X33

X33

X32

BK13

Z[4]

Z[45]

GY-YE 1X0.5

X32

1

1

1X0.5

YE-RD

1X0.5

BN-BK GY-WH

1X0.5

:5

1X0.5

:3

VT-WH 1X0.5

:4

BU

1X0.5

BU

1X0.5

RD

:2

:7 :6

Z[52] Z[48]

17

Z[11] Z[29]

18

1Y2

A3

0.75

Z[31] Z[19]

RD-GN

Z[27]

BU WH-RD

Z[3]

RD BU

1X0.5

:5

1X0.5

:4

1X0.5

:3

1X0.5

:2

1X0.5

:7 :6

0.75

:28

Z[51]

1X0.5

1Y3

19

0.75

:40 :47

Z[14] Z[50]

X10

RD-GY 1X1.5

2Y11

1X0.5 1X0.5 1X0.5 1X0.5

Z[49]

1X0.5 1X1.0 1X1.0

BK-VT

Z[28]

BU

1X0.5

:5

1X0.5

:4

GN-WH 1X0.5

Z[40] Z[47]

WH-OG

1X1

RD

:3

1X0.5

:2

1X0.5

:7

20

2Y5

YE

X23

X23

21

3B1

1Y6

1X0.5

:4

1X0.5

BU

:5

1X0.5

22

1Y7

:18

X36*

:35

X12

X39

X39

X55

X55

:46

23

6B15*

:12

:8

:30

1X1.0

X12

24 25

:34

2B14*

1 BN 0.5

1

3

3

2

2

1

1

1

2

2

BK

1Y8*

X38

2 BU 0.5

2

1

OUT4

25

X38

3

3

24

:33

4

4

1X1.5 1X1.0

PK

BN-BK

1Y9*

5

5

23

6

6

1X1.0

22

7

1X1.0

RD

:3 :2

8

X36*

1X1.0

0.75

:16

1X0.5

RD

OG

9

9

1X1.0 8

RD-GY 1X1.5 7 1X0.5

4H3*

RD-YE

BN

YE-BU

2R5*

RD-GY

0.75

:25 :6

:6

Z[12] Z[30]

Z[34]

2B5*

0.75

X50*

2Y4

1X1.0

2R1

BN-BK

Z[25] Z[6]

2B1

VT

:3

BN WH-BU RD

WH-BK

BU 1X1.0 1X0.5 1X0.5

2R2

3 4 5 6

OG

7

BU-BK

8

GY-GN

9 10 11 12

:52 :48 :11 :29 :31 :19 :51 :49 :14 :50

OUT2

2

3 4 5 6 7 8 9 10 11 12

:27

1

1

2

3 4 5 6 7 8 9 10 11 12

BU 1X1.0

13

BN-BK

14

RD-BK

15

YE-BK

16

2B2

2

2 3 4 5 6 7 8 9 10 11 12

13 14 15 16

X8

BK8

2Y13*

W1

1X0.5

1X0.5

BN 1.5

13 14

:4

BN

BN

WH-BU 1X1.0 YE-BK 1X1.0 RD-GN 1X1.0 1X1.0

BN-GN 1X1

13 14

15

15

:45

2

2

OG-BU 1X1.0 WH

YE-RD 1X1.0

2

2

BU 1.5 BN 1.5 BU1.5

2

16

16 2

0.5

BN-BK Z[33]

10

WH-OG 1X1.0 10

BU

0.5 0.5

GY

2R3

X52:2

X51:2

2

1X0.5

GY-WH 1X1.0 3 2

OG-GN 1X1.0

X46:2 X49:2

X42:2

X48:2

X43:2

X47:2

X44:2

BU

1 2

0.5 0.5 0.5

RD

2B3

X52:1

X51:1

X46:3

X46:4 X49:1

X42:1

X48:1

X43:1

X47:1

X44:1

2 BN

1 2

RD PK-BK YE-GN BU

21

1

1

1X0.5

X46:1

4

1

1

RD-GY

WH

4

0.5

26

X34

X40

1X1.0

1X0.5 1X1.0

BU

BU

28

1B17

1X0.5

GN

Z[10] Z[32]

1X0.5

PK-BK

1X1.0

Z[38] OG-WH

1X0.5

Z[20] BN-WH

1X0.5

Z[36] BN

Z[2]

Z[1]

WH-RD

1X1.0 1

2 3 4 5

6

6

29

:26

:21 :39

X15

1X1.0

1

2 3 4 5

1X1.0

1X1.0

YE-RD

Z[21] YE-GN Z[39]

29

Z[26]

:10 :32

1X0.5

GN-WH

1X1.0

28

1X0.5

RD

GY-PK

:2

1X0.5

RD

OUT3 1X0.5

BU

10

:36 :20 :38 :1

27

1B16

X35

X35

Z[15]

:15

YE-GY

1

7 8 9

X4

1

RD

2 4 6

7 8 9 10

27

9

9

5

6

7 8 10

10

X56

-

30

X25:1

:1

4S1

:2

30

1X0.5

4H2*

1X0.5

BU

1X0.5

V2

BN

31

X25:2

+ 31

:1

32

4H1

:2

32

RD 0.5

4

3

4 5

6

7

RD 0.5

1

BU 0.5

5

A6

OUT1

1

2 3

4 5

6

BU 0.5

RD 1.5

BU 0.5

2

OG 0.5

6

X40

X34

26

7

7

20

1

1

3

4

8

8

19

2

2

3 BN

5 6

9

9

18

1X0.5

4

4

3

3

5 6

10

10

1

2 3

4

YE 0.5

5

RD 0.5 BK 0.5

6

17

1X0.5

YE

BU-RD

3

3

4

4

GN

BN

+

3

3

2

RD 0.5

1

4

4

8

VT 0.5

33

7S1

OG A WH BU YE GY BN BK PK RD GR VT

X57

X57

V1

Y[33]

34 35

:31 :6

1X0.5

X2

Y[34]

1X0.5

YE-GN

:33 :34 :4

Y[4]

1X0.5

OG

BU BU BU BU

1X0.5 1X0.5 1X0.5 1X0.5 1X1.0

36

:8

1X0.5

WH

9M1

M

37

X5

X5

:9 :10

1X0.5

VT

RD 1X1.5 BU 1X1.5

1

1

2

2

3

3

4

4 6

6

5

5

37

6B5

:7

A2

38

BU 1X0.5

38

6B8

GY-RD BU

1X0.5

Y[13]

:13

Tu tti i simboli, i relativ i contrassegni e le a bbr ev iazio ne dei colori dei cavi, in trodotti nel present e s chema, fanno riferimanto alle seguen ti norme: EN 6061 7- x x ; CEI 44-6; VDE 0293 I EC 757

6B4*

:5

:24 :25 :39

1X0.5

WH

X19

1X0.5

WH

1X0.5

BK

X19

:22 :23 :36 :37 :35

1X0.5

BK-RD

GN

BN

1X1.5

1

1

Y[6]

1X1.5

2

2

1X0.5

Y[5] Y[8]

1X1.5

3

3

Y[31]

YE-BK

1X0.5 1X0.5

1X1.5

ARANCIO AZZURRO BIANCO BLU GIALLO GRIGIO MARRONE NERO ROSA ROSSO VERDE VIOLA

X20

X20

GY

4

4

WH-BK

Y[7]

1X1.0

5

5

BU 1X0.5 PK-BK

I4

WH 1X1.0

WH 1X1.5

BU 1X0.5 1X0.5

RD

6

6

1X0.5

39

6B10

1X0.5

RD-GY

1X0.5

RD-YE

Y[32] Y[3]

40

Y[29]

41

41

Lingua : Italiano Documento riservato

1X0.5

:29

YE

40

6B11

1X0.5

BU

:32 :3

1X0.5

BU

39

1

1

WH-YE

1X1.0

7

7

2

2

BU

8

8

BU 1X1.0

10

3

3

7

RD-GY

1X1.0

BN

1X0.5

BN

9

9 10

4

4

YE-RD

1X1.0

BU

1X0.5

BU

5

5 7

36

2

1

6

6

8

8

35

2

1

9

9

34

1

X26:2

2

1

10

10

YE-GN

BU 0.5

2

OG 1X0.5

2

YE 1X0.5 X26:1

2

1

X16

BN 2

33

BU1

2

16

1X0.5

VT

2

2

5

5

YE PK BU

4 1

BK

O

5

5

BN

3

BU 0.5

2

6

BK

O

+

15

1X0.5

1X1.0

RD-GY

1

1

6

6

GY 1 2 3

4

2

BU

-

BU

-

BU

RD-GY 0.5

3

GY-PK 0.5

1

RD-GY 1X1.0

1

14

1

BN

7B2

+B

F3

X41*

1X1.0

BU

X1

1X1.0

1GY

BN

7

7

X22

1X1.5 1X1.5

1BN-BK 1X1.5

2

2

Z[13]

1X1.5

3

1X0.5 3

8

8

1

9

GN

2

BK

O

+

7

1

1

PK

13 12 11 10 8

OG

7

WH-VT 1X0.5

6

1

5 4 3 2

GN

BN

3

BU

-

6

1 2 BN 1X1.0 3

1PK

2

2

9

9

BN 1X0.5 VT

:7 :6

25 24 23 22 21 20 19 18 17 16 15 14

1

1

An YE Dig WH B-

Vcc BN

WH

ch B ch A BVcc

YE

I NO

I NO

I NO

5

X61

RD-GY 1X1.5

1

10

10

1X0.5 8

RD

BN 1X0.5

1B1

BK 35

X22

BN

BK3 35

O

BK15 10

O

+ +

BK7 10

NO

I NO

I

B[1:3]

X81 [1:25]

3R1*

43

MF

1B8*

3

3

2

2

1

1

OG PK OG-GN

1X1.0 1X1.0 1X1.0

Y[30] Y[15] Y[2]

RD 0.5 BU 0.5 BN-WH RD-GN

1X0.5 1X0.5

Y[12] Y[27]

44 45

Sost.

S :A :

Thesi 2

46

888.06.070

:41

:26 :11

6B6*

:40

47

47

Orig.

Schema di collegamento elettrico

Y[42] Y[26] Y[28]

:42

1X0.5 1X0.5

:38

WH-BU

GY-WH 1X0.5

46

Denominazione

:21

Modifica Materiale : Codice grezzo :

6B7

:28

:20

Y[28]

RD 0.5 YE-BU BU 0.5

16

45

Eliminato X23a (S3), X82 (7B4) e X9

:19

RD-WH 1X0.5 BU 0.5

44

Data Cont.

Quote di verifica Quote ausiliarie Data Nome Dis. DS 16.05.01 Cont.

Approv.

Manuf.

Stds.

N 2 2.04.03

42

Protezione secondo DIN34

X11

X11

4

4

:12 :27

5

5

8

8

:18

6

6

9

9

11

:17

7

7

10

10 11

:16

I1 I2

13

13

:14

BN

BN

14

14

43

BK

O

+

BK

12

12

15

15 16

:30 :15 :2

BU

BU

-

BU

O

+

I3

:1

BN YE-GN

I NO

I

-

BU 1X1.0

42

Numero disegno

NO

1BN 1X1.0

2

48

48

49

301693

CID

49

di :2 50

Foglio: 1

Scala :

Status :

Peso in Kg fit Toler.

50

J

I

H

G

F

E

D

C

B

A

THESI - Appendix A – Electrical diagrams

88806070 Electrical connections diagrams (part 1) (version N - 22/04/03 - Applicable rom serial number F24519P00001) Tutti I simboli, I relativi contrassegni e le abbreviazioni dei colori dei cavi , introdotti nel presente schema, fanno riferimento alle seguenti norme EN 60617-xx; CEI 44+6; VDE 0293 IEC 757 BK WH BU OG BN A GN YE GY

PK

All the symbols, markings, and abbreviations for the colors of the wires used in this diagram are in accordance with standard EN 60617-xx; CEI 44+6; VDE 0293 IEC 757 Black White Blue Orange Brown Azure Green Yellow Grey Pink

16.05.01

888.06.070

Rev. 08/03

Page 1

J

I

H

G

F

E

D

C

B

A

1

1

2

4

5

6

Lampeggiante

4H3*

3

Buzzer

4H2*

Fusibile 4A

F8

Clacson

Fusibile 4A

F7*

Batteria 48V

Fusibile 2A

F6

4H1

Fusibile 40A

F5

G1

...

...

Disgiuntore con reset manuale

Fusibile 4A

F3

3F1*

Fusibile 300A

Condensatori 2200uF 100WV

1C1-7

F2

...

...

Fusibile 4A

...

...

F1

...

...

...

...

...

Diodi 30CPF04

Uomo morto

7B2

..

Encoder

6B15*

2D1-6

Sensore usura spazzole sollevamento

6B11

Condensatori 1000uF 100WV

Sensore usura spazzole trazione

6B10

2C1-9

Sensore temperatura motore trazione

6B8

7

Sensore olio freni

6B6*

Sensore freno a mano

Sensore temperatura motore sollevamento

6B5

6B7

...

Sensore filtro olio

...

8

Sensore di sterzo

3B1

6B4*

I-20

Shunt sollevamento

13

14

9

A-20

E-29

A-30

I-2

F-7

F-3

F-3

F-2

H-13

...

F-4

H-5

F-5

...

I-5

I-4

J-8

...

...

...

...

A-4

I-22

F-39

F-38

F-37

F-43

F-45

F-36

MOS W60N10357711

MOV GE V68ZA10

MOV GE V68ZA10

MOV GE V68ZA10

...

...

...

Micro marcia lenta 8500 mm

Pulsante clacson

Pulsante discesa pedana

Pulsante sollevamento pedana

Pulsante marcia lenta

Pulsante marcia indietro

11

12

13

14

Prolunga carro traslatore

MOS IRFP3710

15

1V28-29 MOS (campo F2) IRFP3710

1V26-27 MOS (campo F2) IRFP 3710

16

Pulsante marcia avanti / pulsante 360°

Pulsante autoapprendimento pedaliera

...

17

18

19

19

E-14/F-35

I-5

J-5

I-5

J-4

I-4

J-7

I-7

F-9

A-28

A-31

...

...

...

H-31

A-28

F-11

F-8

A-9

A-8

A-7

A-1

...

H-2

Pulsante di emergenza

...

G-8

F-40

A-19

A-11

A-13

A-15

A-17

...

B-23

E-26

E-14

E-25

...

...

F-34

E-10

I-13

H-11

I-11

H-5

...

E-35

F-44

F-43

F-43

F-6

18

Interruttore chiave

...

Resistenza 10 Ohm/50W

Potenziometro di sterzo

1V24-25 MOS (campo F1) IRFP3710

W1

17

Potenziometro 5^ leva/sincronizzatore forche

1V22-23 MOS (campo F1) IRFP3710

2V1-14

16

Potenziometro sollevamento/discesa colonna

1V10-21 MOS W60N10397675

1V1-9

V3*

V2

V1

...

...

...

7S1

4S1

3S2*

3S1*

1S3

1S2

1S1

/S1

...

S2

S1

...

3R2*

3R1*

2R5*

2R4

2R3

Potenziometro carro traslatore

Potenziometro brandeggio

2R2

15

F-34

...

Uscita programmabile

Uscita programmabile

Uscita programmabile

Uscita programmabile

...

...

Ventola vano motore

Attuatore pedana

Motore idroguida

Motore pompa

Motore trazione

Teleruttore generale

...

Ingresso programmabile

Ingresso programmabile

Ingresso programmabile

Ingresso programmabile

12

...

...

OUT4

OUT3

OUT2

OUT1

...

...

9M1

3M3*

3M1

2M1

1M1

K1

...

I4

I3

I2

I1

11

Potenziometro traslatore forche

10

10

2R1

H-7

I-24

A-18

A-10

A-12

2B19

A-14

A-16

Sensore di zero

Micro traslatore forche

2B1

I-7

2B14*

Shunt trazione

1B20

I-27

I-25

Micro 5^leva/sincronizzatore forche

Sensore rallentamento carro dentro

1B17

Micro sollevamento/discesa colonna

Sensore rallentamento carro fuori

1B16

F-41

2B5*

Sensore presenza batteria

1B8*

A-6

2B4

Pedale freno

1B3*

A-2/4

...

A-25

I-16/18

J-15/19

Micro carro traslatore

Pedale acceleratore

1B1

9

C-2/D-27

2B3

...

...

8

Micro brandeggio

Consolle di programmazione

A6

7

2B2

Controllo elettronico IDROGUIDA

A3

6

Controllo elettronico MASTER

5

Controllo elettronico SLAVE

4

A2

3

A1

2

20

20

24

25

26

X55

...

X52*

X51*

X50*

X49

X48

X47

X46

X44

22

23

Conn. SAAB 10 poli

...

24

25

26

Conn. EV DIN 43650C18209W23MPM

Conn. EV DIN 43650C18209W23MPM

Conn. Dupont Dubox 7 poli

Conn. EV DIN 43650C18209W23MPM

Conn. EV DIN 43650C18209W23MPM

Conn. EV DIN 43650C18209W23MPM

Conn. EV DIN 43650C18209W23MPM

Conn. EV DIN 43650C18209W23MPM

Conn. EV DIN 43650C18209W23MPM

Conn. EV DIN 43650C18209W23MPM

...

...

Conn. SAAB 10 poli

Conn. SAAB 6 poli

Conn. SAAB 4 poli

Conn. JPT 3 poli

Conn. SAAB 6 poli

Conn. SAAB 10 poli

Conn. SAAB 16 poli

Conn. SAAB 16 poli

...

Faston femmina 110 con protezione

Faston femmina con protezione

Faston femmina con protezione

Conn. SAAB 4 poli

Conn. SSAB 10 poli

Conn. SAAB 10 poli

Conn. SAAB 10 poli

Conn. SAAB 6 poli

Faston femnmina con protezione

Terminale a punta

Faston femmina con protezione

Faston femmina con protezione

Conn. SAAB 10 poli

Conn. SAAB 16 poli

Conn. Dupont Dubox 7 poli

27

28

G-21/23

...

G-14

G-14

A-18/19

G-16

G-18

G-19

G-15

G-20

G-18

G-17

G-4

...

...

E-25/27

H-21/23

H-24

A-20/21

G-26/27

F-25/27

F-14/18

E-14/18

...

F-35

E-29

F-5

H-20

B-3/5

E-5/7

E-32/34

B-33/34

A-30/31

A-28

A-9

A-7/8

B-21/23

E-40/44

A-17

...

A-15

...

A-12

A-10

E-36/38

B-25/26

D-32/45

D-2/27

...

...

...

28

Conn. Dupont Dubox 7 poli

X42 X43

27

Conn. Dupont Dubox 7 poli

Conn. Dupont Dubox 7 poli

Conn. SAAB 10 poli

Conn. SAAB 6 poli (consolle SLAVE)

Conn. SAAB 42 poli (impianto MASTER)

Conn. JPT 3 poli (predisp. trasm. dati)

21

23

Conn. AMP 55 poli (impianto SLAVE)

...

...

...

22

X41*

...

...

X40

X39*

X38*

X36*

X35

X34

X33

X32

...

X26

X25

X24

X23

X22

X21

X20

X19

X16

X15

X14

X13

X12

X11

X10

...

X8

X7

X6

X5

X4

X2

X1

...

...

...

21

29

29

30

...

...

...

...

...

...

...

...

...

2Y13*

2Y12*

2Y11

2Y5

2Y4

1Y9*

1Y8*

1Y7

1Y6

1Y3

1Y2

X81

X80

...

X75

X74

X73

X72

X71

X70

X69

X68

X67

X66

X65

X64

X63

X61

X60

X57

X56

30

32

33

34

38

32

33

34

35

MF

36

37

40

41

38

39

40

Protezione secondo DIN34

41

43

44

45

46

42

43

Sost.

S :A :

THESI2

44

45

46

Orig.

888.06.070

Schema di collegamento elettrico

Denominazione

Modifica Materiale : Codice grezzo :

42

Eliminato X23a (S3), X82 (7B4) e X9

Data Cont.

Quote di verifica Quote ausiliarie Data Nome Dis. DS 16.05.01 Cont.

Approv.

Manuf.

Stds.

N 22. 04.0 3

39

Lingua : Italiano Documento riservato

...

31

... ...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

...

G-13

G-14 Ev. chiusura forche

G-15 Ev. apertura forche

G-19

G-18

A-22

A-22

G-20

G-19

G-17

G-16

Ev. sollevamento (2-4) + discesa (1-3) forche

Ev. brandeggio basso

Ev. brandeggio alto

Ev. blocco freno negativo

Ev. sblocco freno negativo

Ev. traslazione laterale volante

Ev. traslazione laterale sedile

Ev. traslazione carro fuori

Ev. traslazione carro dentro

I-15/17

...

I-16

I-16

I-16

J-9

J-9

J-9

I-9

I-9

I-9

H-9

H-9

H-9

H-9

H-5

I-2

G-31

G-28/29

37

Conn. AMP 25 poli

36

B-1

35

Conn. JPT 2 poli

...

Morsetto A3: VMN idroguida

Morsetto A3: - batteria

Morsetto A3: + batteria

Morsetto A1: campo F2 trazione

Morsetto A1: campo F1 trazione

Morsetto A1: - batteria

Morsetto A1: VMN trazione

Morsetto A1:+ dopo teleruttore

Morsetto A1: - batteria

Morsetto A1: VMN pompa

Morsetto A1: + dopo shunt

Morsetto A1: + dopo teleruttore

Morsetto A1: + dopo teleruttore

Morsetto A1: + diretto batteria

Spina-presa batteria (RAVIOLI)

Conn. SAAB 2 poli

Conn. SAAB 6 poli

31

Numero disegno

47

47

CID

48

301693

48

Foglio: 2

Scala :

49

di :2

50

50

fit Toler.

Status :

Peso in Kg

49

J

I

H

G

F

E

D

C

B

A

THESI - Appendix A – Electrical diagrams

88806070 Electrical connections diagrams (part 2) (version N - 22/04/03 - Applicable rom serial number F24519P00001)

Rev. 08/03

Page 1

THESI - Appendix A – Electrical diagrams

88806070 Electrical connections diagrams (part 2) (version N - 22/04/03 - Applicable rom serial number F24519P00001) (continued from preceding page)

Rev. 08/03

Page 2

THESI - Appendix A – Electrical diagrams

88806070 Electrical connections diagrams (part 2) (version N - 22/04/03 - Applicable rom serial number F24519P00001) (continued from preceding page)

16.05.01

888.06.070

Rev. 08/03

Page 3

THESI - Appendix A – Electrical diagrams

88806078 Carriage shift sheath Italian

Alla ….

Blocco discesa Colore base Data Denominazione Guaine DIN 72551-FLRY-B Isolamento guaina DIN40621-sw Contrassegnare il gruppo guaine con il numero del disegno, il codice del fornitore, data costruzione: sett./anno.

Sui connettori deve essere segnato in modo indelebile il codice es. X1.

Tutti i connettori devono essere forniti cablati.

I conduttori (X, Y) sono collegati tra di loro con una saldatura a ultrasuoni.

Isolare la saldatura.

La distanza minima tra le due saldature è 60mm.

La direzione dei conduttori è definita con un trattino (Vedi dis.)

NOTA DI MONTAGGIO CONN. EV. (particolari “i” ad esclusione di X46): Mettere il contatto di terra dal lato opposto all’uscita cavi.

VISTA CONNETTORE LATO CONTATTI Schema guaina carro traslatore per Thesi - 2 Sensore presenza pallet Sensore rall. Fuori/dentro Sensore zero NOTA DI MONTAGGIO CONN.X57: Con colonna 8500 mm togliere conn. X57 p.m. ponticellato e inserire conn.micro ML. NOTA DI MONTAGGIO CONN. EV. X 46.

VISTA CONNETTORE LATO CONTATTI Conn. AMP 16 poli nero P.F. COD. Prot. Faston femm. AMP Contatto maschio ...

CONN. PER ELETTROVALV. Gommino passacavo ...

Contatto femmina Junior ...

Tappo in gomma per ...

Rev. 08/03

English To the Lower function lock-out Standard color Date Description DIN 72551-FLRY – B SHEATHS SHEATHS INSULATED TO DIN 40621 – SW MARK THE SHEATH WITH THE DRAWING NUMBER, THE MODIFICATION, THE SUPPLIER ITEM NUMBER, THE DATE OF MANUFACTURE WEEK/YEAR.

The part number should be indelibly marked on the connectors, for example X1 ALL THE CONNECTORS SHOULD BE SUPPLIED ALREADY WIRED.

Wires (X, Y) are connected to each other by ultrasound welding.

Insulate the welding.

The minimum distance between each weld is 60 mm.

The direction of the wires is indicated by a dash (see drawing) Assembly notes for connecting electrovalve (parts “I” with exception of X46): mount the ground contact from the side opposite the cable exit.

View from the contact side.

Thesi 2 reach truck sheath diagram Pallet detection sensor Decelerator in/out sensor Reset sensor Assembly notes for connecting the X57: for the 8500 mm mast, cut the bridged p.m. X57 connector and insert the ML microswitch connector Assembly notes for connecting X46 electrovalve.

View of connector from contacts side Black 16-pin AMP connector P.F. COD. AMP female faston protection Male contact ...

Electrovalve connector Rubber fairlead ring ...

Junior female contact ...

Rubber cap for ...

Page 1

THESI - Appendix A – Electrical diagrams

88806078 Carriage shift sheath (continued from preceding page) Gommino passacavo per microtimer Guarnizione Guarnizione per SAAB 6 poli Conn. ... poli ... NERO ...

Conduttore colore BLU e sezione 0.75mmq inserito nella posizione X55.9 e X55.10 Tolleranza lunghezza conduttori in mm Fino a 300 Da 300 a 600 Da 600 un poi Se si sommano delle singole misure la tolleranza da considerare è quella della quota totale Codice Colore base BK WH BU OG BN A GN YE GY

PK

Rev. 08/03

Rubber fairlead ring for microtimer gasket ...

Gasket for 6-pin SAAB connector Black ...-pin connector ......

Blue wire and 0.75 sq.mm section inserted into position X55.9 and X55.10 WIRE LENGTH TOLERANCES IN MM UP TO 300 BETWEEN 300 AND 600 FROM 600 AND UP IF THE INDIVIDUAL MEASUREMENTS ARE ADDED TOGETHER, THE TOLERANCE SHOULD BE FOR THE TOTAL LENGTH PART NUMBER STANDARD COLOUR BLACK WHITE BLUE ORANGE BROWN AZURE GREEN YELLOW GREY PINK

Page 2

6

RELEASE BRAKING

4

1°EPROM SYSTEM

2°EPROM SYSTEM

EPROM DISPLAY

TH2-C1.20

TH2-S1.07

TH2-D1.10

ATTENTION: The parameters may be modified only to achieve the level of performance specified in the testing manual

tolerances

Modifiable parameters during testing observing the parameter

Non-modifiable parameters during testing

EVP MAX VOLTAGE

9 7 9 9 5 7 5 9 1 9 0 8 (+/- 1) 5 5 9 5 9 7 5 5 9 7 5 5 9 0 4 8 5 8 5 4 6 6

0

DECELER.DELAY

PEDAL BRAKING INVERS.BRAKING MAX SPEED FORW MAX SPEED BACK CUTBACK SPEED CUTBACK SPEED 1 CUTBACK SPEED 2 MAX I TRACTION CREEP SPEED TR. ARMA CURRENT NOM. WEAK DROPOUT FIELD CURR.NOM. ANGLE CURVE CUT. CUTBACK SPEED 3 1°SPEED COARSE 2°SPEED COARSE REACH FORW SPEED REACH BACK SPEED L-SHIFT SPEED R-SHIFT SPEED TILT UP SPEED TILT DOWN SPEED REACH FWD SLOW REACH BACK SLOW MAX I PUMP CREEP SPEED PUMP LIFT EV.DELAY PU ACCELER. DELAY PU DECELER. DELAY AUX ACC.DELAY AUX DEC.DELAY EV ACC.DEL. EV DEC.DEL. EVP MIN VOLTAGE

6

ACCELER.DELAY

STEER CONFIG

H1/H2 CUTBACK

BLOCK REACH

CUTBACKSPEED

SINC FORK

AUX FUNCTION 5

AUX FUNCTION 4

AUX FUNCTION 3

AUX FUNCTION 2

STEER DISPLAY

CURVE CUTBACK

OPTION #2

OPTION #1

OFF

ON

ABSENT

PRESENT

OFF

ON

ABSENT

PRESENT

LEVEL = 4

LEVEL = 3

LEVEL = 2

LEVEL = 1

LEVEL = 0

LEVEL = 1

LEVEL = 0

OFF

ON

DIGITAL

NORMAL

OFF

ON

OFF

ON

OPTION #2

OPTION #1

RUNNING

HOUR COUNTER AUX FUNCTION 1

~

E

synchronizer lever

26/09/2001

19/07/2002

A.G.

MF

Sets the maximum voltage value on the potentiometri c

synchronizer lever

Sets the minimum voltage value on the potentiometric

Sets the maximum voltage value on the potentiometric carriage

Sets the minimum voltage value on the potentiometric carriage

F

Sets the maximum voltage value on the potentiometric side shift

Sets the minimum voltage value on the potentiometric side shift

Sets the maximum voltage value on the potentiometric tilt lever

Sets the minimum voltage value on the potentiometric tilt lever

Sets the maximum voltage value on the potentiometric lift/lower

l

Sets the minimum voltage value on the potentiometric lift/lower

clockwise direction

Sets the minimum voltage value with rotation of steer wheel in a

an anti clockwise direction

Sets the minimum voltage value with rotation of steer wheel in

PARAMETER SETTING TABLE

ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF ON / OFF

FORWARD SWITCH BACKWARD SWITCH DEADMAN SWITCH CUTBACK SWITCH 1 CUTBACK SWITCH 2 ENABLE SWITCH BRAKE SWITCH LIFT SWITCH DESCENT SWITCH REACH SWITCH TILT SWITCH SIDESHIFT SWITCH LIFT BLOCK ZERO ENCODER REACH RED.FWD REACH RED.BACK HANDBRAKE HPS INPUT PALLET SENSOR TR.BRUSHES KO PUMP BRUSHES KO HYDRO BRUSHES KO BRAKE OIL LEVEL OIL FILTER BATTERY OUT TR.TEMP SWITCH PU TEMP SWITCH DIGITAL IMPUT #1 DIGITAL INPUT #2 DIGITAL INPUT #3

88806115

Parameter setting table

Modification to default parameters and traction curves

H COUNT TRACTION H COUNT LIFTING DEBUG

301381

() () ()

ON / OFF ON / OFF +VB ON / OFF +VB ON / OFF +VB ON / OFF +VB

() V () % ()° () ()°C ()°C

DESCENT CONTROL STEER ANGLE HEIGHT TEMPERATURE #1 TEMPERATURE #2

DIGITAL INPUT #4 G.P. OUT 1 G.P. OUT 2 G.P. OUT 3 G.P. OUT4

() V () V () V () % () V () %

VMN EVP VOLTAGE TR.ACCELERATOR LIFT ACCELERATOR

() V () V () V () A () A () A

TR V MOTOR PU TR I MOTOR PU FIELD CURRENT

BATTERY VOLTAGE

THESI - Appendix A – Electrical diagrams

88806151 Slave sheath diagram Italian Guaine DIN 72551-FLRY-B Isolamento guaina DIN40621-sw Contrassegnare il gruppo guaine con il numero del disegno, il codice del fornitore, data costruzione: sett./anno.

Sui connettori deve essere segnato in modo indelebile il codice es. X1.

Tutti i connettori devono essere forniti cablati.

I conduttori (X, Y) sono collegati tra di loro con una saldatura a ultrasuoni.

Isolare la saldatura.

La distanza minima tra le due saldature è 60mm.

La direzione dei conduttori è definita con un trattino (Vedi dis.)

Conn. AMP 55 poli nero P.F. COD. CON PROT. IN GOMMA Prot. Faston femm. AMP Contatto maschio ...

Cappuccio per SAAB 42 poli nero Gommino passacavo ...

Contatto femmina Junior ...

Tappo in gomma per ...

Guarnizione Guarnizione per SAAB 16 poli Alla scatola fuse Controllo idroguida Prolunga slave Cicalino Prolunga Lamp. Alarm Aliment. Ventola Al selettore M.A. Al pulsante blocco discesa con sinr. Forche Al pulsante CLACSON Al presso stato sterzo Al sensore sterzo Seriale Al CLACSON Chiave Puls. Soll./disc. Pedana Att. Pedana Acceleratore pedaliera Sens. U.M. Freno sens. pedale Tolleranza lunghezza conduttori in mm Fino a 300 Da 300 a 600 Da 600 in poi

Rev. 08/03

English DIN 72551-FLRY – B sheaths Sheaths insulated to DIN 40621 – sw Mark the sheath with the drawing number, the modification, the supplier item number, the date of manufacture week/year.

The part number should be indelibly marked on the connectors, for example X1 All the connectors should be supplied already wired.

Wires (X, Y) are connected to each other by ultrasound welding.

Insulate the welding.

The minimum distance between each weld is 60 mm.

The direction of the wires is indicated by a dash (see drawing) Black 55-pin AMP connector P.F. COD. With rubber protection AMP female faston protection Male contact ...

Cap for black 42-pin SAAB connector Rubber fairlead ring ...

Junior female contact ...

Rubber cap for ... gasket ...

Gasket for 16-pin SAAB connector To the fuse box Power steering control Slave extension sheath Buzzer Extension sheath Alarm warning light Fan power supply To the M.A. selector To the lower lock-out button with fork synchronizer To the HORN button To the steering pressure switch To the steering sensor Serial (or standard depending upon context) To the horn Key Platform lift/lower button To the (alla?) platform Accelerator pedal unit Deadman sensor Brake pedal sensor WIRE LENGTH TOLERANCES in mm UP TO 300 BETWEEN 300 AND 600 FROM 600 AND UP

Page 1

THESI - Appendix A – Electrical diagrams

88806151 Slave sheath diagram (continued from preceding page) Se si sommano delle singole misure la tolleranza da considerare è quella della quota totale Codice Colore base BK WH BU OG BN A GN YE GY PK Introdotto conn. X12 PM Modifica Data Cont.

CID- Fit – Toler.

Quote di verifica Quote ausiliarie Materiale: Codice Peso in kg Nome Denominazione Status Dis. Scala Cont.

Approv.

Schema guaina slave Thesi 2r Manuf.

Foglio 1 di 1 Stds.

Sost. - Orig.

Lingua : Inglese Documento riservato Protezione secondo DIN34

Rev. 08/03

If the individual measurements are added together, the tolerance should be for the total length Part number Standard Colour Black White Blue Orange Brown Azure Green Yellow Grey Pink Intoduction conn. of X12 PM Modification Date Cont.

CID - Fit - Tol Test dimensions Auxiliary dimensions Material: Raw material number : Weight in kg Name Descritpion Status Drawing Scale Checked Approved Slave sheath diagram Thesi 2r Manufactured Sheet: 1 of 1 Standards Replaces - Original Language : English Confidential document Protected to DIN34

Page 2