OM Series 4547 TSR20ac Workshop Manual - PDF DOWNLOAD

Workshop literature

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Workshop literature 45478042102 EN 04/2007

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Workshop literature 45478042102 EN 04/2007

a

This chapter gives information taken from the instruction and maintenance manual, considered as of interest for the assistance technician

Consult the truck instruction and maintenance manual for detailed information on the use of the truck

This forklift has the following characteristics: It is a non-stacking forklift truck equipped with forks for lifting loads from ground level and transporting them.

It is battery powered; The forklift is driven by an operator sitting on board.

Given its construction, it is used to transport loads that fall within specific weight and volume dimensions.

Workshop literature 45478042102 EN 04/2007

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B

A

OM1349

The direction of travel for standard models is defined as follows: = Direction of travel away from the forks (Forward) = Direction of travel towards the forks (Reverse) " " is the preferred direction of travel

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Workshop literature 45478042102 EN 04/2007

OM1350

1.3 1.4

Power unit: electr., diesel, gasoline, gas, mains electr.

Driving: tiller, accompanied, standing, sitting, order picker

Electric sitting with steering wheel

1.5

Load capacity / Load

Q (t)

1.6

Centre of gravity

c [mm]

2 See following table

x [mm]

See following table

y (mm)

See following table 777(1)

1.9

Load distance from load wheel axle with forks raised Distance between axles with forks raised

2.1

Dead weight (without battery)

kg

2.2

Load per axle when loaded (front/rear)

kg

1.8

Workshop literature 45478042102 EN 04/2007

1372/1807(2) -3

kg

967/212(3)

2.3

Load per axle when empty (front/rear)

3.1

Full set of tyres, superelastic, tyre, polyurethane

3.2

Dimensions of front wheels

mm

3.5

Dimensions of rear wheels Wheels: front / rear quantity (x=drive wheel)

mm

3.6

Front track

b10(mm)

584.5

3.7

Rear track

b11(mm)

390

4.4

Lifting

h3(mm)

120

4.9

Tiller height in operating position (min. / max.)

h14(mm)

Missing

h13(mm) l1(mm)

85 See following table

4.20 Length including shoulder of forks

l2(mm)

938

4.21 Maximum width

b1(mm)

886

4.22 Fork dimensions 4.25 External gauge - forks

s/e/l (mm)

52/170/1150

b5(mm)

560

4.32 Clear span at mid wheelbase Working corridor with pallet 1000x1200 fork 4.33 insertion 1200 Working corridor with pallet 800x1200 fork 4.34 insertion 800 4.35 Radiuses of curvature

m2(mm)

153

Ast3(mm)

2165

Ast3(mm)

2365(4)

Wa(mm)

See following table

3.3

4.15 Lowered forks height 4.19 Total length

Vulkollan 250x80 / 125x50 85x80 1x-2/4

5.1

Translation speed (loaded/empty)

Km/h

9/12

5.2

Lifting speed (loaded/empty)

m/s

0.073/0.127

5.3

Descent speed (loaded/empty)

m/s

0.05/0.040

5.7 5.8

Surmountable gradient KB 30 I (loaded/empty) (1) Max. surmountable gradient KB5I (loaded/empty) (1)

% %

5.10 Service brake

/ Electric

6.1

Traction motor, performance KB 60I

kW

3

6.2

kW

2.2

6.4

Lifting motor, performance 15% ED Battery according to British Standard / DIN 43531/35/36 A, B, C Voltage/Nominal capacity

6.5

Battery weight (+/- 5%)

V/Ah kg

6.6

Energy consumption according to VDI cycle

kWh/h

8.1

Control type

6.3

8.4

Noise level in driver s ear

DIN 43535 B 24 / 360-640 312/502

Electronic dB (A)

< 70

1) The data refers to fork arms with length l=1150 mm.

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Workshop literature 45478042102 EN 04/2007

2) Including the operator on board and with the fork arms raised and battery 4PzS 360 Ah. 3) Including the operator on board and with the fork arms lowered and battery 4PzS 360 Ah. 4) For other fork lengths, see table. x

y

l1

Wa

Ast3

600

910

1592

2088

1873

2363

700

1159

1842

2338

2120

2561

1600

800

1359

2042

2538

2318

2759

1800

900

1359

2042

2738

2318

2959

2390

1200

1781

2464

3328

2734

3553

Component length

Terminals

I

c

1150 1400

CompoComponent nent series initials and type

Voltage

Capacity ±5%

Dimensions

24

360

830x273x537 312

7021

4 PzS 360 L

LD

83

24

440

830x273x627 372

7021

4PzS 440 L

LF

83

24

560

835x277x784 502

7021

4PzS 560 L

LG

83

24

640

835x277x784 502

7021

-

LG

83

Weight ±5%

Colour

The forklift is normally transported by road and rail. If the forklift s dimensions exceed the max. clearance size allowed, it is transported disassembled. The sales network is in charge of the disassembly and reassembly operations. The forklift must be secured to the transport means during transport using appropriate restraint systems. Block the wheels with wedges to prevent even the slightest movement.

Workshop literature 45478042102 EN 04/2007

screw type screw type screw type screw type

OM0747

-5

Use a lifting crane to load and unload the forklift, or use an inclined plane or a movable platform (with a slope and structural strength compatible with the specifications stated by the manufacturer as well as both suitably positioned and anchored).

1 2

1 2

¾ To lift the forklift, hook cables (1) suitable for the weight of the forklift into points (2) on the body, then connect the other end of the cables to the hook of a crane.

The cables should have a suitable length so as to not graze the casing or any additional equipment during lifting. Use a lifting beam if necessary. The cables must be pulled vertically.

OM1346

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Workshop literature 45478042102 EN 04/2007

This document gives the danger warnings Each of such danger warnings consists of a graphic symbol, followed by a description of the danger and its consequences, and the description of how it can be avoided. The types of warnings used are described below.

This warning indicates the risk of damaging the truck or parts of the same.

It may be accompanied by additional comments.

This symbol indicates important communications for the assistance technician.

It may be accompanied by additional comments.

This warning indicates serious risk of damaging the truck.

The instructions given here must be followed in order to avoid causing damage to the environment.

It may be accompanied by additional comments.

Do the following before performing maintenance operations:

Switch off the vehicle.

Press the emergency pushbutton.

Place the forklift on a flat surface and make sure that it cannot move accidentally.

Lower the forks fully.

Most accidents that occur in workshops are caused by failure to observe some simple and fundamental rules of prudence and safety.

For this reason, accidents can be avoided in most cases by the necessary care and prudence, paying attention to possible causes of accident and

Workshop literature 45478042102 EN 04/2007

their consequences, scrupulously following the safety rules.

A careful and wise mechanic is the best guarantee against accidents.

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Only allow qualified, trained and authorised personnel to use the forklift.

distances established by the competent authorities.

Do not install equipment on the forklift unless supplied or indicated by the manufacturer.

Never raise the load using just one fork.

Maintain the forklift in full working efficiency in order to keep any type of risk to the minimum.

Do not use the forklift with hoods and doors open.

The data plates found on the forklift must be kept in good condition and replaced if damaged.

Carefully read and follow all of the safety indications found on the forklift.

Make sure that the forklift has sufficient overhead clearance.

Do not park the forklift in front of fire-fighting devices or fire escapes or anywhere that it blocks traffic.

If the forklift shows signs of failure or breakage and there is reason to consider it unsafe, stop, park it and notify the maintenance manager.

Pay attention to the distances from high voltage overhead cables. Comply with the safety

-8

Place the load on the fork carriage or in such a way that the centre of gravity of the load is as close as possible to the fork carriage.

The load must be placed on the forks so that the centre of gravity falls on the mid point between the forks.

Do not drive with loads decentralised laterally with respect to the forklift s median axis. Lack of compliance with this regulation can compromise forklift stability.

Make sure that the surface on which the load rests is able to support its weight.

Always use safety clothing that complies with the current regulations.

Do not travel on loose or hilly ground or on steps.

Do not turn or stack on slopes.

Do not overload the forklift beyond the capacity limits indicated on the capacity plates.

Workshop literature 45478042102 EN 04/2007

Improper use and disposal of operating and cleaning materials cancause serious damage to the environment.

The used oils (brake, engine, gearbox and hydraulic oil) and relative filters contain substances hazardous to the environment and must be disposed of according to current regulations. We advise you to contact the authorised assistance network.

Always use and handle the operating materials in a suitable manner and follow the manufacturer s instructions for the product s use.

Only keep the operating materials in containers intended for this purpose and in a location that satisfies the requirements.

The operating materials may be flammable, so avoid contact with hot objects or naked flames.

When topping up the operating materials, the containers used must be clean.

Follow the manufacturer s safety and disposal instructions regarding operating and cleaning materials.

Do not inhale the vapour: it is poisonous.

Do not disperse oils or other operating liquids!

Any dispersed liquid must be immediately collected and neutralised with a binding material (such as oil binder) and then disposed of in accordance with current regulations.

Battery acid is corrosive: if it should come into contact with your skin, rinse abundantly with water.

Always abide by the regulations of the anti-pollution laws!

Before carrying out work that involves lubrication, filter replacement or hydraulic equipment interventions, the area in question must be thoroughly cleaned.

The replaced parts must always be disposed of in accordance with the anti-pollution laws.

The incorrect or unlawful use of brake fluid is harmful to people s health and the environment.

Avoid contact with the skin.

Do not inhale oil vapours.

Wear appropriate means of individual protection during forklift maintenance work (gloves, goggles etc.) to prevent the oil from coming into contact with your skin.

Workshop literature 45478042102 EN 04/2007

Use adequate means of individual protection to prevent contact with the skin.

Explosive gas mixtures can form when charging the battery; therefore the rooms in which the battery is charged must comply with the specific regulations on the subject.

Do not smoke or use naked flames and lights within a 2 m radius from the charged battery or in the battery charging area.

For more information, consult the specific battery manual that comes with the battery.

The batteries contain substances that are hazardous to the environment. The replacement and disposal of the run-down battery must be carried out as required by law. We advise you to contact the authorised assistance network that is equipped for eco-friendly disposal in accordance with current regulations.

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Workshop literature 45478042102 EN 04/2007

a

In order to keep the forklift safe and in good condition, have it serviced according to the scheduled maintenance operations indicated in the following "synoptic table of maintenance intervals".

When the forklift is used in dusty environments, at below zero temperatures and for especially heavy uses, it is necessary to reduce the interval between the various scheduled maintenance operations.

Check fork wear Clean the steering and lift electric motors Grease the lever system Check insulation between chassis and any electric motors Check insulation between chassis and electronic control Check the condition of the piping Check hydraulic equipment oil level Check reducer oil level Check and adjust front bearings Lubricate gear wheels Check the steering and lift motor manifolds Lubricate the step plate slide guides Check the wear of the steering motor brushes Check and lubricate the fork carriage and slide guides Change the lift motor brushes Change the hydraulic equipment oil = Every 1000 hours or at least every 12 months

During maintenance operations, follow the instructions in the "Safety Regulations Relating to Operating Materials" section in "Chapter 2".

Tutela Matrix

Tutela Matrix

Workshop literature 45478042102 EN 04/2007

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Quantity (l)

Quantity (l)

1.5

1.5

Idraulicar AP31

Tutela GI/M

1

1

Tutela MP 02

Tutela JOTA1

Drive wheel fastening nut

M14x1.5 8.8

Driven unit plate reducer fastening screw

M10x1.5 8.8

Traction motor to flange fastening screw

M6x1.0 8.8

Pinion to drive motor fastening nut

M14x1.5 8

Brake to motor fastening screw

M6x1.0 8.8

Pivoting wheel unit to chassis fastening screw

M12x1.75 8.8

Electrical steering pinion fastening screw-nut

M8x1.25 8.8

Electrical steering flange to reducer

M8x1.25 8.8

Electrical steering unit to chassis of drive unit plate fastening screw

M8x1.25 8.8

Drive unit plate to chassis fastening screw

M10x1.5 8.8

Idle pin to load chassis fastening nut

M24x1.5 8

Spare to tandem rocker arm fastening screw

M12x1.75 8.8

Tandem rocker arm fastening nut

M12x1.75 8.8

Power lead fastening screw

M6x1.0

System fuse nut *

M8x1.25

* with safety washer.

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Workshop literature 45478042102 EN 04/2007

a

The diagnostics connectors can be accessed through the appropriate door by unscrewing the screw (1) using an M4 Allen key.

(A): Connector for the Curtis system diagnostics.

(B): Connector for the LES electrical drive diagnostics.

Workshop literature 45478042102 EN 04/2007

-1

Diagnosis is carried out by the software installed in the special diagnostics case. ¾ The software is represented by the icon shown here:

¾ It is also necessary to use the cable composed of: " " Molex 9848493 wire. " " interface 9848494 wires.

The diagnostics unit must be used only by specially trained personnel. Variation in some parameters or configurations can cause danger for the operator (e.g. an increase in drive speed). .

Connection should be carried out when the truck is switched off.

¾ Connect the PC by means of the interface wiring harness to the 4-pole 6x1 Molex connector leading from the drive controller. ¾ Switch on the truck and close the key contact.

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Workshop literature 45478042102 EN 04/2007

¾ Click on the program icon.

¾ For a few seconds, while the program is loading, the following display will appear.

¾ This will automatically be followed by the window of the program .

¾ Enter the "

" menu, and click on .

Workshop literature 45478042102 EN 04/2007

-3

¾ This display will appear. Select " " and click on " ".

is used for AC motors. is used for DC motors.

¾ Enter the " and then "

menu, choose " ".

¾ Wait for about 1 minute until the main page, shown at the side, appears. ¾

: the program " " contains numerous menus linked to many functions, some typical of programs that function in the MS-Windows environment. It is not possible to explain all the functions; the most important will be dealt with here. However, those who wish to study the matter in more depth can program. refer to the on-line

¾ For access to the main menus, click with the left mouse key on the icon indicated by the arrow in the figure at the side . The initials at the side of the icon represent the electronic control model (initials in the figure: 1243-0225)

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Workshop literature 45478042102 EN 04/2007

¾ To open the drop-down menu, click with the right mouse key.

For access to one of the main menus, click twice on the icon of the chosen menu.

The menus available are the following:

¾" " = This menu allows for the display of information regarding the drive controller.

¾" " = This menu allows for adjustment of the drive controller parameters.

¾ To change a parameter inside the " " menu, click on the parameter. To increase or decrease the value of the paramor and confirm by eter, click on button clicking on " ".

Workshop literature 45478042102 EN 04/2007

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¾

= This menu allows for the display of the values that are monitored in real time.

¾" present.

" = This menu is empty at

" " = This menu allows for the display of alarms in real time ) and of those memorised ( and for cancellation of the same ( ).

¾" " = This menu allows for display of the alarms present at the moment.

¾" " = This menu allows for the display of the record of previous machine alarms.

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Workshop literature 45478042102 EN 04/2007

¾ Further information is available by clicking on the alarm.

¾

= For elimination of the errors record after having read it. For this purpose, select (in the drop-down menu) which appears when the right mouse key is clicked on the menu. The program will ask for confirmation of cancellation of the alarms record.

The Monitor menu allows for the display in real time of the status of inputs, outputs and the various magnitudes.

Workshop literature 45478042102 EN 04/2007

-7

The Monitor menu is useful for checking on controller functioning during initial installation and for localisation and resolution of any problems.

The values displayed depend on the state of the battery and on the functions that the machine is carrying out at that moment.

On the following pages, the terms have the following meanings:

and

= the corresponding function is activated. = the corresponding function is disabled.

The low.

menu contains the following data: : contains the sub-menu described be-

: contains parameters regarding the CAN BUS application, not used on this model. : System model. : System serial number. : System manufacturing date. : Hardware version. : Version of the operating system installed on the controller. : Build number of the controller operating system. : Version of the Start Manager software of the controller. : Version of the parameters block installed on the controller. ware.

-8

: Version of the VCL soft-

Workshop literature 45478042102 EN 04/2007

¾

contains the following sub-menus:

This indicates the four states of the machine/chopper: = STARTUP: awaiting operation = DRIVE_MAX: operator presence pedal and accelerator pedal pressed, without load = DRIVE_LOAD: operator presence pedal and accelerator pedal pressed, with load = DRIVE_REDUCED: presetting for reduced drive conditions

Mapping of the drive potentiometer voltage

0 - 5 Volts

Mapping of the brake potentiometer voltage

0 - 5 Volts

Workshop literature 45478042102 EN 04/2007

-9

-10

Drive wheel potentiometer voltage

- - Volt

Maximum speed in the fork arms direction as a function of the steering angle of the wheel, in relation to the Steering Potentiometer

-- %

Maximum speed in the motor compartment direction as a function of the steering angle of the wheel, in relation to the Steering Potentiometer

-- %

Pin 9 input state

ON - OFF

Pin 10 input state

ON - OFF

Pin 11 input state

ON - OFF

Pin 12 input state

ON - OFF

Pin 22 input state

ON - OFF

Pin 33 input state

ON - OFF

Value of the output PWM of pin 6

-- %

Value of the output PWM of pin 5

-- %

Value of the output PWM of pin 4

-- %

Value of the output PWM of pin 3

-- %

Workshop literature 45478042102 EN 04/2007

Speed in rpm

- - rpm

Truck speed (Km/h)

- - Km/h

Temperature inside motor

- - °C

Load percentage

-- %

Voltage at key

- - Volt

OVERVOLTAGE alarm activation Current on the battery

ON - OFF

RMS current (on the three phases)

-- A

Inverter output frequency

- - Hz

Temperature inside the controller

- - °C

Workshop literature 45478042102 EN 04/2007

-- A

-11

From the , it is possible to change some of the data displayed in the .

The modification of one or more parameters, even though instantly stored by the software, becomes operative only after switching the key off and on again.

¾ The contains the following data:

Both the above items contain drop-down menus detailed below.

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Workshop literature 45478042102 EN 04/2007

¾

contains the following sub-menus:

Lower threshold of the drive potentiometer

0 - 5 Volts

Upper threshold of the drive potentiometer

0 - 5 Volts

Workshop literature 45478042102 EN 04/2007

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-14

Deceleration rate applied to the truck (from high speeds) when closing the throttle (max voltage).

From 0.5 to 10 seconds

Deceleration rate applied to the truck (from low speeds) when closing the throttle (max voltage).

From 1 to 10 seconds

Deceleration rate applied to the truck after slightly closing the throttle (for all speeds).

From 2 to 30 seconds

Lower threshold of steering potentiometer

From 1.5 to 2.5 Volts

Steering potentiometer voltage with wheel centred Upper threshold of steering potentiometer

From 6.5 to 7.5 Volts

"Dead" band of the wheel centre

From 0.2 to 1.5 Volts

Parameter to model the deceleration curve Minimum speed of deceleration when turning, travelling in the direction of the motor compartment Minimum speed of deceleration when turning, travelling in the direction of the fork arms

From 1.5 to 3.8 Volts

EM brake power supply voltage (CONSTANT)

From 18 to 24 Volts

Fan power supply voltage

From 12 to 24 Volts

From 4 to 5.5 Volts

From 0 to 50% From 0 to 50%

Workshop literature 45478042102 EN 04/2007

Temperature for fan activation

From 0 to 70°C

Temperature for fan deactivation

From 0 to 60°C

Minimum speed during turns Maximum speed in the direction of the fork arms when not loaded Maximum speed in the direction of the fork arms when loaded Reduced speed in the direction of the fork arms

38%

From 0 to 50%

67%

From 0 to 50%

67%

From 0 to 50%

38%

From 0 to 33%

Minimum speed during turns Maximum speed in the direction of the fork arms when not loaded Maximum speed in the direction of the fork arms when loaded Reduced speed in the opposite direction to the fork arms

Workshop literature 45478042102 EN 04/2007

From 0 to 50% From 0 to 100% From 0 to 75% From 0 to 33%

-15

¾

menus:

contains the following

Acceleration rate applied to the truck with throttle fully open (at high speeds).

Acceleration rate applied to the truck with throttle fully open (at low speeds).

Acceleration rate applied to the truck with throttle slightly open (at all speeds).

Deceleration rate applied to the truck to return the throttle to the intermediate position (from high speeds).

Deceleration rate applied to the truck to return the throttle to the intermediate position (at low speeds).

Deceleration rate applied to the truck (from high speeds) for throttle inversion (max voltage)

-16

From 0.5 to 30 seconds From 0.5 to 10 seconds From 0.5 to 30 seconds From 1 to 30 seconds

From 1 to 30 seconds From 0.5 to 10 seconds

Deceleration rate applied to the truck (from low speeds) for throttle inversion (max voltage).

From 1 to 10 seconds

Deceleration rate applied to the truck after slight inversion of the throttle (for all speeds).

From 2 to 30 seconds

Workshop literature 45478042102 EN 04/2007

When an alarm blocks the truck, it does not allow closure of the main remote control switch on ignition, and during operation it opens the main remote control switch. In the case of an alarm, the inverter status leds create a code (flash code) to indicate the type of anomaly. To interpret the code, the type of flashing and the colour of the activated led must be observed. In fact, every alarm is represented by a two-digit code: the flashing of the yellow led represents the value of one digit; the flashing of the red led indicates which digit is represented by the successive flashing yellow led.

The red led flashes once: the flashing of the yellow led that follows indicates the value of the first digit of the alarm code. The yellow led flashes twice: the first digit of the alarm is 2. The red led flashes twice: the flashing of the yellow led that follows indicates the value of the second digit of the alarm code.

The yellow led flashes three times: the second digit of the alarm code is 3. (*1): Red (*2): Yellow (*3): First digit (*4): Second digit

(blocks truck) The voltage of the phase exceeds the voltage limit measured (blocks truck) Voltage sensor reads an incorrect value (blocks truck) Failed pre-charge of condensers

(blocks truck) Temperature dissipater lower than -40°C

Short circuit of phase U,V,W of the traction motor.

Phases U,V,W of the traction motor may not be correctly insulated.

External load connected to B+ which prevents recharging of the condenser group.

The truck is being used in an excessively cold environment.

The temperature sensor is damaged.

Workshop literature 45478042102 EN 04/2007

Check wiring and repair if necessary.

If the problem persists, replace the system.

Check wiring and repair if necessary.

If the problem persists, replace the system or the drive motor Check wiring and repair if necessary.

If the problem persists, replace the system.

Heat or change the work environment.

If the environmental temperature is acceptable, replace the system

-17

(blocks truck) Dissipater temperature higher than +95°C

(blocks truck) The condenser group voltage is below the set limit

The truck is being used in an excessively hot environment Work cycles are too heavy.

Ventilation system is out of order.

The temperature sensor is damaged.

Check the work environment Check the ventilation system and repair if necessary Check the dissipater temperature and if it is much below 95°C, replace the system

Power fuses damaged.

Main remote control switch open.

Check the fuse and replace if necessary Check the main remote control switch and replace if necessary

(blocks truck) The battery was disconnected The voltage of the group of during regenerative braking. condensers is above the set limit Incorrect calibration of battery (blocks truck) parameters.

(reduces speed) Dissipater temperature lower than -25°C

(reduces speed) Dissipater temperature higher than +85°C

(reduces speed) The condenser group voltage is below the set limit

The truck is being used in an excessively cold environment.

The temperature sensor is damaged.

The truck is being used in an excessively hot environment Work cycles are too heavy.

Ventilation system is out of order.

The temperature sensor is damaged.

Power fuses damaged.

Main remote control switch open.

Reset the parameters correctly Heat or change the work environment.

If the environmental temperature is acceptable, replace the system Check the temperature of the work environment Check the ventilation system and repair if necessary Check the dissipater temperature and if it is much below 85°C, replace the system Wait until the control has cooled down Check the fuse and replace if necessary.

Check the main remote control switch and replace if necessary

(reduces speed) The battery was disconnected The voltage of the group of during regenerative braking. condensers is above the set limit (no effect) The +5V (pin 26) power supplier is outside the +5V ±10% range

-18

Impedance of external load on pin 26 is too low.

Check the connections and whether there is any anomalous absorption.

Impedance of external load on (output disabled) The voltage on pin 19 output pin 19 is too low. exceeds the 15mA limit

Alarm not expected since pin 19 is not connected.

Impedance of external load on (output disabled) The voltage on pin 20 output pin 20 is too low. exceeds the 15mA limit

Alarm not expected since pin 20 is not connected.

Workshop literature 45478042102 EN 04/2007

(reduces speed) The temperature of the motor has reached that set for the Hot Temperature parameter

(blocks drive) The temperature of the motor has reached that set for the Max Temperature parameter or (blocks truck) The Pin6 driver is open or short circuited or Coil2 Driver Open/Short (blocks truck) The Pin 5 driver is open or short circuited (output disabled) The Pin 4 driver is open or short circuited (output disabled) The Pin 3 driver is open or short circuited (output disabled) The Pin 2 driver is open or short circuited

The truck is being used in an excessively hot environment Work cycles are too heavy.

Ventilation system is out of order.

The truck is being used in an excessively hot environment Work cycles are too heavy.

Ventilation system is out of order.

Temperature sensor is disconnected or out of range.

Check the temperature of the work environment.

Check the ventilation system and repair if necessary.

Wait until the control has cooled down.

Check the temperature of the work environment.

Check the ventilation system and repair if necessary.

Wait until the control has cooled down.

Check the connection of the temperature sensor.

Check wiring and repair if necessary.

The contactor coil is open circuit Check the state of the main or has a short circuit. remote control switch and replace if it is defective Check wiring and repair if necessary.

The electromagnetic brake coil Check the state of the electrois open circuit or has a short magnetic brake and replace it circuit. if it is defective.

Check eABS. The load on the pin 4 output is open circuit or has a short circuit.

Check wiring and repair if necessary.

The load on the pin 3 output is open circuit or has a short circuit.

Alarm not expected since pin 3 is not connected.

The load on the pin 2 output is open circuit or has a short circuit.

Alarm not expected since pin 2 is not connected.

(blocks truck) Error on the motor encoder.

Error detected on a phase of the encoder.

Check wiring and repair if necessary.

(blocks truck) One phase of the motor is open Check wiring and repair if One of the motor phases U, circuit. necessary.

V, W is open circuit. (blocks truck) Main remote control switch is welded

(blocks truck) Main remote control switch is not closed even if commanded

Main remote control switch is stuck.

Phase U of motor is disconnected.

Check wiring and repair if necessary.

Check the state of the main remote control switch and replace if it is defective

Main remote control switch is not completely closed.

Main remote control switch contacts are oxidised.

Check the state of the main remote control switch and replace if it is defective

Workshop literature 45478042102 EN 04/2007

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(blocks drive) Potentiometer power supply is Potentiometer voltage Drive out of range. (pin 16) too high (blocks drive) Incorrect connections.

Potentiometer voltage Drive (pin 16) too high

Reconnect correctly.

(Maximum braking) eABS braking signal is out of Potentiometer voltage Drive range. (pin 17) too high

Check eABS and replace if necessary.

(MaxieABS braking signal is incormum braking) rect.

Potentiometer voltage Drive Incorrect connections. (pin 17) too low

Check eABS and replace if necessary.

Reconnect correctly.

(drive blocked and maximum braking) Current of pin 18 input exceeds the 10mA limit

Incorrect connections.

Alarm not expected since pin Potentiometer resistance is too 18 is not connected. low.

or (blocks truck with maximum braking) The software loaded in the Wrong software loaded. controller does not find correspondence with the parameters already memorised

(blocks drive) Incorrect starting sequence.

Incorrect starting sequence

(drive blocked and maximum braking) Setting of at least one parameter that requires switching off and on again with the key for activation

(blocks drive) Activates due to incorrect startup sequence.

-20

Check power supply of the drive potentiometer.

Load the correct software.

Check that the sequence is carried out correctly (key+dead man+gear+drive potentiometer).

Note: this alarm is generally substituted by alarm No.53 (more restrictive VCL software).

Setting of at least one parameter that requires switching off Switch off and then on again. and on again with the key for activation If at least one of the following signals is on when the truck is started up: Interlock_Switch Speed_Reduction Backing_Enable Forward_Switch Reverse_Switch or the throttles are not in the idle position (non-blocking alarm)

Check that at rest the signals concerned are correct Check the wiring.

Replace any damaged components (e.g.: switch, etc.).

Workshop literature 45478042102 EN 04/2007

(blocks

drive)

(blocks drive)

(non-blocking) Activates if the truck does not brake as expected on release of the gear request. (blocks truck) Activates with alarm 17 (blocks truck) Activates with alarm 24 (blocks truck) (drive blocked and maximum braking)

(no effect) (blocks truck) (blocks truck)

(blocks truck)

Check that at rest the signals concerned are correct Both drive signals (Forward and Check the wiring Reverse) are active simultaneReplace the drive potenously (non-blocking alarm). tiometer or the handlebar logic if necessary.

The drive potentiometer already exceeds 0.25 V on starting up.

Check that at rest the signals concerned are correct Check the wiring.

Replace any damaged components (e.g.: switch, drive potentiometer, handlebar card).

If the truck does not brake on release of the drive request Check that the electronic within the time expected for the control is working properly. eABS, the EM brake is activated Check the drive motor. (non-blocking alarm).

See alarm 17. The electromagSee alarm 17. netic brake is forced open.

See alarm 24. The electromagSee alarm 24. netic brake is forced open.

The brake potentiometer input has a voltage value out of range.

Check wiring and voltage on the relative pin of the eABS.

Incorrect software.

Replace the system with new software.

Anomalous absorption on pin 26 and pin 25 outputs.

Check connections and repair if necessary

Internal error on the controller.

Error on the CAN BUS communication.

Error on the encoder.

Check connections and repair Stalled motor Problems with the power supply if necessary to the encoder.

(blocks truck) One phase of the motor is open Check wiring and repair if One of the motor phases U, circuit. necessary.

V, W is open circuit.

Workshop literature 45478042102 EN 04/2007

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The diagnostics PC and LES control are connected through the sheathed cable interface code 300 365 25 01 The diagnostic software can be used to change parameters and display alarms.

The procedure to be carried out is the following: ¾ Connect the PC with the sheathed cable interface to the 4-pin Saab connector leading from the LES control (see the "Connectors for diagnostics" section). ¾ Switch on power to the truck and close the contact key. ¾ Click on the LES program icon.

On opening, the program shows the window (1) which displays general information.

1st line

Programming environment.

2nd line

Software version of 1st processor / software version of 2nd processor.

3rd line

System identification.

4th line

Truck type identification code.

The correct connection between PC and LES control is represented by the symbol in the lower part of the LES program window.

If the connection between PC and LES control is not made correctly, a failed connection symbol is shown in the lower part of the LES program window. .

To effectively use this programming environment, it is necessary to know the functionalities related to the various keys. The description is provided in the table.

ESC

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Terminatesthe function being used

Workshop literature 45478042102 EN 04/2007

F1

Help that describes how to use the software

F3

Loads the last parameter vector (only if the controller is active)

F9

Prints the parameters in the window (only if the printer is connected and the controller is active)

ALT X

Exits the program

F4

Exits the program

SHIFT F1 PgUp

Provides the program version Moves to the page above

PgDn

Moves to the page below

HOME

Moves to the beginning of the text

END

Moves to the end of the text

1 ... 9

Allows to select the desired window Stores the value of the parameters (only if the controller is active)

F2 Up arrow

Increases the value of the parameter

Down arrow Backspace

Decreases the value of the parameter

ENTER

Accepts the value of the parameter To select a function

For example, press the F1 key at any point in the program to access the help page of each window.

To scroll through the windows, press the PgUp and PdDn keys.

1:

Software version, truck control and identification

2:

Display of alarms occurring during the last time the truck was switched on

3+:

Display of alarms memorised in the microprocessor after the last maintenance action (if cancellation is allowed)

31+:

Display of all alarms that have occurred (Alarms history)

32+:

Display of values of important variables memorised at the moment of the breakdown

33+:

Time passed since last switch-on and time passed between last switch-on and appearance of last error

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34+:

Total cancellation of breakdowns from the memory (only PC MASTER)

4+:

Display of the status of logic inputs of the main microprocessor

41+:

Display of the status of logic inputs of the supervisor microprocessor (only PC MASTER)

5+:

Display of the status of the logic outputs of the main microprocessor

51+:

Display of the status of the logic outputs of the supervisor microprocessor (only PC MASTER)

6+:

Display of the status of the analog inputs: PWM, motor current, temperature, battery voltage

61+:

Display of the status of the analog inputs: potentiometer voltages and potentiometer power supply

62+:

Display of the status of the analog inputs: potentiometer voltages compared to a power supply of 10V

63+:

Display of the status of the analog inputs seen by the supervisor microprocessor (only PC MASTER)

7+:

Adjustable parameters: Y and PowerSave

71+:

Adjustable parameters: P, D, Ft

8+:

Steering potentiometer adjustments

81+:

Drive wheel potentiometer adjustment

82 +:

Reading of the potentiometer adjustments: gain and offset (only PC MASTER)

-24

Workshop literature 45478042102 EN 04/2007

I dati espressi in figura sono puramente indicativi.

Workshop literature 45478042102 EN 04/2007

-25

Vs1

Voltage reading on steering potentiometer No.1 (Pin 19)

32+/61+

Vs2

Voltage reading on steering potentiometer No.2 (Pin 20)

32+/61+

Vpo

Power supply of potentiometers (Pin 8)

32+/61+

Ub

Battery voltage

32+/6+

Va1

Voltage reading on drive wheel potentiometer No. 1 (Pin 22)

32+/61+

Va2

Voltage reading on drive wheel potentiometer No. 2 (Pin 10)

32+/61+

Tpo

Temperature of module at the power MOS-FET

32+/6+

On Time

Time passed since last switch-on

33+

Err Time

Time passed between last switch-on and last error detected

33+

DeadM

Dead man (0 polarised input, 1 non-polarised input)

4+/41+

SecRel AuxAB

Status of contacts inside the safety circuit relay (0 relay open, 1 relay 4+/41+ closed) Auxiliary inputs for coding the type of truck for the wiring (0 polarised 4+/41+ input, 1 non-polarised input)

StErr

Status of "drive deactivation" emergency output (0 drive abled, 1 drive 4+/41+ disabled)

ForSt

Status of input of permanent steering activation (0 drive always activated, 1 the drive determines its activation automatically on the basis of the presence of the operator, sudden piloting variations, truck speed, etc.)

4+/41+

Code

Input coding (Pin 4) to encode the type of truck by the wiring (0 polarised input, 1 non-polarised input)

4+/41+

SteerError

Steering error with drive blocked (0 activation, 1 deactivation)

5+

Motor Relay

Allows for piloting the power relay, and thus for stabilising the drive motor power supply (0 relay open, 1 relay closed)

5+

Enable PWM

Control of MOS-FET enabled by PWM signal (0 deactivated, 1 activated)

51+

MotRelay

Power relay activation enabled by emergency microprocessor (0 relay deactivated, 1 relay activated)

51+

X

Emergency relay activation enabled (0 relay deactivated, 1 relay activated) Motor current Motor temperature Cyclical ratio of PWM signal (%)

Vt

Truck speed (Km/h)

6+

Us1

Voltage of steering potentiometer No. 1 (relative value)

62+

Us2 Ua1

Voltage of steering potentiometer No. 2 (relative value) Voltage of drive wheel potentiometer No. 1 (relative value)

62+ 62+

Ua2

Voltage of drive wheel potentiometer No. 2 (relative value)

62+

Uak

Correct value of drive wheel potentiometer No. 1 according to initial adjustment

62+

Ust

Voltage of steering potentiometer No. 1 in respect of value foreseen for drive wheel potentiometer

62+

Dif

Voltage differential between Ust and Uak

62+

SecRelay Imo Tmo

-26

51+ 6+ 6+ 6+

Workshop literature 45478042102 EN 04/2007

Uset1

Conversion value of voltage of steering potentiometer No. 1 (from 0 to 255)

PWML

Conversion value of left PWM signal (from 0 to 255)

Uact1 PWMR

63+

63+ Conversion value of voltage of drive wheel potentiometer No. 1 (from 63+ 0 to 255) Conversion value of right PWM signal (from 0 to 255)

63+

Breakdowns are always managed and displayed by means of a numeric code in the corresponding windows

Breakdowns codes and control state at the moment of the truck block

2

Breakdown codes and relative frequency memorised after the last RESET

3+

Breakdown sequence memorised in the LES card memory

31+

Cancellation of all errors memorised in window 31 (only with PC MASTER)

34+

The following list shows how alarms are displayed and gives suggestions of possible corrective action ¾ The window (2) shows the errors that have appeared since last switch-on with the key and allows for immediate diagnosis as soon as a breakdown occurs

¾ The window (3) shows the breakdowns memorised in the microprocessor since the last maintenance The windows (2) and (3) are interpreted as follows: Error No. 28 appears once (2) and 3 times (3); Error No. 33 appears once;

20-23

Problems in truck identification by Pincodes

Workshop literature 45478042102 EN 04/2007

-27

24

27

28

29

30

31

Incorrect truck coding: for electrical drive, truck is identified by wiring (combination of inputs 21, 18 and 4).

The emergency relay K1 does not open on initialisation: On ignition, relay K1 must be open.

33

34

-28

If this code appears, the contact may be stuck or short circuited. Check that there is no short circuit between Pins 2 and 14 on the module side and on the wiring side (switch off the truck)

Emergency relay open during functioning: Open the LES module and check: the safety relay is closed by the LES during If the internal k1 relay has a mechanical normal functioning and opened in the case of or electrical defect, the module must be rebreakdown. placed Before replacement check: If the relay is mechanically intact, that the RC circuit is not oxidised if the relay contacts are not burnt out, that the truck is correctly wired The 3K1 external power relay contact is not Check the 3K1 relay. If the contacts are stuck at rest before activation of the command. together, the probable clause is a short cir: when the key contact is closed, the cuit in the motor; in this case check: LES circuit examines the protection devices the power cable, which may be damaged before supplying the power relay. the FU4 fuse the mos-fet (LES card) Breakdown in the external 3K1 power relay piloting.

The external 3K1 power relay contact has been unable to close.

The right and left motor connections are inverted

32

Check the code given in window 4 (AuxAB and Code) Check the corresponding wiring

Breakdown inside the LES module Possible causes: there is no power supply to the relay the mechanical contact is broken the contact is oxidised This error may appear only at the end of the assembly line or in the case of a SAV intervention that requires disconnection of the motor wires This breakdown code may appear also in association with another defect. In this case, other errors appear in the window (3)

Power status of the motor: Short circuited or Possibilities: motor disconnected.

Blown fuse HS motor (breakdown?)

Low quality connections on the whole power line Motor brushes damaged Voltage supply to potentiometers outside Open the window (61) to check the voltage limits. reading (between 9 and 9.5V) The voltage of the potentiometer is beyond Then open the window (32) which shows the action allowed by the processor to guar- the voltage at the moment of the breakdown. antee good functioning of the steering.

The defect also appears when: The battery is very low The potentiometer power supplier is short circuited Defect in the internal adjustment device

Workshop literature 45478042102 EN 04/2007

35

36

37

38

39

Anomalous value of the steering potentiome- Possible causes: Interrupted wire (cut or broken) ter: Cut out or short circuit of one or more Poor connection connections.

Oxidised connector Potentiometer badly fitted mechanically, involving stress at the edge of the tracks Potentiometer damaged Mechanical limits of the stroke-end have been exceeded Anomalous value of the drive wheel poten- The same possible causes of error 35 tiometer.

Interruption or short circuit of one or more connections.

Overheating of the stage at MOS-FET. This overheating occurs in the module that contains all the MOS-FET power components, free wheel diode, and the voltage regulator 24V short circuit at the output of the wheel position indicator.

The steering potentiometer signals are inPossible causes: compatible in the sense that under normal Potentiometer breakdown conditions the sum of the two signals must Low quality wiring contact be equal to the 10V power supply (Vpo).

Disconnected cursor

40

The drive wheel potentiometer signals are Possible causes: incompatible in the sense that under normal Potentiometer breakdown conditions the sum of the two signals must Low quality wiring contact be equal to the 10V power supply (Vpo).

Disconnected cursor

41

Output 11, which enables functioning of the Causes of the error: LDC module, is already at the battery negaExternal LES connections short circuited tive when the control is supplied with power: Problem inside the cars when functioning normally before the end of To identify the cause of the error, detach Pin initialisation, output 11 is not at negative 11 and initialise the truck again. If the problem persists, the cause is inside the module.

42

43

44

45

Output 11, which enables functioning of the LCD module, is inactive during normal functioning of the truck.

The drive wheel potentiometer is outside the tolerance limits.

On starting, this potentiometer is not in the normal position (probable cause: forcing of the wheel outside the steering range when the truck is off).

The LES does not put the truck in emergency conditions, but attempts to restore drive wheel potentiometer voltage to its normal working interval.

If the operation is carried out correctly, error 43 is memorised and truck functioning is enabled.

The 3K1 power relay control output (Pin 3) is short circuited at the battery positive.

The motor terminals are short circuited with the battery voltage: the motor power relay contacts have probably fused together.

Workshop literature 45478042102 EN 04/2007

As for code 41

Subsequent to variations in the ratios between the steering gears and the mechanics inside the potentiometer, the steering range may be altered.

Therefore, if error 43 is present in the LES memory (window 3) the drive wheel potentiometer must be adjusted. : if the LES cannot restore voltage to the drive wheel potentiometer in its normal interval, truck functioning is not enabled.

This error occurs if the processor reads a voltage of 24V on foot 3 during functioning..

-29

46

Low voltage: of battery (<13V) of potentiometer supplier (<7.9V)

50

Broken or short circuited wire between Pins 16 and 24 (reduced speed signal).

70

Failure to "RESET" the emergency microprocessor.

71

Low quality transmission of data series for initialisation of the emergency processor.

72

Different results on initialisation of the two processors.

73 74 80 81 82

83

84 90+

Low quality transmission of data between the main processor and the emergency processor.

Low quality transmission of data between the main processor and the emergency processor.

The left PWM signal does not correspond to the difference between order and reading.

The right PWM signal does not correspond to the difference between order and reading.

Transmission error during testing or after transmission of a new order/reading curve.

Error generated only by the control processor Error generated only by the control processor

Lack of synchrony between the main proces- Error generated only by the control processor and the control. sor Cause: main processor synchrony signal absent on start up.

Error generated only by the control procesThe first transfer of the correspondence sor curve by the main processor has not been carried out within the established time interval.

Typical microprocessor errors.

1

truck code

02

71+

P

2.20

71+

D.

0.15

-30

Error generated only by the control processor

truck type identification code, displayed in the window (1) when the LES is connected to the diagnostics PC parameter that adjusts the response speed and intensity of the steering motor to the steering control; the value shown represents the standard value parameter that adjusts the response speed and intensity of the steering motor to the steering control; the value shown represents the standard value

Workshop literature 45478042102 EN 04/2007

a

Preparations: ¾ open the motor compartment; ¾ remove the entire electronic panel.

Disassembly: ¾ Unscrew the drive motor fastening screws.

¾ Screw a suitable eyebolt onto the drive motor.

Workshop literature 45478042102 EN 04/2007

-1

¾ Attach the motor to a hoist or similar lifting system and lift it vertically until the drive motor is taken completely off the reducer gearbox group.

¾

Protect the pinion appropriately and put down the motor.

During this phase, it is essential to avoid blows to the teeth of the pinion.

For reassembly, proceed in the reverse order, adopting the tactics described below to facilitate the various operations. ¾ Replace the motor in its seat.

Do not strike the teeth of the pinion "A" and do not damage the OR on the bushing of the drive shaft.

Observe the orientation as well, ensuring that the terminal board "B" is located at the side guard "C".

-2

Workshop literature 45478042102 EN 04/2007

¾

¾ Use a ¼ inch drive 5 mm hexagon bit "D" a slender ¼ inch drive extension "E" with a length of at least 300 mm. Insert all the fastening screws and tighten them to the correct tightening torque as shown in the paragraph "Safety screws tightening torque table".

¾

Workshop literature 45478042102 EN 04/2007

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-4

Workshop literature 45478042102 EN 04/2007

a

Preparations: ¾ open the motor compartment; ¾ remove the entire electronic panel; Remove the traction motor. ¾ Remove the side door by slipping it off upwards.

In order to avoid blows and relative damage, the position potentiometer group must be removed (see relative instructions).

¾ Using a jack, raise the truck from the drive group side by about 4÷5 cm above the ground; block it with a wooden block " " under the body. At the same time, place slats " " under the drive wheel so as to create a thickness close to the thickness of the wheel itself. ¾ Unscrew and remove the screws fastening the plate to the body; at this point the drive wheel should be rested on the slats underneath " ".

¾ Drag the plate with the reducer gearbox group in the direction opposite the fork arms, rest the entire group on the fascia of the body and block the drive wheel from behind with the wooden chock " ".

Workshop literature 45478042102 EN 04/2007

-1

¾ Remove the 8 screws which fix the plate to the reducer gearbox.

¾ Hold the plate and separate it from the reducer gearbox group by pulling it upwards.

Replace the plate, being careful to suitably protect the pinion of the steering motor reducer gearbox in order to avoid blows that may damage it.

¾ At this point we have freed the reducer gearbox group, then to extract it we will use no.2 M10 eye bolts.

¾

-2

Workshop literature 45478042102 EN 04/2007

¾ The eye bolts should be screwed onto the two holes diametrically opposed on the fifth wheel of the reducer gearbox and with the aid of a sling and lifting equipment (hoist) with suitable capacity, we will hook it, lift it and separate it from the machine.

For reassembly, proceed in the reverse order, adopting the tactics described below to facilitate the various operations. ¾ Add a slat "A" with a thickness of about 1 cm in the resting point of the drive wheel so that, once the wheel is rested, it remains raised by 2 cm. ¾ Position the reducer gearbox complete with wheel inside its compartment, resting it on the fascia of the body.

Do not strike the ring gear of the reducer gearbox.

¾ Block the movement of the wheel with a wheel chock "B".

The wheel must be positioned straight, the body of the reducer gearbox must be positioned towards the platform and the holes on the fifth wheel must be positioned approximately as shown in the figure (pair of fastening holes of the motor parallel to the body).

Workshop literature 45478042102 EN 04/2007

-3

¾

¾ Position the plate, complete with motor reducer gearbox and electrical drive, on the reducer gearbox assembly being careful to match up the fastening holes of the plate on the reducer gearbox and being careful that the pinion of the motor reducer gearbox engages in the ring gear of the reducer gearbox without receiving mechanical blows.

If the fastening holes are not perfectly aligned, centre the plate as follows:

¾ Hold the plate stationary using the electronic system support bar "C". ¾ Manipulate the pinion "D" of the motor reducer gearbox on the ring gear of the reducer gearbox: in this manner the reducer gearbox itself moves in a fine manner until the fastening holes of the plate / reducer gearbox coincide.

¾ Fasten the anchor plate to the reducer with the 8 M10 screws and tighten to the correct torque, as shown in paragraph "Safety screw tightening torque table". ¾ Remove the wooden block that blocks the wheel.

-4

Workshop literature 45478042102 EN 04/2007

¾ Push the entire assembly towards its housing, or rather towards the battery, and fit the fastening screws of the anchorage plate onto the body, tightening them by hand as far as possible.

¾ Using a jack, raise the body from the drive group side until the anchorage plate rests against the body. ¾ Tighten all screws to the correct tightening torque, as shown in paragraph "Safety screw tightening torque table".

¾ Remove the wooden slats under the drive wheel, and rest the machine on the side chock "D".

Workshop literature 45478042102 EN 04/2007

-5

¾ Check the oil level in the reducer gearbox and top up if necessary: the level is correct when the oil just touches the bottom part of the top ring gear

-6

Workshop literature 45478042102 EN 04/2007

The reducer connects to the drive shaft with a guide ring and incorporated bearing that inserts into a seat of the reducer box and a pinion fixed directly onto the drive shaft.

Ring with incorporated bearing Helicoidal pinion

To guarantee an always perfect operation of the reducer, the maintenance must be performed by qualified technical personnel.

The guide bearing is supplied full of grease.

The reducer is supplied without drive motor.

During the assembly of the motor, it is necessary to check that the contact surfaces of the motor and guide ring have not be scratched or damaged.

It is also very important, in order to prevent the gears from damaging one another, that the pinion axis is parallel to the axis of the gear with which the pinion couples.

If the profiles of the teeth have been damaged, excessive noise will be produced during operation of the reducer, normally in a single operation direction.

The technical service interventions on the reducer include the following points:

For normal use, the guide bearing does not require any maintenance.

If a fixing column of the wheel is replaced, it is important to clean the thread of the wheel shaft flange after having unscrewed the worn column.

Before mounting a new column, make sure that the thread of the column and the threaded cavity are clean and free of any oil or grease residues.

To replace the wheel shaft gasket, disassemble the lower cover of the reducer, where the oil cap is also located. This allows access to the central screw of the wheel shaft so that it can be unscrewed.

Once the wheel shaft is disassembled, replace the old gasket of the shaft with a new one.

The helicoidal pinion is installed directly on the drive shaft.

Before inserting the gasket on the shaft in the correct position, it is important to clean and immediately protect the contact surface of the shaft gasket housing.

During assembly of the helicoidal pinion it is important to avoid striking the pinion with a hammer or other object.

Before remounting the wheel shaft in the reducer, spread some grease on the internal part of the shaft gasket to facilitate assembly.

Workshop literature 45478042102 EN 04/2007

-7

To complete the assembly of the wheel shaft, screw on the central screw until it is completely tight.

Before fixing the screw, check that the entire threaded cavity and the screw are clean and free of any oil/grease residue.

Then protect the thread. It is also important to use, as for any screw, the proper tightening torque.

For the replacement of gears and/or bearings, remove the wheel shaft (as indicated in the previous point) and the bevel pinion if necessary.

It is very important that the form of the contact impressions on the teeth of the bevel gear system is correct!!

Before being able to extract the bevel pinion from its housing, it is necessary to unscrew the safety nut located on the threaded end of the bevel pinion shaft.

The nut is blocked by a caulking that must be removed in order to unscrew it.

If the reducer is reassembled after the replacement of any component, it is very important that the position of the taper roller bearings is set correctly and that the form of the contact impressions on the profile of the bevel gears is correct. This can only be obtained with a perfect shimming of the taper roller bearings.

For a better understanding of the correct form for the contact impressions on the gear teeth of a bevel gear transmission system, see the drawings shown below.

shiny areas that represent the contact zones of the gear teeth.

To adjust the bevel gear system, the following rule holds:

In order to perform this check, oil paint must be applied on the teeth of the bevel gears. Then, putting the reducer into motion, after a few revolutions dots of colour will appear along the profiles,

-8

Workshop literature 45478042102 EN 04/2007

Internal side Crest of the tooth Shiny impression positioned on the internal side and towards the crest of the pinion tooth.

Shiny impression positioned on the internal side and towards the crest of the crown tooth.

Excessive distance Impression towards the external side on the lower part of the pinion tooth.

Impression towards the internal side on the lower part of the pinion tooth.

Impression towards the internal side on the lower part of the crown tooth.

Workshop literature 45478042102 EN 04/2007

Based on the real impressions and their comparison with the theoretical ones, some corrections can be made by inserting shimming rings under the bevel pinion so as to re-establish the correct crown wheel and pinion clearance.

Impression towards the external side on the lower part of the crown tooth.

When the contact impressions of the teeth appear as shown in the figure, the pinion must be advanced towards the crown by adding shims behind the pinion itself.

-9

Insufficient clearance Impression towards the external side, towards the crest of the pinion tooth Impression towards the internal side, towards the crest of the pinion tooth Impression towards the internal side, towards the lower part of the crown tooth.

Impression towards the external side, towards the lower part of the crown tooth.

When the contact impressions of the teeth appear as shown in the figure, the pinion must be moved back by removing shims.

Pour the oil into the upper part of the reducer. The correct oil level corresponds to the lower edge of the upper crown wheel (large gear ).

Perform the first oil change after the first 250 hours of operation and the subsequent oil changes every 2000 hours of operation or, alternatively, at least once a year.

To extract the oil from the reducer, unscrew the lower oil cap located on the lower cover of the reducer.

Before reusing this cap, make sure that the magnetised part is clean and free of any contamination.

SAE 80 W 90 oil is recommended for the oil change.

The reducer is supplied without oil. Thus make sure to have filled with oil before using the reducer for the first time.

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1.

2.

3.

23 Nm 170 Nm 300 Nm

Workshop literature 45478042102 EN 04/2007

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-12

Workshop literature 45478042102 EN 04/2007

a

In order to use the truck, the covers for access to the inner parts must be closed and secured properly.

¾ To access the upper part of the battery, disconnect the battery plug (1) from the socket, push the battery cover release lever (2) in the direction (A) and raise the battery cover (3) using the handle (4); block the cover using the lever (5) and check that the lever (5) is fixed correctly inside the appropriate seat (6)marks.

A 2 4

3 1 5 3

6 5

OM1334

Workshop literature 45478042102 EN 04/2007

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¾ To access the auxiliary fuses, unscrew the screw (8) and open the door (9)marks. ¾ To access the side of the battery, remove the side covers (6)by pushing the two bushings positioned inside the slots (7) inwards, tilting the cover outwards and raising it.

8

9

7

3 1

6

-2

2

OM1335

Workshop literature 45478042102 EN 04/2007

¾ To access the motor compartment, fold the seat back down over the seat using the lever (10), unscrew the screw (11)and completely raise the seat using the handle (12)marks.

10

11

12 OM1336

Workshop literature 45478042102 EN 04/2007

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¾ Unscrew the two screws (13) and open the motor compartment cover (14) by rotating it around its own fastening axis.

13

14 OM1337

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Workshop literature 45478042102 EN 04/2007

a

¾ Fold the seat back over the seat using the appropriate lever.

¾ Operate the horizontal adjustment lever and drag the seat towards the control panel until it is completely extracted from the slide guides.

¾

Workshop literature 45478042102 EN 04/2007

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¾ Raise the seat support using the handle.

¾ Remove the seat support by releasing it from the two hinge points.

For reassembly, proceed in the reverse order.

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Workshop literature 45478042102 EN 04/2007

¾ Remove the seat and open the motor compartment. ¾ Remove the " " connector (dead man s micro switch connector) from the electrical panel and remove the dead man s switch micro switch sheath.

¾ Remove the two platform fastening screws.

¾ Use the two holes, extract the platform from its housing by pulling it upwards and remove the carriage from the platform.

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¾ ¾ For reassembly, proceed in the reverse order.

¾ Operate the button, depress the mobile structure to its lower stop, closing the gas spring pack and supporting the mobile part.

¾ Holding the gas spring compressed with a size 15 wrench, loosen or remove the upper fastening nut.

¾ With a size 5 Allen key with extension, remove the lower fastening nut from the gas spring rod and release the lower part of the gas spring itself.

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Workshop literature 45478042102 EN 04/2007

¾ Remove the mobile part of the structure upwards and place a wooden wedge between the mobile part and the body to support the mobile part.

¾ Remove the gas spring from its seat.

¾ To remove the gas spring, remove the control latch from the operating button with two size 19 wrenches.

¾

Workshop literature 45478042102 EN 04/2007

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¾ The gas spring may be disassembled into two parts: the body and the sheath with pneumatic actuator.

¾ Operate with two size 17 wrenches on the nut and lock nut on the actuator fastened onto the gas spring for disassembly.

¾ Holding the latch on the end of the spring rod pressed, compress the gas spring to make the rod recede by approximately half its stroke.

Release the latch so as to keep the rod at mid stroke.

(A)Gas spring removal latch. ¾ Fit the lock nut on the rod. ¾ Fasten the actuator to the rod gradually and stop as soon as the rod start moving out. Go back by approximately half a turn and then fasten the actuator in this position with respect to the rod using the lock nut. ¾ Refit the spring in the platform holder structure and fasten it with the corresponding screw and nut. ¾ Position the sheath in its housing and insert the other end of the actuator in the button and in the specific support.

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Workshop literature 45478042102 EN 04/2007

¾ Fasten the actuator in the support with the nut and lock nut so as to leave a small clearance between the control rod and the button in its home position.

¾ Test operation of the platform holder structure.

¾ The mobile part of the platform must be in the fully raised position in order to access the four fastening screws of the structure. Therefore, if removal is performed with the gas spring fitted, the mobile part will be kept up by the gas spring. If instead the gas spring has previously been removed, keep the mobile part of the platform structure raised on wooden wedges.

¾ Access the screws directly with a size 5 Allen key and corresponding extension. ¾ A spacer for supporting the fixed structure during removal and refitting of the structure may be useful.

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¾ Remove the platform holder structure from the truck.

¾ If the bearings need replacing, rest the platform holder structure on the work bench and replace the components (all parts are accessible and clearly visible). ¾ For easy refitting, first work at the bench to install the gas spring which holds the structure fully open.

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Workshop literature 45478042102 EN 04/2007

a

The well-known L.E.S. (Linde Electrical Steering) applied to the steering wheel is used.

The steering wheel is stiffened by a clutch system.

The maximum rotation of the steering wheel is equal to 4.25 turns, while that of the drive wheel is +80° clockwise and -100° anticlockwise.

The steering motor is of the serial type with two split field coils. Specifications: Power supply voltage 24V DC Power 0.15 kW The steering system is started by pressing the dead man s switch pedal.

Released

Stand-by (steering motor not powered)

Pressed

On (steering motor constantly on)

For passing from condition system requires mode.

to condition , the to switch to

The software is invoked by means of an appropriate connection to the " " input pins as shown in the following table:

Connected to -B

Not connected

Connected to -B

(central motor)

This electronic module supplies and receives the electrical signals of the potentiometers, controls the steering motor, and manages system safety.

In the case of breakdown, the truck is automatically blocked by electronic braking. Brake action is guaranteed by the simultaneous presence of two separate control signals:

Workshop literature 45478042102 EN 04/2007

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L.E.S. electrical internal relay contact opening control disconnects power to the electromagnetic brake.

The L.E.S. unit disconnects the power supply to relay 7K1 deactivating the dead man s switch and consequently activating braking.

An " " output monitoring function when the dead man s switch pedal is released has been introduced.

The calibration procedure of the electrical steering system consists of the following steps: centre the steering and drive wheel potentiometers: this step is required after potentiometer replacement and during potentiometer assembly; PC required check steering potentiometer using PC: this step is required whenever the steering potentiometer or electrical steering system is replaced check drive wheel potentiometer using PC: this step is required whenever the drive wheel potentiometer or electrical steering control system is replaced.

The steering and drive wheel potentiometer are based on the same principle.

They are opposite sense signal (redundant) potentiometers: when one is at maximum the other is at minimum.

Each potentiometer has two tracks, completely separate from each other, which manage two separate voltages.

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Workshop literature 45478042102 EN 04/2007

¾ The steering potentiometer, directly operated by the steering wheel through a resilient joint, generates signals proportional to the set rotation angle. In the diagnostic software, the value of the two cursors are indicated as Vs1 and Vs2. The value must be Vs1=Vs2 with steering wheel and potentiometer in central position.

¾ The drive wheel position potentiometer is coupled to the main crown of the drive unit through an planetary gear reducer and generates signals proportional to the position of the drive wheel. In the diagnostic software, the value of the two cursors are indicated as Va1 and Va2.

With the wheel in central position, the value must be Va2=Va1+0.6V. Therefore, the steering is centred when the wheel is in straight position and Va2=Va1+0.6V with the steering wheel in central position and Vs1 = Vs2.

The calibration procedure is described in the following paragraphs.

This procedure is required after replacing one of the potentiometers and is used to identity the electrical middle point of the potentiometer itself thus allowing correct assembly with the steering wheel in central position (steering potentiometer) and the wheel in central position (drive wheel potentiometer).

For this purpose, menu 61 in the LES program (see chapter 02) is used to check the two potentiometer signal voltages. ¾ Arrange the steering wheel in central position.

Workshop literature 45478042102 EN 04/2007

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The steering wheel is fully steered in 4.25 turns.

By default, the steering wheel is centred with rotation of approximately 2 turns and with knob at approximately 9 o clock. The position may be changed using PC. ¾ Arrange the wheel in straight position, i.e. parallel to the fork arms.

This operation is easier if the truck is lifted on a jack. ¾ Remove the power fuse 3F1

Removing the fuse will prevent uncontrolled movements of the reducer/wheel during calibration.

¾ Connect the PC to the diagnostic interface (see chapter 02). ¾ Switch on the truck. ¾ Start the LES program (see chapter 02). ¾ Key in 6 1 to access calibration menu 61.

Menu 61 displays the following voltages: supply voltage of the potentiometers. = voltage of the two signals from the steering potentiometer = voltage of the two signals from the drive wheel potentiometer ¾ Check that voltage Vpo is approximately 9.2 v.

If this is not so, the electrical steering system may need to be replaced. ¾ Check that the voltage values of the steering potentiometer Vs1 and Vs2 are reciprocally equal: .

The voltage difference between Vs1 and Vs2 can be up to 1 V. ¾ Proceed as follows if the two values are not the same and the voltage difference is higher than 1 V: ¾ remove the potentiometer fastening screws and release them from the steering wheel unit ¾ adjust the shaft of the potentiometer itself to obtain the required voltages

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Workshop literature 45478042102 EN 04/2007

¾ only when you see Vs1 = Vs2 = Vpo/2, fit the potentiometer back it its seat without moving it and fasten its position. ¾ Check the voltage values related to the drive wheel potentiometer: Va1 and Va2 must be: .

On some PCs, you may need to press white space to view the values. ¾ To obtain the required voltages Va1 and Va2, loosen the two screws (A) and turn the potentiometer unit, exploiting the possibility of rotation offered by the two slots on the potentiometer fastening flange. ¾ If you cannot obtain the required values, turn the shaft of the potentiometer itself, then fully loosen the two screws (A), extract the potentiometer unit. Leaving leave it electrically connected, turn the pinion until the required voltages are obtained. ¾ Fit the potentiometer back in its seat without moving it and fine-tune it using the fastening slots. ¾ At this point, you may secure the two fastening screws(A).

Run a further test using the diagnostic software. ¾ Turn off the truck. ¾ Insert fuse 3F1. ¾ Switch on the truck. ¾ Arrange the PC on-board the truck and start the LES software. ¾ Check of the steering potentiometer calibration. ¾ Check of the drive wheel potentiometer calibration.

The procedure described below assumes that the steering and drive wheel potentiometers have been assembled and set correctly. ¾ Arrange the steering wheel in central position.

The steering wheel is fully steered in 4.25 turns.

By default, the steering wheel is centred with rotation of approximately 2 turns and with knob at approximately 9 o clock. During this operation, Workshop literature 45478042102 EN 04/2007

-5

the position of the centred steering wheel may be slightly changed by positioning the knob between 6 o clock and 9 o clock approximately according to the user s preferences. ¾ Arrange the wheel parallelly to the fork arms. ¾ Switch on the truck.

Do not move the steering wheel until prompted to do so.

¾ Key in 8 . ¾ Press ENTER (first adjustment step). ¾ A 0 will appear between dashes or arrows if the potentiometer is working correctly; otherwise, perform the electrical/mechanical centring procedure and search for the middle point again. ¾ Press SPACE BAR to confirm; a confirmation will be heard. ¾ Check for the OK message on the SetPadj C line.

The software will automatically go to the second setting step: ¾ Turn the steering wheel stroke.

to end of

¾ Press SPACE BAR (to display the current value). ¾ A 0 will appear between dashes or arrows if the potentiometer is working correctly; otherwise, perform the electrical/mechanical centring procedure and search for the middle point again. ¾ Press SPACE BAR to confirm; a confirmation will be heard. ¾ Check for the OK message on the SetPadj R line.

The adjustment of the steering potentiometer is finished.

Perform this check after checking the steering potentiometer calibration. The initial conditions are: truck on PC connected and LES program running

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Workshop literature 45478042102 EN 04/2007

¾ Key in 8 1 ¾ Arrange the steering wheel in central position. ¾ Press ENTER (first setting step). ¾ A 0 will appear between dashes or arrows if the potentiometer is working correctly. ¾ If the 0 is not present, press ARROW UP or ARROW DOWN to display it.

The space bar may need to be pressed on some PCs at the same time.

If you cannot display the 0 symbol in any way, perform the electrical/mechanical centring and middle point search procedure again.

The value indicated by the ActPadj C variable may be adjusted by a few mV to the right and to the left of the zero point (error voltage). ¾ Check that the truck is moving in a straight line.

The truck must move in a straight line; operate on the ActPadj C parameter again. ¾ Press SPACE BAR to confirm; a confirmation will be heard. ¾ Check for the OK message on the Actpadj C line.

The software will automatically go to the second setting step: ¾ Automatic access to the second setting point. ¾ Turn the steering wheel clockwise to end of stroke. ¾ Press SPACE BAR (to display the current value). ¾ A 0 will appear between dashes or arrows if the potentiometer is working correctly. ¾ If the 0 is not present, press ARROW UP or ARROW DOWN to display it.

The space bar may need to be pressed on some PCs at the same time. ¾ Press SPACE BAR to confirm; a confirmation will be heard. ¾ Check for the OK message on the Actpadj R line.

This completes the calibration procedure.

Workshop literature 45478042102 EN 04/2007

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¾ Before carrying out this operation, make sure that the drive wheel is completely parallel with the side of the truck; we suggest using two straight-edges, place one straight-edge at the drive wheel and the other at the side of the truck, position the drive wheel so that the two straight-edges are parallel.

¾ Insert the pinion of the potentiometer into its seat,

Be careful that the pinion does not move and that the marks made on the pinion and the plate line up.

Do not strike the ring gear of the potentiometer pinion.

¾ Check the electrical calibration of the potentiometer using the Diagnostics PC, as described in the relative section.

The electrical calibration of the potentiometer is essential if the potentiometer is being replaced; otherwise, if the potentiometer is being reassembled, it acts as a check to verify that the pinion has not moved and that the reference marks have been kept aligned. ¾ Reconnect the cables. ¾ Reinstall the entire electronic panel. ¾ Reconnect the battery. ¾ Test operation of the drive with the wheel raised.

-8

Workshop literature 45478042102 EN 04/2007

¾ If it works properly, raise the machine with the jack "A" and remove the wooden blocks. ¾ Replace the machine on the ground and complete reassembly of the covers and seat.

Workshop literature 45478042102 EN 04/2007

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Workshop literature 45478042102 EN 04/2007

a

¾ To access the retaining nuts of the drive wheel, position the truck so that the appropriate slots on the body are completely aligned with the nuts.

1

Check the wheel nut tightening according to the intervals indicated in the maintenance table and when a wheel is replaced.

3

Follow the instructions provided in the relative chapter when replacing a wheel.

The figures at the side indicate the order in which the wheel fastening nuts should be tightened.

The nut tightening torque values are given below.

140 ±5% Nm / 14 ±5% kgm

4 2

5 OM0963

The wheels and rollers on the forklift should be replaced when they appear to be worn.

Contact the service center authorized by the manufacturer for replacement of the wheels and rollers.

OM1290

Workshop literature 45478042102 EN 04/2007

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¾ Loosen the locking nuts using the appropriate slots.

¾ Raise the body with the aid of a jack.

¾ Rest the body on a wooden block. ¾ Operate the steering to position the traction wheel so that the nuts are accessible from the front side.

¾ Unscrew and remove the locking nuts.

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Workshop literature 45478042102 EN 04/2007

¾ At this point the wheel can be removed.

To reassemble the wheel, proceed in the reverse order and tighten the nuts as indicated in the section "Wheel nut tightening check".

Workshop literature 45478042102 EN 04/2007

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a

Before removing the electromagnetic brake, first immobilise the truck, disconnect the battery, and remove the casing ¾ Position the system support in the position for access to the motor compartment.

¾ Disconnect the connector "1X2".

¾ The electromagnetic brake is equipped with a connector fastened to the support, thus disconnect the connector "1X2" from the same support.

Workshop literature 45478042102 EN 04/2007

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¾ Unscrew the Allen screws.

¾ Remove the coil "A" and the disk-pusher "B".

¾ Remove the brake disk.

¾ Extract the brake plate.

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Workshop literature 45478042102 EN 04/2007

¾ Remove the seeger blocking the pinion, using a special pair of pliers.

¾ Pull out the motor pinion, using a wide, flat screwdriver as a lever.

When replacing the electromagnetic brake, carry out the sequence of operations in the opposite order.

Workshop literature 45478042102 EN 04/2007

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The system is composed of the following components: Dead man s pedal interlock switch (U.M.).

Traction controller. e-ABS module.

Traction motor.

This is a compound type of braking, where the system (e-ABS) suitably manages the motor brake / electromagnetic brake (patented system) combination.

During braking, the e-ABS system acts on the electromagnetic brake to avoid, as far as possible, locking of the wheel.

The advantages are the following: The set deceleration prevents, as far as possible, the wheel from locking during braking.

Reduction of drive wheel wear.

Stopping distances are reduced with respect to friction braking when grip is poor.

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Workshop literature 45478042102 EN 04/2007

The stopping distance, at equal speeds with the truck loaded and unloaded, is the same under normal grip conditions.

When grip is scarce, the stopping distances are limited as far as physically possible, avoiding wheel lock and without swerve.

This type of braking occurs in the following working conditions: On release of the dead man s pedal interlock switch when the truck is in motion.

The e-ABS module manages braking when the dead man foot interlock switch is released.

Main features of the e-ABS module: Nominal supply voltage 24V DC. Inputs and output drivers protected from short circuits.

Built-in LED for signalling status and failures.

On board Flash memory programmable by PC. The following table shows the inputs and outputs of the e-ABS module in detail:

1 2

14-pole connector.

Diagnostics LED.

1

B+

Input +24V DC

2

GND

Negative

3

HSD_In

High Side Driver FEM IN

4

HSD_Out

High Side Driver FEM OUT

5

INT

6

Traction interlock K1 diagnosis

7

K1-contact TLR Gen K1-out TLR gen

8

CH_A

Channel A encoder

9

CH_B

10

Gear on forks side Gear on side opposite the fork arms

Channel B encoder Fork-side gear signal

11 12

Poti_Traz

13

BPW nc

14

Workshop literature 45478042102 EN 04/2007

K1 general TLR coil negative

Gear signal for side opposite the fork arms Analogue drive potentiometer signal Analogue braking signal -

-5

¾ The status LED "A" of the e-ABS is incorporated in the same card. In the case of an alarm, the LED "A "creates a code (flash code) to indicate the type of anomaly. To interpret the code, the activated flashing must be observed.

Note: All alarms block the truck (power supply to the electromagnetic brake is opened by the internal High Side - Driver and the general K1 contactor is opened). To reset the machine, it must be switched off and then on again.

One short pulse One flash Two flashes Three flashes Four flashes Five flashes Six flashes LED always on LED always off

Module functioning No alarm Sicstate error

Constate error

Genstate error

-6

/ Auxiliary MOSFETs already short-circuited at start-up Internal relay series to the electromagnetic brake already short circuited at start-up Contactor K1 already closed at start-up

Channel A encoder error

Incorrect channel "A" encoder signal

Channel B encoder error

Incorrect channel "B" encoder signal

Electromagnetic brake error

Brake coil or wiring open

/ Check wiring and replace module if necessary Check wiring and replace module if necessary Check wiring and replace contactor if necessary Check wiring and replace encoder or module if necessary Check wiring and replace encoder or module if necessary Check the electromagnetic brake coil and associated wiring

Workshop literature 45478042102 EN 04/2007

Main microprocessor error Main microprocessor error

Workshop literature 45478042102 EN 04/2007

Microprocessor KO

Replace module

Microprocessor KO or no power supply to logics

Check power supply fuse and replace if necessary

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-8

Workshop literature 45478042102 EN 04/2007

a

1 2 3 4 5 6

24V dc Battery Plug/socket Handlebar card eABS module K1 contactor coil Dead man s pedal

Workshop literature 45478042102 EN 04/2007

7 8 9 9 10 11

Inverter Drive motor Drive motor temperature sensor Drive motor encoder L.B.I. (Low battery charge indicator) Lifting motor -1

12 13 14 15 16 17 18 18 18 18 19

9K1 relay 3K1 relay Fan Resistance Steering motor L.E.S. Controller Drive wheel potentiometer Steering potentiometer Traction cut-out safety 3K1 relay control PC with "Service" 1314 Curtis and "Service" L.E.S. software

20 20 20 20 20 20 20 20 20 20 20 20

9K1 relay coil Horn relay coil 2K1 contactor coil Fork lifting end limit switch Electromagnetic brake Alarm horn Emergency stop button K2 remote control switch coil Fuses Ignition key Load detector pressure switch Interlock 7K1 relay

To simplify the diagram, the optional elements have not been included.

Nominal supply voltage 24V, 36 V DC Maximum current absorbed 300A DC High frequency Mos technology (Static) Algorithms for motor control of the vector type (Field orientation) Various functional configurations, which can be selected from the console to respond to the user s needs Good drive motor efficiency thanks to the high frequency commutation of the MOSFET power transistors Runs silently at high frequencies Complete diagnostics from the console and No. 2 LEDS showing internal status Regenerative braking that allows for shorter stopping distances, increases available energy from the battery and reduces motor and brake overheating Inputs and output drivers protected from short circuits On board Flash memory re-programmable

by PC CAN Bus communication VCL (Vehicle Control Language) programming software, can be customised to meet our needs Automobile-type interface connector IP65

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Workshop literature 45478042102 EN 04/2007

The following table shows the inputs and outputs of the "Curtis" system in detail: 1

+24VDC input

2

Ksi Prop. Driver

3

Driver 4

4

Driver 3

Cooling fan coil relay negative

5

Driver 2

Electromagnetic brake negative

6

Driver 1 I/O ground

K2 drive TLR negative

7 8

Ana_ 2

9

Switch 3

10

Switch 4

11

Switch 5

12

Switch 6

13

Coil return Program Throttle Potentiometer High Throttle Potentiometer Wiper Brake Potentiometer Wiper

B+ auxiliaries Program input download

Potentiometer 0 V power supply

19

Potentiometer Low Digital output 1

20

Digital output 2

Unused

21

Can Term H

Unused

22

Switch 7

Gear on forks side

23

CanH

24

Ana_ 1

Unused Speed reduction when turning (Drive wheel potentiometer)

25

+ 12V Out

+ 12V Curtis console

26

+ 5V Out Brake Potentiometer Height

+ 5V drive motor encoder

27

TX Serial

Curtis console TX signal

29

RX Serial Analog Output

Curtis console RX signal

30 31

Speed Encoder A

Channel A encoder

32

Speed Encoder B

33

Switch 8

Channel B encoder Forward travel on side opposite the fork arms

34

Can Term L

Unused

35

CanL

Unused

14 15 16 17 18

27

B. Drive motor temperature sensor Interlock Connected to positive +24V - Speed reduction setup Second UM contact Load detector pressure switch

Potentiometer +5 V power supply Central drive potentiometer Analog brake signal Unused

Unused

Unused

Workshop literature 45478042102 EN 04/2007

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The electrical devices are all positioned on a single electronic panel.

The electronic panel is fastened so that it can be moved in order to conveniently access the interior of the motor compartment without having to remove the entire panel.

To access the electronic panel: ¾ Access the motor compartment as described in the "Internal Accessibility" section. ¾ For more convenient access, remove the seat and seat support as well.

The panel rests on two puffers (1) e (2), and it is blocked by the two pins (3) e (4)marks.

In the pin (4) there is another pin inserted that acts as a safety stop.

To move the electronic panel and access the interior of the motor compartment: ¾ Extract the retaining pin on the pin (4)marks. ¾ Raise the panel to release it from the pin (3)marks. ¾ Rotate the panel anticlockwise while keeping it constrained to the pin (4)marks.

¾ Finally rest the panel on the anchorage plate of the reducer.

It is not necessary to disconnect the connectors of the sheathed cables in order to perform this manoeuvre, since the sheathed cables are laid so as to allow this movement.

To completely remove the electronic panel:

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Workshop literature 45478042102 EN 04/2007

¾ Disconnect the power cables on the system and on the contactors ¾ Disconnect the steering potentiometer ¾ Disconnect the connector of the encoder on the drive motor ¾ Disconnect the cables on the terminal board on the panel

¾ Disconnect the connectors on the appropriate bracket on the back of the panel ¾ Disconnect the fork arms descent electromagnetic valve and the pressure switch ¾ Disconnect the fan plug

¾ Disconnect the connector of the fork arms lifting end position microswitch positioned above the battery

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¾ and release the respective cable

¾ at this point, the entire panel can be removed by raising it.

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Workshop literature 45478042102 EN 04/2007

3

V3 16

V3 8

4

4F1

5

15

7

F5

F5

6

F4

14 13

4H3

4F1

6

F4 5

4H3

7

12

4

9F1

9F1

8

F1

9

3F1

3F1

10

2

11 10

2

1

3

F1 2

Turn off the forklift and perform the operations preliminary to maintenance.

OM1345

Access the fuses as indicated in the " " section.

The power fuses (2) and (3) are located near the contactors, the service fuses (fuses 4, 5, 6, 7, 8, 9) are located in the relevant fuse box (1).

Loosen the screws, replace the fuses (2) and (3) and tighten the screws.

Before replacing the fuse, eliminate the cause that led to its burnout. The burned out fuse must only be replaced with a fuse of the same amperage. Do not tamper with the forklift s electrical system.

Workshop literature 45478042102 EN 04/2007

Remove the cover and replace the blown fuse, then replace the cover.

-7

= Traction fuse = Pump fuse

= 250A = 125A

= Fuse

= 5A

= Fan wheel rotor fuse

= Fuse

= 5A

= Fuse

= Fuse

= 1A

= Electrical drive fuse

= 5A

= 10A =30A

Particular care is required during assembly.

This fuse is actually fitted to a bolt which carries the cables both prior to and following after the fuse.

In order to avoid continuity between the cables prior to and following after the fuse, a plastic material bush insulates the cable prior to the fuse from the bolt.

Incorrect assembly of the fuse will prevent its operation in case of overcurrent.

Pay the utmost attention to fuse assembly.

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Workshop literature 45478042102 EN 04/2007

(for example: battery charger installed on board) the reset voltage is equal to per cell.

Battery voltages : Volts per cell (Adjustable with the switch located on the back of the indicator.

See figure above).

These voltages can be measured only while the battery is working.

In the absence of special conditions (gel batteries, hermetic batteries, work in a cold-storage room, etc.) the indicator is set on the letter .

The low battery charge indicator has a fixed reset voltage threshold.

For normal recharge conditions, with the from the truck while recharging, the reset voltage is equal to or greater than per cell.

This function totals the hours of operation in a permanent manner and indicates the result on the Display The Display is composed of 10 LEDs distributed respectively from right to left in this manner: 5 green, 3 yellow and 2 red. As the work hours pass, the LEDs shut off from right to left. The illuminated LEDs indicate the residual charge of the battery. At the prealarm threshold the next-to-last red LED begins to flash. When the 80% discharge level is reached, the last red LED also begins to flash alternatively with the next-to-last LED and at the same time the interlock relay is activated. (see figure above).

For recharge conditions with the to the truck system while recharging,

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¾ Turn off the forklift and perform the operations preliminary to maintenance. ¾ Disconnect the plug from the battery socket. ¾ Open the battery cover and the battery side doors as described in the "Internal accessibility" section. ¾ Lift the battery holding bar it.

, tilt it and remove

5

¾ Position the extraction roller unit next to the forklift (see the relevant section on using the roller unit), then remove the battery onto the roller unit.

4

¾ Replace the battery and reassemble it by performing the extraction procedures in reverse. ¾ Position the plugs mounted on the battery doors in the best position to reduce the lateral clearance of the battery to a minimum.

The plugs should be positioned according to the width of the battery and have three possible settings .

Maximum width setting

3

:

1

The plugs should be placed in the upper housing on both battery side doors.

Intermediate width setting

:

2

One plug should be placed in the upper housing on one of the two side doors, while the other plug should be placed in the lower housing on the opposite battery side door.

Minimum width setting

:

The plugs should be placed in the lower housing on both battery side doors.

6

A When closing the battery cover, be careful to position the battery plug cables in their holding fixture to prevent damaging them.

To decide which type of battery to use, check the battery characteristics provided in the "TECHNICAL DATA" chapter.

B C OM1344

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Workshop literature 45478042102 EN 04/2007

A

C

D B B 1 OM1343

Position the stand with battery extraction roller unit at the battery outlet.

Raise the battery latch .

Line up the height of the stand with the height at which the battery is to be removed; the height adjustment is made using the adjustable supports .

Raise the hood (1) and check the level and density of the electrolyte as indicated in the battery instructions.

Adjust the height of the supports so that the surface of the roller unit is perfectly horizontal.

Slide the battery up to the mechanical stop .

Slide the battery latch and insert it into the most appropriate slot of those available to lock the battery into place.

1

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Turn on the external battery charger.

The battery is recharged with the forklift off.

Connect plug the battery charger in to begin charging.

After the battery charging operation is completed, turn off the battery charger.

Unplug the battery charger.

Replace the battery caps (if removed previously).

Plug the battery in again.

Lower the battery compartment cover.

Access the upper part of the battery as described in the "Internal accessibility" paragraph.

Refer to the battery charger manual for more information.

Remove the battery caps (if indicated in the battery maintenance booklet).

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Workshop literature 45478042102 EN 04/2007

a

¾ Remove the battery by extracting it sideways. ¾ Remove the object tray top cover. ¾ Remove the lifting limit switch microswitch. ¾ Remove the side covers. ¾ Remove the lift cylinders.

¾ Raise both the body and the mobile structure off the ground and rest them on wooden shims so that the fork arms remain horizontal and the body remains supported even after having removed the hinge pins. ¾ Remove the two hinge pins of the rear levers with the fixed structure:

1) The pins are blocked with an elastic pin that should be extracted by striking it downwards with a suitable plug remover using the appropriate hole.

Workshop literature 45478042102 EN 04/2007

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2) The two pins are extracted by striking them inwards from the outside.

¾ Using two slings of suitable capacity, hook the body in the two holes provided and raise it slowly until the side bearings come out of the guide profiles. ¾ While keeping the body raised, move it away from the mobile frame.

¾ Replace the body on the ground on wooden shims located on both the front and rear sides.

For reassembly, proceed in the reverse order taking the following tactics into consideration. ¾ Rehook the body in the two top side points and raise it with the hoist so that the body remains hanging in a centred manner, symmetrical and perpendicular to the ground.

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Workshop literature 45478042102 EN 04/2007

¾ Reassemble the body to the mobile structure by moving the body close to the mobile structure and inserting the side bearings into the guide stands, then rest it on the ground on the wooden shims .

¾ Hook the mobile structure with the hoist using the two anchoring holes of the lift cylinders and raise the mobile structure slightly. This allows clearance on the lever systems so that by manually operating the "Tandem rollers" group, the rear levers can be moved to align the relative holes with the attachment holes on the body.

Workshop literature 45478042102 EN 04/2007

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¾ Then it is possible to insert the pins and the relative elastic pins on both sides of the machine.

Using the hoist, move the mobile structure up and down to check that there are no mechanical obstacles. ¾ Rest the mobile structure on wooden shims on the ground. ¾ Reassemble the lift cylinders. ¾ Adjust the bearings. ¾ Reassemble the lifting limit switch microswitch.

¾ Remove the battery. ¾ Remove the side covers. ¾ Through the appropriate windows from the battery compartment, disconnect the supply tubes of the lift cylinders and use suitable male and female hydraulic plugs to prevent foreign matter from entering the cylinders and hydraulic circuit.

¾ With an articulated Allen key, remove the retaining screw of the lower safety split pin of the cylinder and remove the split pin itself.

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Workshop literature 45478042102 EN 04/2007

¾

¾ Use pliers to rotate the rod of the cylinder so as to position the top pin at the hole on the stand and extract it.

¾

Workshop literature 45478042102 EN 04/2007

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¾ Position the jack on the front side of the mobile structure and raise it until the side cylinders are completely freed. Place timber baulks under the mobile structure in order to be able to work safely.

¾

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Workshop literature 45478042102 EN 04/2007

¾ Extract the cylinders from the machine.

¾ The reassembly of the cylinders is carried out by performing the various operations described up until now in the reverse order, with the only difference of inserting spherical washers in the lower and upper part of the cylinder according to the order shown in the photo.

This adjustment should be carried out with the machine on a flat surface and the fork arms on the ground.

¾ The mobile structure is supported on its sides by a pair of "load bearings" that work inside the guide profiles of the mobile structure.

Workshop literature 45478042102 EN 04/2007

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¾ The mobile structure is also guided sideways by a second pair of "side grip bearings" that work crosswise on the side of the guide profile of the mobile structure.

¾ The load bearings are equipped with an eccentric pin that can be turned with an Allen key to move the top part of the mobile structure forward or backward and thus adjust the inclination of the fork arms.

Usually, if the adjustment of the tension rods has been performed correctly, the position of the eccentric pin is established a priori with the engraving positioned at 8 o clock when observing the pin from the side of the hexagonal hole for the wrench. ¾ In this position the bearings keep the top part of the structure almost completely towards the operator and the tip of the fork arms at the highest point. ¾ The fixing of the pin is carried out by holding the eccentric pin stationary with an Allen key and tightening the lock nut with an open-end spanner suitable for the torque value.

If it is necessary to modify this attitude, both sides must be worked on, turning the eccentric pins by the same amount.

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Workshop literature 45478042102 EN 04/2007

¾ For the adjustment of the "side grip bearings" , proceed as follows: ¾ Loosen the central fastening screw of the bearings. ¾ Stand on the fork arms and use crosswise movements to make the entire mobile structure oscillate in order to make it settle mechanically. ¾ Using the nut of the eccentric pin, turn the two pins until the two side grip bearings rest on the rib of the profile; hold the eccentric pin stationary in this position and tighten the central fastening screw. ¾ Perform some lifting and lowering manoeuvres to check that there is no jamming or excessive play. If jamming or excessive play is found, the adjustment must be repeated.

¾ Disassemble the lift cylinders of the machine and remove the feed line connection from each cylinder. ¾ Completely drain the oil from the cylinder.

¾ Extract the rod to the end position.

Workshop literature 45478042102 EN 04/2007

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¾ With the rod at the end position, look through the feed hole; a metal retaining ring can be seen, housed in its seat, along with a groove that will be used only during the reassembly of the rod.

The groove must not be used for disassembly since doing so would cause, when extracting the rod, the retaining ring to become stuck in the gasket.

¾ Use a sturdy screwdriver passing through the hole to force the metal retaining ring and push it towards the blind end of the cylinder.

Slipping off the retaining ring towards the end of the barrel, it is possible to extract the rod, once the rod is completely extracted it is also possible to extract the metal retaining ring left in the barrel. ¾ Now the worn gaskets can be extracted and replaced, see the figure at the side.

Heat the new gaskets in hot water in order to be able to insert them in their seats without damaging them. ¾ After replacement of the gaskets, position the retaining ring inside the deepest groove on the rod. ¾ Spread grease on the surface of the rod at the metal retaining ring and the gaskets zone on the barrel and insert the rod. ¾ Position the retaining ring at the hole of the feed line and use a sturdy screwdriver to move the retaining ring from the deepest groove to the smallest groove. ¾ Perform some movements with the rod, up to the end position, to check the efficiency of the mechanical stop. ¾ Reassemble the feed line connection.

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Workshop literature 45478042102 EN 04/2007

¾ To access the lever systems, it is necessary to separate the mobile structure from the body .

Workshop literature 45478042102 EN 04/2007

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Position the mobile structure upside down using a hoist, see the figures for phase 1 and 2.

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Workshop literature 45478042102 EN 04/2007

In this manner, all parts will be accessible and within reach and thus easy to replace, without the need for particular instructions since they simply involve pivots and pins. ¾ During reassembly, some adjustments must be made in order to obtain a correct attitude of the mobile structure, minimizing the need for adjustments on the assembled machine which are rather difficult with the machine on the ground.

Workshop literature 45478042102 EN 04/2007

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FORK ARM LENGTH

1150

1400

1600

1800

2390

DIMENSION " "

847.8

1097.8

1297.8

1297.8

1718.3

DIMENSION " " DIMENSION " " (obtained by empirical measurement)

987

1237

1437

1437

1857.5

997

1247

1447

1447

1867.5

¾ If the struts must be completely disassembled for maintenance reasons, before reassembling them adjust them so that dimension " " corresponds to the value indicated in the table. ¾ To adjust the struts in position, refer to dimension " " using the procedure described below: ¾ Use two clamps to block the front roller levers at the end position against the fork arm.

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Workshop literature 45478042102 EN 04/2007

¾ Place a piece of gummed paper tape at the retaining pin centre on the pin hinging the strut with the front levers.

¾ Place a piece of gummed paper tape on the rear levers at the centre of the hinge pin of the strut and the centre of the hinge pin of the levers ; in this manner the tape transversally crosses the eye of the strut, creating the reference point for the measurement of dimension " ". ¾ Perform the measurement of dimension " " between the two references created.

Workshop literature 45478042102 EN 04/2007

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Workshop literature 45478042102 EN 04/2007

¾ The strut length is adjusted by operating on the hexagonal block located between the rod of the strut and the ball-and-socket head and blocking it with the lock nuts, as shown in the figure.

Check the centring of the rear lever, following the procedure described below:

¾ Make certain that both the clamps on the front wheels are fixed correctly and keep the front levers at the end position against the upper part of the fork arms.

Workshop literature 45478042102 EN 04/2007

-17

¾ If the adjustment of the struts has been performed correctly, the rear lever group will automatically be centred and the distance measured between the deflection plate and the inside of the lever hinging to the body will be 95 mm on both the right and the left.

If the two dimensions are different, then it is necessary to adjust the hexagonal adjustment blocks of the struts in order to shorten the strut on the side that measures less than 95 mm and lengthen the strut on the side that measures more than 95 mm until both the dimensions are 95 mm.

Adjust the two struts gradually, unscrewing the hexagonal adjustment block of a strut by one turn at a time and simultaneously tightening the hexagonal block of the other strut by the same amount.

¾ When finished, fix the hexagonal adjustment blocks with the respective lock nuts. a

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Workshop literature 45478042102 EN 04/2007

Copyright by OM Carrelli Elevatori S.p.A. Viale De Gasperi, 7 I-20020 Lainate www.om-mh.com 45478042102 EN Edition 04/2007

Workshop literature

Workshop literature 45478042102 EN 04/2007

a

-1

BU

GY

-2

YE

grey

RD

GN VT

red yellow

violet

BN

OG

WH

blue orange

brown green

BK

white

Electronic drive control, 8-19/32-33 Electrical drive control, 2-5 e-ABS control, 20-23 Drive motor encoder, 17-19 Drive motor heat sensor, 16 Fuse (10A), 24 Fuse (5A), 33 Safety fuse (1A), 23 Drive fuse (250A), 8 Pump fuse (125A), 7 Electrical drive fuse 30A, 2 Fan wheel rotor fuse 5A, 27 Safety fuse 8A, 30 Battery, 1

black

A1 A2 A4 1B1 1B2 F1 F4 F5 1F1 2F1 3F1 9F1 9F3 G1

K1 K2 2K1 3K1 9K1 L4 1M1 2M1 3M1 9M1 6P2 9P1 3R1 S1

General contactor contact, 8 Drive contactor contact, 8 Pump contactor contact, 7 Electrical drive relay contact, 2 Fan relay contact, 26-28 Snubber, 29 AC drive motor, 10 DC pump motor, 7 Electrical drive motor reducer, 3-4 Fan, 27 Drive system console, 12-15 Data terminal, 30 Resistance, 2 Key, 27-28

7S1 7S3 X1 X2 X3 X4 X5 X7 X10 X11 1X1 1X3 3X2 6X2

Emergency pushbutton, 25 Dashboard closure micro (OPT), 31 Battery socket - plug, 1 35-pin AMP-Seal plug, 12-19/32-33 8-pin MTA fuse holder, 2/23/24/27/33 BLACK 10-pin SAAB plug, 33 BLUE 10-pin SAAB plug, 31 GREY 10-pin SAAB plug, 25/31 Black 2-pin SAAB plug, 30 14-pin Molex plug, 21-23 4-pin AMP-JPT plug, 17-19 Grey 2-pin SAAB plug, 16 3M1 power cables, 2-5 4-pin Molex plug, 12-15

9X1 9X2 (*1) (*2) (*3) (*4) (*5) (*6) (*7) (*8) (*9) (*10)

Workshop literature 45478042102 EN 04/2007

Wittrin plug for micro-relay, 26-28 PF 2-pin AMP-Seal plug, 27 Console (Rx) Negative logic supply Console (Tx) Drive motor temperature sensor Channel A encoder Channel B encoder K1 diagnosis Optional 10-pin Auxiliary

Workshop literature 45478042102 EN 04/2007

-3

WH

BU

blue orange

VT

RD

YE

GY

red yellow

grey

-4

GN

violet

BN

brown green

OG

BK

white

Electronic drive control, 43-54 Callipers, 37-56 e-ABS control, 35-40 Fork lifting limit switch micro, 50 Fuse (5A), 55 Horn, 55 Lifting contactor coil, 49 Snubber, 50 Snubber, 56 B.S.I. + hour meter, 34-36/50 Steering position indicator (OPT), 57-61 Steering potentiometer, 62-65

black

A1 A3 A4 2B2 4F1 4H1 2K1 L5 L6 6P1 6P4 3R2

2Y2 V3 X2 X3 X4 X7 X9 X11 2X1 2X2 3X3 6X1

Fork lowering electromagnetic valve, 51 Free-wheeling diode, 52 35-pin AMP -SEAL plug, 44-53 8-gauge MTA fuse holder, 52/55 BLACK 10-pin SAAB plug, 44-48/55 GREY 10-pin SAAB plug, 34/50-51/57/62-65 18-pin Molex Micro-Fit plug, 38-55 14-pin Molex plug, 36-39 4-pin ITT CANNON plug, 50 DIN 43650 plug, 51 4-pin MOLEX plug, 62-69 8-pin Molex plug, 34-36/50

6X4 (*8) (*9) (*10) (*11) (*12) (*13) (*14) (*15) (*16) (*17) (*18)

Faston contacts, 57-61 Optional 10-pin Auxiliary Direction of travel towards operator Direction of travel towards forks Drive potentiometer Negative Potentiometer negative Potentiometer positive High/Low Deadman s switch

(*19) (*20) (*21) (*22) (*23) (*24) (*25) (*26) (*27) (*28) (*29)

Workshop literature 45478042102 EN 04/2007

Forward/reverse signal common High/low signal common Reverse travel Forward travel Optional electrical drive with reverse function Interlock Steering Potentiometer 1 output Potentiometer positive Potentiometer negative Potentiometer 2 output

Workshop literature 45478042102 EN 04/2007

-5

WH

BU

blue orange

VT

RD

YE

GY

red yellow

grey

-6

GN

violet

BN

brown green

OG

BK

white

Electronic drive control, 77-89/94-97 e-ABS control, 73-77/90-94 Reverse gear warning buzzer, 79-80 Drive contactor coil, 91 Drive contactor coil, 88 Interlock relay contact, 84-85 Fan activation relay coil, 82 Snubber, 94

black

A1 A4 4H2 K1 K2 7K1 9K1 L7

1S8 Y1 X2 X4 X5 X11 1X2 7X2

Load manostat, 87 Electromagnetic brake, 92 35-pin AMP -SEAL plug, 78-79/95-97 BLACK 10-pin SAAB plug, 70 BLUE 10-pin SAAB plug, 94 14-pin Molex plug, 74-76/91-93 Black 2-pin SAAB plug, 92 Wittrin plug for micro-relay, 84-85

9X1 (*8) (*9) (*24) (*30) (*31) (*32) (*33)

Wittrin plug for micro-relay, 82 Optional 10-pin Interlock Drive consent Braking potentiometer Not used Switch

(*34) (*35) (*36) (*37) (*38)

Workshop literature 45478042102 EN 04/2007

Load manostat Electromagnetic brake input Electromagnetic brake output Electromagnetic brake Speed reduction on curves

Workshop literature 45478042102 EN 04/2007

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WH

BU

blue orange

VT

RD

YE

GY

red yellow

grey

-8

GN

violet

BN

brown green

OG

BK

white

Electrical drive control, 99-126 Diagnostic LED, 123 Electrical drive relay coil, 121 Interlock relay coil, 120 Electrical drive control console, 112-115 Driving wheel potentiometer, 180-111 Dead man s pedal, 124-126 MTA 8-pin fuse holder, 123 BLUE 10-pin SAAB plug, 124-126 25-pin AMP plug, 100-121 4-pin DEUTSCH plug, 108-111

black

A2 4H3 3K1 7K 6P3 3R3 7S2 X3 X5 3X1 3X4

6X3 7X1 7X2 (*1) (*2) (*3) (*9) (*10) (*18) (*25) (*26) (*27)

Black 4-pin SAAB plug, 112-115 Black 4-pin AMP JPT plug, 124-126 Wittrin plug for micro-relay, 120 Console (Rx) Negative logic supply Console (Tx) 10-pin Auxiliary Dead man s switch Steering Potentiometer 1 output Potentiometer positive

(*28) (*29) (*30) (*39) (*40) (*41) (*42) (*43) (*44) (*45) (*46) (*47)

Potentiometer negative Potentiometer 2 output Drive consent Speed sensor (A) Speed sensor (B) Free Steering potentiometer (B) Steering position Steering potentiometer (A) Driving wheel potentiometer (A) Negative potentiometer supply Truck code (B)

(*48) (*49) (*50) (*51) (*52) (*53) (*54) (*55) (*56) (*57)

Workshop literature 45478042102 EN 04/2007

Driving wheel potentiometer (B) Truck code (C) Truck code (A) Safety relay Forced activation Drive block 3K1 relay Dead man s micro switch 8-pin fuse holder 4-pin

Workshop literature 45478042102 EN 04/2007

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WH

BU

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VT

RD

YE

GY

red yellow

grey

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GN

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BN

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OG

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white

Safety fuse 8A, 128 Bimetal switch, 131 Heater fan, 129 Heater fan, 130

black

9F2 9F4 9M2 9M3

9R2 9R3 9R4 X10

Heating resistor, 131 Heating resistor, 132 Fork limit micro switch heating resistor (100R), 133 Black 2-pin SAAB plug, 128 S5 X14

Programmable Security Lock, 148-153 3-pin p.m. Fastin-Faston block, 149-155

X21 (*60)

Workshop literature 45478042102 EN 04/2007

Black 4-pin ITT CANNON SURE-SEAL plug, 149-152 Numerical keypad

Workshop literature 45478042102 EN 04/2007

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-12

ON

OFF

ON

PUMP MOTOR OFF

2Y2

TRUTH TABLE

Fork lifting Ascent

Forks descent Fork lifting

(*1) (*2)

Workshop literature 45478042102 EN 04/2007

Workshop literature 45478042102 EN 04/2007

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45478042102 EN Edition 04/2007

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