Still OM Forklift XOP07 Series 4540 Workshop Manual- PDF DOWNLOAD

Workshop literature Series 4540

XOP07

45408042303 EN Edition 03/2007

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Workshop literature 45408042303 EN 03/2007

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Workshop literature 45408042303 EN 03/2007

V

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

Workshop literature 45408042303 EN 03/2007

-1

A

B

OM1270

This forklift has the following characteristics: It is a non-stacking lift truck in which the operator station rises together with the forks and is used for manual removal from shelves; Given its construction, it is used to transport loads that fall within specific weight and size limitations.

The forks rise together with the platform, remaining at the same level; The forkscan be raised and then levelled, through special controls, independently of the lifting of the platform.

It is battery powered;

It is available in the versions:

The forklift is driven with the operator standing on the platform using the handlebar tiller;

-2

Workshop literature 45408042303 EN 03/2007

B

A

OM1246

The direction of travel is defined in the following manner: = Direction of travel toward motors (forward) = Direction of travel toward forks (backward) " " is the preferred direction of travel

Workshop literature 45408042303 EN 03/2007

-3

2.1 1.3

1.4

Version without levelled forks

Model Propelling unit: electr., diesel, gasoline, gas, network electr.

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

Version with fixed levelled forks Electric

Tiller

1.5

Load capacity / Load

Q (t)

0.7

1.6

Centre of gravity

c [mm]

600

-4

Version with movable levelled forks

Workshop literature 45408042303 EN 03/2007

1.8 1.9 2.1 2.2 2.3

3.1 3.2 3.3 3.5

Load distance from load wheel axis Wheelbase Dead weight (without battery) Load per axle when loaded (front/rear) Load per axle when empty (front / rear) Full set of tyres, superelastic, tyre, polyurethane Dimensions of front wheels Dimensions of rear wheels Wheels: front / rear quantity (x=drive wheel)

x [mm]

105

y (mm)

100 1210

kg

807

910

945

kg

459/1524 (1)(2)

451/1636 (1)(2)

416/1704 (1)(2)

kg

863 / 420(1)(2)

855 / 532(1)(2)

846 / 574(1)(2)

Polyurethane mm

ø 250 x 80

mm

ø 120 x 50 1x / 4

3.6

Front track

b10(mm)

-

3.7

Rear track

b11(mm)

780

h1(mm)

1577

h3(mm)

1040

h4(mm)

2343

h7(mm)

160

h14(mm)

1245

4.2 4.4 4.5 4.8 4.9

Height with lift mast retracted Lifting Height of upper extremity of handlebar with platform raised Operator platform height Tiller height in operating position

4.10 Total free elevation Operator platform 4.14 height when raised 4.15 Lowered forks height 4.19 Total length Length including shoul4.20 der of forks 4.21 Maximum width 4.22 Fork dimensions

140

h9(mm)

/

h12(mm)

674

712

1200

h13(mm)

85

85

45

I1(mm)

2648

2643

2683

I2(mm)

1498

1493

1533

b1(mm) s/e/l (mm b5(mm)

4.25 External gauge - forks Clear span below lifting m1(mm) 4.32 mast Working corridor with Ast3 4.34 pallet 800x1200 fork (mm) insertion 800

Workshop literature 45408042303 EN 03/2007

810 50x160x1150

55x160x1150

35x100x1150

540

540

300/680

45 2899

2894

2934

-5

4.35 Radiuses of curvature

Wa (mm)

1395

5.1

Translation speed (loaded/empty)

km/h

8.5/8.5

5.2

Cab lifting speed (loaded/empty)

m/s

0.18/0.26

5.3

Cab descent speed (loaded/empty)

m/s

0.24/0.24

%

-

%

-

s

/

Surmountable gradient KB 30I (loaded/empty).

Max. surmountable 5.8 gradient with/without load Acceleration time 5.9 with/without load 5.10 Service brake 5.7

6.1 6.2 6.3 6.4

Electric

Traction motor, performance KB 60 I Lifting motor, performance 15% ED Battery in accordance with DIN 43531/35/36 A, B, C Voltage / Nominal capacity

kW

3

kW

2.2 DIN elements

V/Ah

24 / 420-480

6.5

Battery weight (+/- 5%)

kg

389 / 410

6.6

Energy consumption according to VDI cycle

kWh/h

/

8.1

Control type

8.4

Noise level in driver s ear

Electronic dB (A)

1) Including the operator on board

<70 2) With 480 Ah battery

Data missing!!!

0 / -10 mm 0 / -10 mm 0 / +7 mm +3 / -3 mm +2 / -2 mm

-6

Workshop literature 45408042303 EN 03/2007

Drive speed when unloaded

0 / -5%

Drive speed with nominal load

0 / -5%

Fork lifting speed

± 5%

Fork descent speed

0 / -10%

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 45408042303 EN 03/2007

OM0747

-7

1 1

2 2 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, which must be suitably positioned and anchored).

OM1258

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.

-8

Workshop literature 45408042303 EN 03/2007

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 45408042303 EN 03/2007

their consequences, scrupulously following the safety rules.

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

-9

During maintenance and repair procedures, scrupulously follow the prescriptions indicated below and the instructions given in this manual. Maintenance operations must be performed by qualified technical personnel authorized by the manufacturer. Always work within the limits of safety, according to the standards in force.

Carefully follow the safety regulations pursuant to the provisions in force when handling working materials.

Important information regarding knowledge of the truck and its safe use along with basic information on truck maintenance are given in the .

If maintenance operations are carried out with the battery connected, the machine may accidentally be started, or sparks may cause harm to the technical staff or to the machine itself. The battery must therefore be kept disconnected, unless expressly prescribed by the maintenance or repair instructions.

All service actions must be carried out with maximum care and attention.

During maintenance operations, approved protective clothing must be worn, such as overalls, helmets, protective footwear with non-slip soles, gloves and safety goggles.

Do not wear rings, wrist watches, jewellery, unfastened or hanging garments such as ties, torn clothing, scarves, unbuttoned jackets or blouses, or open zips, which could be caught in the moving parts.

Operate in separate work areas specifically intended for maintenance or specially marked off to indicate work in progress.

During maintenance operations, engage the parking brake, turn off the truck and remove the keys from the dashboard, unless expressly required by the operation being carry out.

Ensure that the machine cannot be moved accidentally.

-10

The brakes are not activated when they are manually released for maintenance or repair operations: in this case provide for control of the machine using suitable chocks or similar.

Ensure that no one is within range of any movement of the machine or equipment.

Do not carry out any maintenance or repair on the machine with a person sitting in the seat, unless the person is qualified and necessary for execution of the operation.

Do not switch on the machine or activate its equipment from any position other than sitting in the driver s seat.

To avoid improper use or use in unsafe conditions, label all controls to mark that repairs are in progress.

Do not leave the machine unattended with parts in movement.

Immobilise the machine and all equipment or parts that are subject to maintenance while raised, or which could accidentally move.

When carrying out operations from beneath the truck, always use a maintenance well or a bridge crane of adequate capacity.

The areas for maintenance must be level, and must be kept dry and clean; any puddles of water or oil stains must be removed immediately.

Do not pile up rags soaked in grease or oil: they represent a serious fire hazard. Always place them inside a closed metal container.

If working on a sloping surface is inevitable, immobilise the machine before starting to work, and move it to a level surface as soon as this can be done with a certain margin of safety.

Service stepladders and platforms used in the workshop or on the worksite and other equipment must conform with the accident prevention standards in force.

After completing maintenance operations, the truck must be returned to normal conditions of use, taking care to check the correct installation of all prescribed safety and protective devices. Take care to remove all equipment from the machine, and check accurately that all parts are firmly fixed.

To tow the truck, comply with the instruction in this manual, using the provided connection points exclusively. Make all connections carefully/ensure than pins and/or latches foreseen are firmly fixed before starting to tow the truck.

Do not remain in the vicinity of the tow bar, ropes or chains working under tension.

Workshop literature 45408042303 EN 03/2007

To move a machine that has broken down, use a trailer or a truck with a lowered loading platform, if available.

When transporting the truck, follow the indications in this manual. To load and unload the machine on and off the transport means, choose a level area with a solid surface to support the wheels of the trailer or lorry. Anchor the machine firmly to the loading platform of the lorry or trailer and block the wheels.

The chains must be firmly fixed: make sure that the anchorage is sufficiently resistant to support the foreseen load. No one must be within the vicinity of the chain or rope anchorage points under tension.

protective side guards, helmets, protective footwear and safety gloves.

During welding operations, always use protective accident-prevention devices. Protective goggles must also be worn by anyone in the vicinity, even if not carrying out work. Never look at the welding arc without adequate eye protection.

With use, metal cables become frayed: when handling them, always use adequate protection (gloves, goggles, etc.). Do not use chains or ropes that are worn or bent for lifting or pulling.

Handle each part with extreme care. Keep hands and fingers away from interstices, rotating parts and similar.

When lifting or transporting heavy parts, use pulleys or similar of adequate capacity, and keep all persons at a safe distance.

Move with great care when carrying out work beneath the machine, and also when in the vicinity of the same.

Stop the motor and make sure that there is no pressure in the hydraulic circuits before removing caps or covers.

If any part is blocked, free the same only when the motor is off and the battery is disconnected.

Do not check or top up the fuel tank, the hydraulic oil or the battery while smoking since the fluids used are inflammable.

Never pour petrol or diesel oil into open, wide or low recipients because of the risk of inflammable vapours and spills.

Never use petrol, diesel oil or inflammable fluids for cleaning: always use non-toxic commercial solvents.

When using compressed air for cleaning small parts, use protective goggles with side guards; use a maximum pressure of 2.1 bars according to local or national legislation in force.

When handling easily inflammable material, do not smoke, do not use open flames, and do not cause sparks in the vicinity.

When using the batteries, it must be remembered that both ends of the cables must be linked to the terminals in the correct manner: (+) to (+) and (-) to (-).

Avoid short circuiting the battery terminals.

The gas released from the battery is highly inflammable. When recharging, leave the battery compartment open to allow for more effective ventilation and remove the caps. Ensure that ventilation is adequate in order to avoid the possibility of accidental explosions due to the accumulation of gas released during recharging.

Never check the state of the battery by means of a bridge created by placing a metal object on the terminals.

Avoid sparks and flames in the battery area.

Do not smoke near the battery or in the maintenance area in order to avoid the risk of explosions.

Before any operation, check that there are no electrolyte leaks: eliminate such leaks before proceeding with the work.

Refer to the specific Instruction and Maintenance Manual of the drive battery.

Do not use flames as a means of illumination when proceeding with operations or when searching for leaks on the machine.

Before any operation, check that no elements are short circuited: eliminate such short circuits before proceeding with the work.

Do not carry objects in pockets which could accidentally fall into the open parts of the machine.

For electric heaters, battery chargers and similar appliances, use only effectively earthed auxiliary power sources in order to avoid the possibility of electric shocks.

When there is any possibility of being hit by metallic parts or similar, use goggles with

Workshop literature 45408042303 EN 03/2007

-11

Lift and handle all particularly heavy parts by means of lifting gear of an adequate capacity.

Ensure that pieces are supported by appropriate harnesses and hooks.

Penetration of the skin by hydraulic oil under pressure spurting from the hydraulic system is dangerous. If this type of lesion should occur, contact a doctor immediately. Small leaks should be sought by the aid of a piece of cardboard or a piece of wood. Avoid using the hands to look for leaks.

Use special instruments to check the pressure of the hydraulic system.

-12

Use the lifting rings specifically provided for the purposes. Pay attention to persons in the vicinity of the load to be lifted.

Handle all pieces with great care.

Do not place hands or fingers between one piece and another.

Avoid twisting the chains and metal cables.

Workshop literature 45408042303 EN 03/2007

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 45408042303 EN 03/2007

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.

-13

-14

Workshop literature 45408042303 EN 03/2007

a

Check and adjust chains Check and lubricate the fork carriage and slide guides Fork wear check Clean the steering and lift electric motors Check the steering and lift motor manifolds Check insulation between chassis and any electric motors Check power cables are securely fixed 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 cab bearings Check the adjustment of the lateral retaining pads for versions with "levelled forks" Replace the lift and steering motor brushes Change the hydraulic equipment oil = To be carried out absolutely every 3 months or according to current legislation. = Every 1000 hours or at least every 12 months

Tutela Matrix Tutela Matrix * Quantity (lt)

1.5 Idraulicar AP31

Quantity (lt)

Tutela GI/M * 2.5 Tutela MP 02 Tutela JOTA1 *

Workshop literature 45408042303 EN 03/2007

-1

Kluber / Structovis EHD Kluber / Structovis FHD * * For Cold-Storage Room version

-2

Workshop literature 45408042303 EN 03/2007

a

¾ After raising the cover of the battery compartment, the connectors for diagnostics are easily accessible by means of a special hole in the motor compartment bonnet. : Connector for the "LES electrical drive diagnostics" : Connector for the "Curtis system diagnostics"

¾ The 2 connectors are shown here

Workshop literature 45408042303 EN 03/2007

-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.

-2

Workshop literature 45408042303 EN 03/2007

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 45408042303 EN 03/2007

-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)

-4

Workshop literature 45408042303 EN 03/2007

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 45408042303 EN 03/2007

-5

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.

-6

Workshop literature 45408042303 EN 03/2007

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.

Workshop literature 45408042303 EN 03/2007

-7

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

It is useful for checking on controller functioning during the initial installation and for localising problems, should any arise.

The values displayed depend on the status of the battery and the functions that the machine is carrying out at that moment. We will therefore indicate the value plus the corresponding unit of measurement in the table.

The meaning of

and

is explained below:

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

-8

Workshop literature 45408042303 EN 03/2007

The the following data:

contains

: Contains a drop-down sub-menu described below. : System model. : System serial number. : System construction date. : Hardware version. : Version of the operating system installed in the controller. : Build number of the controller operating system. : Version of the Start Manager software of the controller. : Version of the parameters lock installed in the controller. : Version of the VCL soft-

ware.

¾

contains the following sub-menus:

This indicates the four states of the machine/chopper: = STARTUP = DRIVE_MAX = DRIVE_LOAD = DRIVE_REDUCED = DRIVE_BACKING

Mapping of the drive potentiometer voltage Workshop literature 45408042303 EN 03/2007

0 - 5 Volts -9

-10

Mapping of the brake potentiometer voltage

0 - 5 Volts

Drive wheel potentiometer voltage

- - Volt

Max speed on forks side depending on angle

-- %

Max speed on motor compartment side depending on angle

-- %

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:

Pin 19 input state

ON - OFF:

Pin 20 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

-- %

Workshop literature 45408042303 EN 03/2007

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 45408042303 EN 03/2007

-- 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.

-12

Workshop literature 45408042303 EN 03/2007

¾

contains the following sub-menus:

Lower threshold of the drive potentiometer

0.15 Volt

0 - 5 Volts

Upper threshold of the drive potentiometer

5 Volts

0 - 5 Volts

Workshop literature 45408042303 EN 03/2007

-13

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

0.9 seconds

From 0.5 to 10 seconds

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

1.8 seconds

From 1 to 10 seconds

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

2 seconds

From 2 to 30 seconds

Lower threshold of steering potentiometer

2 Volts

From 1.5 to 2.5 Volts

Steering potentiometer voltage with wheel centred

4.46 Volts

From 4 to 5.5 Volts

Upper threshold of steering potentiometer

7 Volts

From 6.5 to 7.5 Volts

"Dead" band of the wheel centre

0.25 Volts

From 0.2 to 1.5 Volts

2.8 Volts

From 1.5 to 3.8 Volts

38%

From 0 to 50%

Minimum speed of deceleration when turning, travelling in the direction of the fork arms

38%

From 0 to 50%

EM brake power supply voltage (CONSTANT)

18.8 Volts

From 18 to 24 Volts

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

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Workshop literature 45408042303 EN 03/2007

Fan power supply voltage

24 Volts

From 12 to 24 Volts

Temperature for fan activation

55 °C

From 0 to 70°C

Temperature for fan deactivation

45°C

From 0 to 60°C

24%

From 0 to 24%

38%

From 0 to 38%

67%

From 0 to 67%

67%

From 0 to 67%

38%

From 0 to 38%

38%

From 0 to 38%

24%

From 0 to 24%

38%

From 0 to 38%

81%

From 0 to 81%

81%

From 0 to 81%

Minimum speed on curves with the cab raised Minimum speed on curves with the cab lowered 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 Second reduced speed in the direction of the fork arms

Minimum speed on curves with the cab raised Minimum speed on curves with the cab lowered Maximum speed in the direction of the fork arms when not loaded Maximum speed in the direction of the fork arms when loaded

Workshop literature 45408042303 EN 03/2007

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Reduced speed in the opposite direction to the fork arms Second reduced speed in the opposite direction to the fork arms

¾

menus:

38%

From 0 to 38%

38%

From 0 to 38%

4 seconds

From 0.5 to 30 seconds

4 seconds

From 0.5 to 10 seconds

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

5.9 seconds

From 0.5 to 30 seconds

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

2.3 seconds

From 1 to 30 seconds

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).

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Workshop literature 45408042303 EN 03/2007

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

2.3 seconds

From 1 to 30 seconds

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

0.5 seconds

From 0.5 to 10 seconds

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

1 second

From 1 to 10 seconds

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

2 seconds

From 2 to 30 seconds

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

Workshop literature 45408042303 EN 03/2007

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(blocks truck) The current of the phase exceeds the current limit measured

; Short circuit of phases U,V,W on the drive motor

· Phases U,V,W of the drive (blocks truck) motor possibly not correctly The current sensor reads an insulated incorrect value (blocks truck) Failed precharge of condensers (blocks truck) Temperature dissipater lower than -40°C

(blocks truck) Temperature dissipater higher than +95°C

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

· External charge connected at B+ which prevents recharging of the condenser group · The truck is working in an excessively cold environment · The temperature gauge is damaged

· 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 the work environment or work elsewhere · If the environmental temperature is acceptable, replace the system

· The truck is working in an excessively hot environment · Work cycles are too heavy · Ventilation system is out of order ·· The temperature gauge 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

· The power fuse is damaged · Main remote control switch open

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

(blocks · Battery disconnected during truck) The condenser group volt- regenerative braking age is above the set limit · Incorrect calibration of battery · Reset the parameters cor(blocks truck) parameters rectly · Heat the work environment · The truck is working in an or work elsewhere excessively cold environment (Reduces speed) · If the environmental temper· The temperature gauge is Temperature dissipater ature is acceptable, replace damaged lower than -25°C the system

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Workshop literature 45408042303 EN 03/2007

(Reduces speed) Temperature dissipater higher than +85°C

· The truck is working in an excessively hot environment · Work cycles are too heavy · Ventilation system is out of order ·· The temperature gauge is damaged

(Re· The power fuse is damaged duces speed) · Main remote control switch The condenser group voltopen age is below the set limit

· 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 condenser group voltage is above the set limit

· Battery disconnected during regenerative braking

(No effect) The +5V (pin 26) power supply is outside the +5V ±10% range

· Check connections and · Impedance of external charge check that there is no abnoron pin 26 is too low mal absorption

· Impedance of external charge · Alarm not expected since pin (output is disabled) The current on pin 19 output on pin 19 is too low 19 is not connected exceeds the 15mA limit · Impedance of external charge · Alarm not expected since pin (output is disabled) 20 is not connected The current on pin 20 output on pin 20 is too low exceeds the 15mA limit · Check the temperature of · The truck is working in an (Reduces speed) the work environment excessively hot environment The motor temperature · Check the ventilation system · Work cycles are too heavy has reached the value set and repair if necessary · Ventilation system is out of for the Hot Temperature · Wait until the control has order parameter cooled down · Check the temperature of · The truck is working in an the work environment excessively hot environment (Drive is blocked) · Check the ventilation system · Work cycles are too heavy and repair if necessary The motor temperature · Ventilation system is out of · Wait until the control has has reached the value set order for the Max Temperature cooled down ·· Temperature gauge is disconparameter · Check the connection of the nected or out of range temperature gauge 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

· Check wiring and repair if necessary. · The remote control switch coil · Check the state of the main is open or short circuited remote control switch and replace if it is defective · Check wiring and repair if necessary. · The electromagnetic brake coil · Check the state of the elecis open or short circuited tromagnetic brake and replace if it is defective · Check eABS

Workshop literature 45408042303 EN 03/2007

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(output is disabled) The Pin 4 driver is open or short circuited

· The charge on pin 4 output is open or short circuited

· Check wiring and repair if necessary.

(output is disabled) The Pin 3 driver is open or short circuited (output is disabled) The Pin 2 driver is open or short circuited

· The charge on pin 3 output is open or short circuited

· Alarm not expected since pin 3 is not connected

· The charge on pin 2 output is open or short circuited

· Alarm not expected since pin 2 is not connected

· Main remote control switch 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 perfectly closed · Main remote control switch contacts are oxidised

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

· Power supply potentiometer out of range

· Check power supplier of drive potentiometer

· Incorrect connections

· Reconnect correctly

(Maximum braking) Braking potentiometer voltage (pin 17) too high

· eABS braking signal out of range

· Check eABS and replace if necessary.

(Maximum braking) Braking potentiometer voltage (pin 17) too low

· eABS braking signal incorrect · Incorrect connections

· Check eABS and replace if necessary. · Reconnect correctly

(Drive is blocked and braking is · Incorrect connections maximum) · Potentiometer resistance too The voltage on pin 18 input low exceeds the 10mA limit

· Alarm not expected since pin 18 is not connected

(Blocks truck) Main remote control switch stuck (Blocks truck) Main remote control switch is not closed even if commanded (Drive is blocked) Drive potentiometer voltage (pin 16) too high (Drive is blocked) Drive potentiometer voltage (pin 16) too low

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

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· Load correct software

Workshop literature 45408042303 EN 03/2007

(Drive is blocked) · Incorrect starting sequence Incorrect starting sequence

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

· Setting of at least one parameter that requires switching off · Switch off and then switch on and on again with the key for ac- again tivation For a question of safety · 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 butterfly levers are not in the at-rest position (nonblocking alarm)

· Check that at rest the signals concerned are correct ·· Check the wiring · Replace any damaged components (e.g.:Switch etc)

· Both movement signals (For(Drive is ward and Reverse) simultaneously activated (these alarms do not block the truck).

· Check that at rest the signals concerned are correct ·· Check the wiring · Replace the drive potentiometer or the logic handlebars 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 wheel moves from the "central" position during driving with the backing function (this alarm does not block the truck).

Check that the electrical drive is functioning correctly Check the actual manoeuvre of the operator

(Drive is blocked)

blocked)

· 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)

(Drive is blocked)

· If the machine does not brake on release of the interlock · Check that the electronic within the times foreseen by the control is functioning correctly eABS, the EM brake is activated ·· Check the drive motor (non-blocking alarm).

(Drive is blocked and braking is maximum) (No effect)

· Incorrect software

· Replace plant with new software

· Anomalous absorption on pin 26 and pin 25 outputs

· Check connections and repair if necessary

Workshop literature 45408042303 EN 03/2007

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Linking the X54 connector to the PC (Personal Computer) with the special interface sleeve cod.

300 365 25 01 the necessary adjustments for correct functioning of the system can be carried out.

In the case of breakdown, it is also possible to detect the origin of the problem.

The procedure to be carried out is the following: ¾ Connect the PC with the interface sleeve to the 4-pole Saab connector leading from the L.E.S. control. ¾ Switch on power to the truck and close the contact key. ¾ Click on the LES28 program icon.

The connection is confirmed when window (1) opens with the display of 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 connection is not made if the dashboard microswitch is not closed. The window that will appear if the connection is not made is instead the following:

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

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ESC

Terminates the function being used

F1

Help that describes how to use the software

Workshop literature 45408042303 EN 03/2007

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 Memorises 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 menu.

To scroll the menu, press the keys Pag. up and Pag. down.

Menu 1:

Software version, truck control and identification

Menu 2:

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

Menu 3+:

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

Menu 31+:

Display of all alarms that have occurred (Alarms history)

Menu 32+:

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

Menu 33+:

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

Menu 34+:

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

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Menu 4+:

Display of the status of logic inputs of the main microprocessor

Menu 41+:

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

Menu 5+:

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

Menu 51+:

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

Menu 6+:

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

Menu 61+:

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

Menu 62+:

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

Menu 63+:

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

Menu 7+:

Adjustable parameters: Y and PowerSave

Menu 8+:

Steering potentiometer adjustments

Menu 81+:

Drive wheel potentiometer adjustment

Menu 82 +: Reading of the potentiometer adjustments: gain and offset (only PC MASTER)

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Workshop literature 45408042303 EN 03/2007

The data expressed in the figure are purely indicative.

Workshop literature 45408042303 EN 03/2007

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Vs1

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

Window 32/61

Vs2

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

Window 32/61

Vpo

Power supply of potentiometers (Pin 8)

Window 32/61

Ub

Battery voltage

Window 32/6

Va1

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

Window 32/61

Va2

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

Window 32/61

Tpo

Temperature of module at the power MOS-FET

Window 32/6

On Time

Time passed since last switch-on

Window 33

Error Time

Time passed between last switch-on and last error detected

Window 33

DeadM

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

Window 4/41

SecRel AuxAB

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

StErr

Status of "drive deactivation" emergency output (0 drive enabled, 1 drive disabled)

Window 4/41

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.)

Window 4/41

Code

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

Window 4/41

SteerError

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

Window 5

Motor Relay

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

Window 5

Enable PWM

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

Window 51

MotRelay

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

Window 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)

Window 6

Us1

Voltage of steering potentiometer No. 1 (relative value)

Window 62

Us2 Ua1

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

Window 62 Window 62

Ua2

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

Window 62

Uak

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

Window 62

Ust

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

Window 62

Dif

Voltage differential between Ust and Uak

Window 62

SecRelay Imo Tmo

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Window 51 Window 6 Window 6 Window 6

Workshop literature 45408042303 EN 03/2007

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

Window 63

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

Window 63

Some electrical drive parameters can be adjusted

Distance between axes

Window 7

Steering potentiometer

Window 8

Drive wheel potentiometer

Window 81

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

Window 2

Breakdown codes and relative frequency memorised after the last RESET

Window 3

Breakdown sequence memorised in the LES card memory

Window 31

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

Window 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.

Workshop literature 45408042303 EN 03/2007

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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

24

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

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

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

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)

27

28

29

30

31

Emergency relay open during operation: the Open the LES module and check: safety relay is closed by the LES during norIf the internal k1 relay has a mechanical mal operation 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 cirwhen the key contact is closed, the cuit in the motor; in this case check: LES circuit examines the protection devices the power line, 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

-28

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)

Workshop literature 45408042303 EN 03/2007

33

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

HS motor (breakdown?)

Low quality connections on the whole power line Motor brushes damaged

34

Voltage supply to potentiometers outside Open the menu (61) to check the voltage limits. reading (between 9 and 9.5V) The voltage of the potentiometers is beyond Then open menu (32) which shows the the action allowed by the processor to guar- 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

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 Low quality connection connections.

Oxidised connector Potentiometer poorly fitted mechanically, involving stress at the edge of the tracks Potentiometer destroyed 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.

This overheating occurs in the module that Overheating of the stage at MOS-FET. 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

Output 11, which enables functioning of the As for code 41 LCD module, is inactive during normal functioning of the truck.

Workshop literature 45408042303 EN 03/2007

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43

44

45

46 50 70 71 72 73 74 80

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 interval 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 melted.

Low voltage: of battery (<13V) of potentiometer power supply (<7.9V) Broken or short circuited wire between Pins 16 and 24 (reduced speed signal).

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 pin 3 during functioning.

Failure to "RESET" the emergency microprocessor.

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

Different results on initialisation of the two processors.

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

Low quality exchange of cyclic data between the main processor and the emergency processor.

The left PWM signal does not correspond to Error generated only by the control procesthe difference between order and reading. sor

81

The right PWM signal does not correspond Error generated only by the control procesto the difference between order and reading. sor

82

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

Error generated only by the control processor

Lack of synchrony between the main processor and the control.

Cause: main processor synchrony signal absent on start up.

The first transfer of the correspondence curve by the main processor has not been carried out within the established time interval.

Typical microprocessor errors.

Error generated only by the control processor

83

84 90+

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Error generated only by the control processor

Workshop literature 45408042303 EN 03/2007

a

This is a three-phase motor with an internal triangular connection with the following characteristics: Voltage supply 14 V AC Nominal power 3 kW The use of a three-phase motor and the dedicated software present in the Inverter allow for the motor to be run with the following benefits: Low rotation noise Energy recovery with decreased energy consumption

It must also be emphasised that the motor is fitted onto the fixed part of the drive reducer and therefore remains immobile during steering. This gives the following advantages: It eliminates the risk of breakage of the electromagnetic brake supply cable due to torsion It eliminates the risk of breakage of the motor wires It reduces the minimum distance between the motor body and the more distant related components, allowing for a more compact motor compartment

No type of maintenance is required

Workshop literature 45408042303 EN 03/2007

-1

¾ Before removing the drive motor, the truck must be immobilised, the battery must be disconnected, and the casing and the part above the motor must be removed, then the wires must be disconnected as indicated in the figure.

It is advisable to immobilise the truck by blocking the load wheels or the stabiliser wheels. ¾ A ringbolt with pitch M8 is necessary.

¾ Screw the ringbolt, fixing it perfectly to the drive motor.

¾ Use a 6 mm Allen wrench, with a special length of 32 cm, to unscrew all the screws holding the motor.

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Workshop literature 45408042303 EN 03/2007

¾ With the aid of hoisting equipment, lift the motor out; the ringbolt must be securely attached to the lifting hook.

The motor must be extracted carefully so that the pinion of the motor and the respective gear that remains on the reducer do not strike one another, see the figure below.

The figure shows pinion (B) of the drive motor and sealing gasket (A) between the motor and reducer.

Remember that during reassembly of the drive motor it is also important to not strike or cut the gasket "A" and to spread a thin layer of grease on the gasket itself to facilitate introduction into its seat, see the figure to the side.

(C) Crown wheel of the upper cylindrical pinion gear that couples to the pinion of the drive motor.

¾ Fit the pinion onto the drive shaft and block with the special gasket at a torque of 50Nm.

Workshop literature 45408042303 EN 03/2007

-3

¾ Using the same oil as that used for the reducer, lubricate the O-ring fitted onto the flange of the drive motor before replacing the reducer.

¾ Position the drive motor so that the terminal board is in the same forward position. ¾ Tighten the plate with No. 8 screws at a torque of 11 Nm.

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Workshop literature 45408042303 EN 03/2007

a

Before proceeding to the removal of the drive reducer, it is necessary to:

It is also necessary to disassemble:

- stop the truck - disconnect the battery - remove the casing and disassemble all the parts above the reducer.

Part of these operations are explained in the paragraph

¾ Unscrew the screws on the anchorage plate with an Allen wrench as indicated in the figure.

Workshop literature 45408042303 EN 03/2007

-1

¾ Then unscrew the other screws on the anchorage plate with an Allen wrench, as indicated in the figure.

¾ Raise the plate upwards and extract it.

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Workshop literature 45408042303 EN 03/2007

¾ Harness the body of the reducer with two robust bands.

¾ Extract the reducer lifting it upwards; the bands must be perfectly hookedto the lifting hook.

The reducer must be extracted with care to avoid blows. ¾ When reassembling the drive reducer, repeat the sequence of operations in the opposite order. If the reducer has been replaced, check that the oil inspection and drain caps are closed before reinserting it into its seat.

¾ First fix the reducer anchorage plate with No. 8 screws and tighten to a torque of 40 Nm.

Workshop literature 45408042303 EN 03/2007

-3

¾ Then fix the anchorage plate to the forklift chassis using the special screws and tighten to a torque of 40 Nm.

¾ Fill with oil. Fill the cylindrical gear box half full with oil.

This reference is used when the drive motor is not fitted onto the reducer group.

For every lubrication, follow the safety standards and discard the used oil according to the legislation in force.

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Workshop literature 45408042303 EN 03/2007

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.

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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,

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Workshop literature 45408042303 EN 03/2007

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 45408042303 EN 03/2007

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.

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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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Workshop literature 45408042303 EN 03/2007

1.

2.

3.

23 Nm 170 Nm 300 Nm

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a

3

To access the battery (1) and relative plug/outlet, press down lightly on the battery compartment cover (2), at the same time pressing pushbutton (3), then raise the battery compartment cover (2).

2

To access the inner parts of the forklift (electronic, electric and mechanical parts), remove the hood (4) by unscrewing the relative screws.

1 Access to the inner parts of the forklift by personnel not authorized by the manufacturer is forbidden.

4

OM1257

¾ Unhook the tiller cover by pressing the specific button.

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¾ Raise the tiller cover.

¾ Unscrew the 5 fixing screws on the rear part of the plastic bonnet.

¾ Slide the plastic cover off the tiller.

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Workshop literature 45408042303 EN 03/2007

¾ Slide off the second cover.

¾ Remove the upper plastic bonnets.

¾ Raise the bonnet " ".

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¾ Unscrew the gas spring fixing screws from the battery compartment cover.

¾ Remove the fixing components.

¾ Remove the gas spring from the side of the battery compartment cover.

¾ Unscrew the gas spring from the truck chassis.

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¾ Remove the gas spring. ¾ To replace the gas spring, repeat the above instructions in the opposite order.

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a

The system is composed of the following components: 1 Potentiometer indicating the position of the tiller arm 2 Electronic L.E.S. control unit

3

The electrical L.E.S. driving system is used.

(Linde Electrical Steering).

at maximum, the other is at minimum. Each potentiometer has two tracks, completely separate from each other, which manage two separate voltages. The system guarantees 100 million operations.

Steering is rendered more rigid (handlebar shaft) by a disk brake system.

Braking is regulated in order to allow the operator to turn while stationary without excessive force and to go at maximum speed without a "loose steering" sensation.

The handlebar/wheel transmission ratio is 01:01.2, taking into account that the rotation of the shaft arm is equal to ±75° while that of the drive wheel is ±90°.

The potentiometers used are of the crossed double signal type (with redundancy): when one is

Workshop literature 45408042303 EN 03/2007

4 5

Potentiometer indicating the position of the drive wheel Electric steering motor PC with diagnostics software

The position of the steering potentiometer, coupled to the control organ (shaft/handlebars) by means of system of cog wheels, generates signals proportionate to the set rotation angle of the steering.

The position of the drive wheel potentiometer is coupled to the motor reducer with a system of cog wheels and generates signals proportionate to the position of the drive wheel.

-1

Nominal power supply voltage 24V d.c.

Maximum steering motor current 30A d.c.

High frequency Mos technology (Static) Real time control of the internal and external parts that can influence behaviour of the steering system with self-diagnosis of the same control circuits Supervisor microcontrollor that controls the functions of the main microcontrollor (Safety redundancy) When the handlebar shaft is turned, the voltage values on the steering position potentiometer vary.

L.E.S. control module which also receives the signal from the potentiometer of the real position of the steering driving wheel, and compares the values and controls the steering motor potentiometer. In addition, the L.E.S. control unit automatically recognises the truck on which it is installed and selects the corresponding parameters.

This is achieved by means of a wiring code that is different for each type of truck, with negative polarisation or non-connection of some L.E.S. control inputs.

There are 3 inputs and these are called:

Connected to

Disconnected

Disconnected

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: 1. Electrical command to open the relay contacts in the L.E.S. which cuts off the power supply to the electromagnetic brake.

2. The L.E.S. unit cuts off the power supply to the relay 7K1, disabling the deadman s switch authorisation, and activates the braking.

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Workshop literature 45408042303 EN 03/2007

1

Ground

Negative of the Test Module power supply

2

Safety-Relay A

Internal safety relay

3

Power-Relay

Negative of external power relay energy supply

4

Truck-Code A

Not used

5

Speed-Sensor A

Not used

6

Ground signal

Negative of steering/drive wheel potentiometer power supply

7

TX

Serial transmission of data for diagnostics

8

10V-supply

9

Force Steering

10

Act. Value-poti A

11

Enables drive

Value of instantaneous voltage of the drive wheel potentiometer A Enables drive

12

N.C.

Not connected

13

RX

Serial reception of data for diagnostics

14

Safety-Relay B

Internal safety relay

15

N.C.

Not connected

16

Steering display

Not used

17

Speed-sensor B

Not used

18

Truck-Code B

Not used

19

Setpoint-potiA

20

Setpoint-poti B

21

Truck-Code C

22

Act. Value-poti B

23

Footswitch +

24

Footswitch -

25

24V-supply

Workshop literature 45408042303 EN 03/2007

Positive of power supply to steering/drive wheel and Test Module potentiometers Permanentg activation of electrical drive

Voltage value (setting) of steering potentiometer A Voltage value (setting) of steering potentiometer B, used to monitor correct functioning of the potentiometers themselves Select the truck type and the relative parameters Instantaneous voltage value from the drive wheel potentiometer B, used to monitor correct functioning of the potentiometers themselves Not used Electrical drive activated with contact open or connected to the negative: micro dead man 24V control supply from battery

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¾ Before removing the steering motor reducer, immobilise the truck, disconnect the plug connected to the battery, and remove the casing, as indicated in the figure.

¾ Lift out the battery from above, using a pulley and the anchorage points indicated in the figure.

¾ Disconnect the motor wires with a special spanner.

¾ Above the motor, there are two boxes* which must be removed; before removing them, disconnect the connectors, then release the special lock springs. *One is the electrical drive box (LES) and the other is the brake system box (eABS).

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¾ Release the upper part of the motor reducer, then proceed to remove it.

¾ With an articulated "T" spanner, unscrew the 4 screws, as shown in the figure.

¾ Extract the motor reducer from the body, lifting it upwards.

The extraction of the steering motor reducer must be performed carefully so that its pinion does not hit the drive reducer gear.

¾

Pinion of the steering motor reducer.

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Gear of the drive reducer.

¾

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The steering potentiometer is intended as: the drive wheel position detection potentiometer.

To avoid calibration of the potentiometer after reassembling the same, before removing it do the following:

¾ Position the drive wheel exactly straight longitudinally. ¾ Make two reference marks between the potentiometer and the anchorage plate as indicated in the figure to the side.

¾ Remove the potentiometer complete with flange and pinion by loosening the two screws .

¾ Using a screwdriver as a lever, remove the potentiometer block from the anchorage plate.

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¾ Lift out, taking care not to hit and turn the potentiometer pinion to avoid modifying the cursor position.

¾ After removal of the potentiometer, two reference marks must be made between the potentiometer and its pinion as indicated in the figure.

Do not rotate the position of the pinion with respect to the potentiometer.

For the reassembly of the potentiometer group without replacing the components, simply repeat the sequence of operations in the opposite order, being careful to remount everything properly with the reference marks in place.

If instead one of the three components - potentiometer, reducer or pinion - is to be replaced, the pinion is disassembled by removing the elastic pin while the potentiometer is disassembled by removing the two fixing screws.

In this case the potentiometer must be adjusted before being reassembled on the anchorage plate of the drive reducer (see assembly instructions).

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The figure shows seat of the steering motor reducer group and seat of the potentiometer on the anchorage plate of the drive group . ¾ Position the steering motor reducer in its seat and the potentiometer in its seat .

¾ Mount the pinion pull tag steering motor reducer.

onto the shaft of the

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¾ Position the coupling flange on the motor reducer so that the machined part is facing to the left of the terminal board, as shown in the figure. Fit No. 4 screws and tighten to a torque of 20Nm. = machined part

¾ Fit the pinion onto the steering motor reducer shaft, being careful not to ruin the pull tag.

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¾ Fix the pinion with a safety screw and washer at a torque of 20 Nm.

¾ After tightening the screws, caulk a lip of the safety washer

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¾ Position the motor reducer in its seat turning the machined part of the coupling flange towards the drive motor.

¾ Fix the drive reducer group with No. 4 screws and tighten to a torque of 20Nm.

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¾ Fix the resistance on the drive reducer with the connecting nut on the terminal board. ¾ Position the puffer on the drive group plate and fix the resistance with the special screw, as indicated in the figure.

¾ Reassemble the two boxes of the tric drive and the controlled braking

elec-

¾ Reconnect the power supply cables to the terminal board of the electric drive motor.

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Potentiometer Reducer Pinion

¾ Fit the pinion onto the small shaft of the potentiometer reducer, pushing the elastic plug home with the help of a suitable tool.

¾ Fit the potentiometer with # 2 screws, as illustrated in the figure.

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¾ Before fixing the potentiometer group onto the anchorage plate of the drive steering motor reducer, the pinion must be rotated until the cursors are positioned in the central position of the potentiometer. This adjustment is performed by inserting a tester such as an ohmmeter onto the pins of the 3 X 4 connector of the potentiometer and performing some resistance measurements as indicated below.

PINION REDUCER POTENTIOMETER 3 X 4 CONNECTOR

¾ The double potentiometer is composed of two sections, each with a resistance of about 1000 Ohm, internally connected in parallel with one another, with cursors that move opposite each other so that when the potentiometer spindle rotates the total resistance value between the two cursors remains constant.

¾ Numbering of the 3X4 connector pins and their position in the connector.

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¾ Using a tester such as an ohmmeter, insert a tip of the tester on one of the two cursors (pin 1 or 2) of the 3 X 4 connector. Position the other tip first on one of the two ends of the potentiometer (pin 3) and then on the other (pin 4) and rotate the potentiometer until the two values read on the tester are equal.

Example: a) reading between pins 2 and 3 = 450± 5 b) reading between pins 2 and 4 = 450± 5

The value of 450 is indicative; furthermore, when using the other cursor as reference, reading the pin 1 resistance value with respect to the ends, pins 3 and 4, the reading may be quite different from the 450 indicated above.

¾ At this point the potentiometer is centered. , the potentiometer group can be inserted into its housing on the anchoring plate of the drive reducer, being careful not to move the pinion during assembly.

¾ After insertion of the potentiometer group into its housing on the anchoring plate, it is advised to remake the measurements described above in order to perfectly center the potentiometer, using the clearance provided by the two slots in the potentiometer s fixing flange.

The aforesaid adjustment is for preliminary purposes only; the final adjustment is performed using the PC and relative electrical drive diagnostics program (Menu 61), but this is possible only at the commissioning of the forklift.

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¾ Fix the potentiometer group to the plate. = potentiometer connector

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1.

2.

3.

Diagnostics PC L.E.S. interface 6 pin connector

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4.

5.

6.

4 pin connector L.E.S. 6X2 connector Forklift wiring

Workshop literature 45408042303 EN 03/2007

¾ Connect the special L.E.S. interface for serial communication to the COM1 port of the PC. ¾ Turn on the PC and start the communication program.

The LES_DIAG communication program requires a WINDOWS_95/98 operating system. If WINDOWS_2000 is used, it is advisable to use the MS_DOS boot disk provided during the course.

¾ Since it is not connected to the connector, an unconnected graphic will be displayed on the computer screen, represented by two red connectors separated from one another.

1. Connection on the COM1 2. Status of the connection 3. Help key

¾ Press the key at any point in the program to access the help page of each menu. To scroll the menu, press the keys and 1. Message display area 2. Bar graph that indicates the quantity and position of the pages of help messages

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¾ Insert the 4 pin connector of the interface into the connector of the L.E.S. system.

¾ Remove the fuse cover and extract the fuse . This is the main fuse of the electrical drive system.

Caution : during the electrical drive calibration procedure, remove the fuse . Insert it when indicated in the explanation, and before the final inspection.

¾ Lift the machine slightly off the ground and, through the oval hole in the body, perfectly align the drive wheel with the longitudinal axis of the machine.

¾ Make sure that the shaft head is in its rest position and perfectly straight.

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Workshop literature 45408042303 EN 03/2007

¾ Turn the key switch to the ON position. (started)

¾ After starting the truck the PC screen will display the connection graphic (green connectors joined together) and the system description will appear: manufacturer, EPROM version, and type of system. The program will automatically position on menu .

1. Number of the menu.

¾ Pass to the menu to begin the calibration.

To access menu 61 it is enough to press the keys 6 and 1 in this order. Then the effective value of the output voltage of the potentiometers will appear. = supply voltage of the potentiometers.

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¾ If during menu selection, the requested menu does not exist, an empty window will appear to indicate that the menu is incorrect with the presence of the symbol .

Type the number of an existing menu. See the table (menu diagram).

¾ Check that the voltage values regarding the shaft potentiometer and are equal

.

NOTE: some NoteBooks do not require pressure on the space bar. ¾ If the two values are not equal and the voltage difference is more than 1 Volt, the defect is due to the potentiometer and thus it should be replaced. The shaft potentiometer, in fact, has a fixed assembly position that centers automatically and cannot be adjusted. (see photo to the side ) ¾ For replacement of the potentiometer, the connector (1) must be disconnected and the screws (2) removed.

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¾ Then slip off the potentiometer.

¾ Adjustment of the drive wheel position potentiometer. Loosen the two screws and, making use of the possibility of rotation provided by the two slots in the potentiometer fixing flange, rotate the potentiometer group so that the value Va1 is equal to the value Va2.

If it is not possible to obtain this value, it means that the previous calibration performed with the tester was not sufficiently precise. In this case it is necessary to completely unscrew the two screws and extract the potentiometer group while leaving it electrically connected. It will be necessary to search for the aforesaid condition by turning the pinion of the potentiometer group while keeping the entire group in hand and then trying to reinsert it into its seat without moving it.

¾ At this point it is possible to tighten the two fixing screws definitively.

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¾ Position the PC on the truck. ¾ ¾ ¾

. The program will automatically connect with the L.E.S. system.

¾ ¾

The procedure described below assumes that the steering and drive wheel potentiometers have been assembled and set correctly. ¾ The setting occurs as follows: The shaft must not be moved before performing the adjustment.

Type Press

.

(First adjustment point).

If the potentiometer works correctly, 0 appears between some dashes or arrows; otherwise replace the steering potentiometer.

Press

to confirm;

Check for the presence of the OK message on the SetPadj C line.

Automatic access to the second setting point: Rotate the shaft clockwise until the stop.

Press the "SPACE BAR" (To see the live value). ¾ If the potentiometer works correctly, 0 appears between some dashes or arrows.

Press

to confirm;

Check for the presence of the OK message on the SetPadj C line.

The adjustment of the steering potentiometer is finished.

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Workshop literature 45408042303 EN 03/2007

Type

.

The procedure described below must be performed with the truck switched on. ¾ With the shaft in the central position operate the operation authorization levers and then release them.

The value indicated by the variable ActPadj C can be adjusted by some mV to the right (DX) and left (SX) of the zero point (error voltage).

With the truck stationary, observe the references on the reducer group which should be aligned, or check the coarse of the moving truck (shaft arm and drive wheel parallel to the forks).

The truck must move in a straight line.

Press signal will be heard.

to confirm; an acoustic

Check for the presence of the OK message on the Actpadj C line. ¾ Automatic access to the second setting point.

Rotate the shaft clockwise until the stop (space bar pressed).

Press

to confirm;

Check for the presence of the OK message on the Actpadj R line.

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If on key ignition the traction wheel vibrates and continues to vibrate, the sensitivity needs to be adjusted.

Enter menu with the PC and adjust the default parameters and .

P = 3.30

(ideal value)

D = 0.15

(ideal value)

If the parameters have already been modified, check that both the potentiometers are mechanically fastened well.

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If this doesn t work, start varying without going too far below the ideal value, otherwise the traction wheel group will become too slow in following the shaft.

The parameter ideal value of

should always be kept at the .

To increase or decrease the values, press the or

Workshop literature 45408042303 EN 03/2007

¾ Unhook the shaft bonnet by pressing on the specific button

¾ Raise the shaft bonnet.

At the back of the shaft bonnet, a plastic bonnet covering the potentiometer is accessible.

¾ Unscrew the 4 fixing screws of the plastic bonnet.

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¾ Remove the plastic bonnet.

In this way, the potentiometer can be reached.

¾ Disconnect the connector (1) and unscrew the two fixing screws (2).

At this point, the potentiometer can be removed.

¾ No calibration is necessary during reassembly.

In fact, the position of the potentiometer is determined by the fitting between the pin on the head side of the shaft and the compartment on the potentiometer itself.

¾

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Workshop literature 45408042303 EN 03/2007

Disconnect the battery

To act on the components of the shaft head, follow the instructions below. ¾ Unscrew the 4 fixing screws of the shaft head

¾ It is now possible to remove the shaft head

¾ Turn the shaft head 180° ¾ Block the head using two of the 4 fixing screws and the two supports on the side of the forks.

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¾ In this way, the removable cover of the shaft head is turned upwards, and it is possible to carry out operations on the shaft components (such as: butterfly levers, consent buttons).

¾ unscrew the fixing screws of the plastic cover

¾ Remove the cover using a screwdriver. ¾ At this point, the inside of the shaft head is accessible.

After removing the cover of the shaft head, access to the shaft head card is possible, where the shaft head buttons are connected. It is then possible to check the buttons of the shaft head, carrying out an Ohm test, for example.

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Workshop literature 45408042303 EN 03/2007

¾ Disconnect the relative connector of the button to be tested ¾ Position the push rods onto the pins corresponding to the buttons concerned, checking that the Ohm reading indicates a closed circuit when the button is pressed, and an open circuit when the button is released.

To identify the measuring points, observe the wiring on the shaft head itself, or consult the electrical diagram.

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¾ On the shaft card, disconnect the connector relative to the potentiometer.

¾ Loosen the screw holding the potentiometer group.

¾ To facilitate extraction of the shaft potentiometer group, disconnect also the connector indicated in the figure.

¾ At this point, the potentiometer group can be removed from the shaft head.

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¾ If it is necessary to replace the potentiometer, remove the butterfly lever, unscrewing the fixing screws.

The accelerator and gear selector functions are carried out using a plastic film potentiometer, suitably coupled to the shaft of the butterfly lever.

Inside the potentiometer, three separate tracks manage three separate signals: The analog potentiometer signal 0÷5 V as shown in the figure. The signal generated by the potentiometer is (as seen to the side) and is that managed directly by the .

Digital On signal (Rot. + 7°), Off (rest position) for the fork side gear lever.

Digital On signal (Rot. + 7°), Off (rest position) for the motor compartment side gear lever.

Rotation angle

¾ Using a pair of cutters, cut through the 3 elastic washers holding the shaft button cover onto the shaft head.

The elastic washers must be replaced during reassembly.

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¾ At this point, the horn cover can be removed, and then the horn card.

¾ To facilitate assembly, it is useful to fit one of the elastic washers onto the cover ...

¾ ... and then insert it into the seat, and then apply the other two washers.

The consent buttons are removed by simply disconnecting the relative connector from the shaft card, then sliding the wires, and the button including the plastic cover, spring and micro switch, from their seats. ¾ During reassembly, care must be taken to position the electric wires correctly, which could be frayed or broken by the cover. Position them as indicated in the figure.

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Workshop literature 45408042303 EN 03/2007

¾ Disconnect the connector of the button to remove the shaft card. ¾ With the aid of a screwdriver, move the pivot pin that holds the button to the tiller head.

¾ Remove the pivot pin completely with a pair of pliers.

¾ At this point the button card can be removed, and the relative plastic cover.

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¾ Free the shaft card from the various connectors. ¾ Unscrew the 2 fixing screws of the shaft card in order to remove it.

The fixing screws of the shaft card are not directly on the card, but there is a shim beneath each screw.

Take care not to remove the shim during reassembly.

This electronic card has the function of collecting the electric signals of the fork lifting / descent, horn, and platform lifting / descent buttons and the accelerator potentiometer, and sends them to the drive controller (Inverter) and partly to the eABS module.

This new card is also equipped with a an automatic heating system for the use of the truck in cold-storage rooms.

This system is constructed using Multilayer technology, and also includes a heat compensation circuit: the temperature of the logics is maintained within a set range (from 36°C to 42°C approx.) by the use of a heat sensor that reduces the current absorbed and thus also the power dissipated by the inbuilt voltage stabiliser (7805).

(Patented system).

The advantages obtained are: - Impossibility of the formation of condensation on the card.

- Elimination of additional costs for the transformation of standard logics to cold store type.

- Increased lifetime of the electronic components (the electronics used are of the automotive type).

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¾ Open the shaft head as described previously.

¾ Disconnecting the X4 connector, the shaft head is also disconnected electrically

¾ Unscrew the screws that anchor the shaft head to its support

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¾ Remove the fixing screws situated on the button side of the shaft head.

¾ At this point, release the shaft head from its support.

¾ After removal of the shaft head, it is possible to proceed to the removal of the

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¾ Remove the electrical drive control potentiometer from the shaft support housing, unscrewing its two fixing screws.

¾ Disconnect the shaft support housing from the truck by removing the four fixing screws. ¾ Without removing the cable, rest it on a work surface. ¾ The dashboard surface could be used for this purpose.

¾ Unscrew and remove the six M5 screws indicated in the figure that fasten the lower part to the central support.

¾ Slip the lower housing off the support.

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¾ Remove the seeger on the coupling pin between cam and rotating central support.

¾ Slip off the control spindle of the potentiometer and relative elastic joint.

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¾ Slip off the coupling pin between the cam and the central support.

Sheathing Cams Pin

¾ Slip the sheathing off the central support and the lower housing.

¾ Slip the cams off the central support.

Cams Central support

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¾ Slip off the centre plate

¾ Slip the turntable off the central shaft.

¾ At this point it is possible to extract the bearings and the elastic pins.

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¾

¾

¾ Slip off the roller cylinders.

-44

Workshop literature 45408042303 EN 03/2007

¾ Remove the gasket and slip off the springs.

¾ For the decomposition of the roller cylinders, remove the side screw and slip off the pin.

¾ The figure to the side shows the disassembled roller cylinders.

Workshop literature 45408042303 EN 03/2007

-45

For reassembly, it is necessary to proceed in the reverse order. ¾ Reassemble the lower part being careful that the two springs have different lengths, thus the roller cylinders will have different heights.

¾ Assemble the roller cylinders as indicated in the figure, inserting the washer on the screw side. Insert the roller with the wider part on the screw side and grease, in addition to the roller, the entire external part of the cylinder.

Washer Screw Wide part of roller Or Narrow part of roller ¾ Position the housing with the holes as shown in the figure, insert the two cylinders into their seats keeping in mind that the cylinder with the short spring goes on the left and the other on the right and that the screws on the cylinders must face the outside of the housing.

Cylinder with short spring Cylinder with long spring Reference holes

-46

Workshop literature 45408042303 EN 03/2007

¾ On the flat part of the rotating flange, insert the 5x20 mm elastic pin into the only unthreaded hole with 5.

Elastic pin Rotating flange

¾ When the central shaft is inserted into the rotating flange, position it so that the elastic pin remains on the same side as the threaded hole of the central shaft T plate.

Elastic pin T plate with threaded hole Central shaft

¾ Fit the central plate onto the shaft with the smaller diameter facing the flange.

Workshop literature 45408042303 EN 03/2007

-47

¾ Insert the sheathing into the lower part of the previously preassembled shaft housing.

¾ Fit the plastic cam onto the rotating flange. Fit the sheathing into the shaft and assemble the group using the special pin.

Sheathing Elastic pin Pin

Orientate the cam with the open part of the cone facing the elastic pin of the flange, also keeping the sheathing towards the elastic pin between the pin and the middle of the hole. Block the pin with the seeger.

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Workshop literature 45408042303 EN 03/2007

a

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

¾ Using a cross screwdriver, unscrew the 2 screws holding the cover, thus allowing access to the drive wheel.

¾ Remove the cover.

Workshop literature 45408042303 EN 03/2007

-1

¾ Reconnect the battery socket and plug and raise the emergency button if it is pushed down. ¾ Switch on the truck, turning the ignition key. ¾ Turn the shaft towards the right and keep it in this position, as shown in the figure.

¾ Keeping the shaft turned, press the emergency button.

This operation allows for the drive wheel to be turned with the shaft at rest, thus allowing access to the fixing screws of the wheel.

¾ Using a tube wrench, unscrew the screws fixing the drive wheel, which can be reached from the special oval shaped compartment. ¾ Harness and lift thetruck using a pulley of adequate capacity. ¾ Rest the truck in a safe manner on two wooden blocks ¾ Raise the emergency button, previously pressed. ¾ Turn the shaft towards the right, and keeping it in this position, gently turn the butterfly" ".

Turn the butterfly " "as far as necessary to permit access through the special oval shaped compartment to the screws still fixed to the drive wheel.

During this operation near the drive wheel while it is in motion.

¾ At this point, keeping the shaft turned, press the emergency button.

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Workshop literature 45408042303 EN 03/2007

¾ Using a tube wrench, unscrew the remaining screws holding the drive wheel.

¾ Remove the wheel. ¾ To refit the wheel, carry out the above sequence of operations in the opposite order, making sure to tighten the screws at .

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

Workshop literature 45408042303 EN 03/2007

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-4

Workshop literature 45408042303 EN 03/2007

a

The following braking devices are present:

Braking the stationary truck and emergency braking is carried out after every service braking or by pressing the emergency button, and it consists in the activation of the electromagnetic brake.

Inversion braking is carried out on the moving truck by inverting the direction using the butterfly lever controlling the drive. This is a modular type of braking: the braking effect increases as the inversion rotation angle of the butterfly lever is increased.

The following braking methods are used:

Service braking is electronically controlled by the eABS module.

By suitable management of the drive motor current on the part of the system, motor braking is achieved.

This system allows for use of the motor as a generator during braking, and to send the energy (current) to the battery (energy recovery).

This type of braking allows for a reduction in the heating of the motor (since there is no heat generated by friction braking) and a reduction in the wear of the electromagnetic brake disk.

¾ This device is controlled when current is on.

The magnetic field, created by supplying energy to the same, allows for the release of the brake: no active braking. When the current ceases, the brake is applied: active braking.

Braking is achieved by means of a system of helicoidal springs which push the brake disk onto the drive motor flange. The torque remains fixed during braking, both with and without load. ¾ The device chosen is a new type of brake without a brake torque regulation gasket (the springs are already pre-calibrated) and it is provided with a 2-way Saab connector socket.

kg

mm

mm

XLogo1

2000

0.3

± 0.05

XLogo2

1000

0.3

± 0.05

Workshop literature 45408042303 EN 03/2007

-1

¾ Before removing the electromagnetic brake, first immobilise the truck, disconnect the battery, and remove the casing

¾ The entire brake, at 360°, must be inspected, check the gap between the brake coil "A" and the pressure plate "B" with a feeler gauge. The correct gap is 0.35 mm.

¾ If the gap is too big, adjust the three screws "A" to bring it to the correct distance; the screws "A" can be adjusted by loosening first the screws "B"; the screws "B" must then be tightened after adjustment.

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Workshop literature 45408042303 EN 03/2007

¾ Before removing the electromagnetic brake, first immobilise the truck, disconnect the battery, and remove the casing

¾ Disconnect the 1X3 connector.

¾ Unscrew the Allen screws.

¾ Remove the coil "A" and the pressure plate "B".

Workshop literature 45408042303 EN 03/2007

-3

¾ Remove the brake disk.

¾ Extract the brake plate.

¾ Remove the circlip retaining the pinion, using a pair of circlip 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.

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Workshop literature 45408042303 EN 03/2007

This is a compound type of braking system, suitable managed by means of the anti-lock system (eABS), of the motor brake + the electromagnetic brake (patented system).

The whole is composed of the following components: Dead man consent handle on the handlebar controls (U.M.1, U.M.2) Drive controller eABS module Drive motor During braking the eABS system avoids wheel lock, as far as possible, by algorithms.

The advantages are the following: The deceleration imposed prevents the braked wheel from locking as far as possible Reduction of drive wheel wear Arrest distances are more reduced compared to friction braking when grip is scarce Arrest distance, at equal speed with loaded and unloaded truck, is the same under normal grip conditions When grip is scarce, the arrest 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 handle when the truck is in motion On release of the backing buttons

Apart from controlling braking on release of the dead man lever, the e-ABS module pilots 3 electromagnetic valves of 24V of the on-off type for management of ascent and descent of the forks and the platform and for activation of the 2K1 remote control switch for pump insertion.

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

Workshop literature 45408042303 EN 03/2007

-5

Automatic heating system of the thermo-compensated logic for use in refrigerator cells (As also the handlebar card) Output for external led indicating state and breakdowns On board Flash memory re-programmable

by Pc

¾ The eABS alarms are displayed by a status led, situated inside the 8-way fuse holder. ¾ In the case of an alarm, the status led creates a code (flash code) to indicate the type of anomaly. To interpret the code, the activated flashing must be observed.

All alarms block the truck (power supply to the electromagnetic brake is opened by the internal relay and the general K1 switch is opened)

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

/ Check wiring and replace module if necessary Check wiring and replace module if necessary Check wiring and replace contactor if necessary

Workshop literature 45408042303 EN 03/2007

Channel A encoder error

Incorrect channel "A" encoder signal

Check wiring and replace encoder or module if necessary

Channel B encoder error

Incorrect channel "B" encoder signal

Check wiring and replace encoder or module if necessary

Electromagnetic brake error

Brake coil or wiring open

Check the electromagnetic brake coil and associated wiring

Microprocessor KO

Replace module

Microprocessor KO or no power supply to logics

Check power supply fuse and replace if necessary

Main microprocessor error Main microprocessor error

Workshop literature 45408042303 EN 03/2007

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-8

Workshop literature 45408042303 EN 03/2007

a

1 2 3 4 5 5 5

24 Vdc battery Plug/socket Handlebar card eABS module Fork lowering solenoid valve Fork lifting solenoid valve K1 contactor coil

Workshop literature 45408042303 EN 03/2007

6 7 8 8 9 10 11

Inverter Drive motor Drive motor temperature sensor Drive motor encoder L.B.I. (Low battery charge indicator) Lifting motor 9K1 relay

-1

12 13 14 15 16 17 17 17 17 17 17 17 17 17

3K1 relay Fan Resistance Steering motor L.E.S. Controller Fork arms rested microswitch Step plate microswitch h12=300mm Step plate end limit microswitch Horn relay coil 2K1 contactor coil Fork lifting end limit switch Electromagnetic brake Alarm horn Emergency pushbutton

17 17 17 17 17 17 17 18 18 18 18 19 20

1K1 contactor coil Fuses Ignition key Load detector pressure switch Interlock 7K1 relay Battery cover position microswitch Chain loosening microswitch Drive wheel potentiometer Steering potentiometer Traction cut-out safety 3K1 relay control PC for diagnostics Operator presence pedal

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 45408042303 EN 03/2007

Ksi Prop. Driver

+24VDC input

2 3

Driver 4

4

Driver 3

Not used Cooling fan coil relay negative

5

Driver 2

Emergency brake negative

6

K2 general TLR negative

7

Driver 1 I/O ground

8

Ana_ 2

1

Not used

BDrive motor temperature sensor

9

Switch 3

10

Switch 4

Drive consent Speed reduction (6 km/h)

11

Switch 5

Backing consent

12

Switch 6

Load sensing pressurestat

13

Coil return Program

B+ auxiliaries Program input download

14 15 16 17 18

Throttle Potentiometer. High Throttle Potentiometer Wiper Brake Potentiometer Wiper

Not used Central drive potentiometer Analog brake signal

Potentiometer Low Digital Out1

Not used

19 20

Digital Out2

Not used

21

Can Term H

Not used

22

Switch 7

Drive towards tiller

23

CanH

24

Ana_ 1

Not used Speed reduction when turning (Drive wheel potentiometer)

25

+ 12V Out

26

+ 5V Out Brake Potentiometer Height

27

Not used

+ 12V Curtis console + 5V drive motor encoder Not used

27

TX Serial

Curtis console TX signal

29

Curtis console RX signal

30

RX Serial Analog Output

31

Speed Encoder A

Channel A encoder

32

Speed Encoder B

Channel B encoder

33

Switch 8

Drive towards forks

34

Can Term L

Not used

35

CanL

Not used

Not used

Workshop literature 45408042303 EN 03/2007

-3

Before removing the drive system, immobilise the truck, disconnect the battery plug and remove the casing to allow access to the plant. ¾ Disconnect the wires at the points indicated in the figure.

¾ Remove the connecting bar at the points indicated in the figure.

¾ Using a suitable wrench, unscrew the 4 screws holding the drive system.

¾ At this point, turn the system upside down, and with the aid of a screwdriver apply leverage to the pin locking the connector to the system.

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Workshop literature 45408042303 EN 03/2007

¾ Then, with one hand pull out the connector, and the system will be freed from the body.

¾ Instructions for the disassembly of the complete system support, as illustrated to the side, are given below.

¾ Free the wires connected to the electrical drive, unscrewing the fixing nuts.

¾ Disconnect the connector from the potentiometer.

Workshop literature 45408042303 EN 03/2007

-5

¾ Disconnect the power wires of the drive motor, unscrewing the three fixing screws.

¾ Disconnect the connector of the drive motor speed sensor.

¾ Disconnect the wires from the horn.

¾ Disconnect all the connectors fixed to the special support, shown in the diagram.

Fit two small pipes onto the system support to avoid leakage of the oil contained in the supply tank of the swivelling wheels.

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Workshop literature 45408042303 EN 03/2007

¾ Unscrew the pipe coupling on the solenoid valve group.

¾ Loosen coupling . After unscrewing this coupling, the pipe can be turned upwards and the appropriate accumulator can be connected to allow the complete system support to rest on the floor after being removed. ¾ Completely unscrew the coupling .

¾ Unscrew the four screws that fix the system support to the body.

Workshop literature 45408042303 EN 03/2007

-7

¾ Harness and remove the system support using slings and a hoist.

To refit the support, carry out the sequence of operations in reverse order.

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Workshop literature 45408042303 EN 03/2007

The fuses (1) are located under the motor compartment hood; to access them, remove the hood as indicated in the section on " ".

See the " " chapter for fuse values and replacement operations.

1

OM1275

Workshop literature 45408042303 EN 03/2007

-9

8

6 2

7

4 5

1

3

OM1291

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

Loosen the screws, replace fuses (7), (8) and retighten the screws.

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

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.

Access the fuses as indicated in the " " section.

Power fuses (7) and (8) are located near the contactors, the service fuses are located in the relative fuse box (fuses 1,2,3,4,5,6).

-10

= Fan safety fuse

= 5A

= Warning horn safety fuse = Safety fuse

= 10A

= Safety fuse

= 2A

= Steering safety fuse

= 2A

= 30A

= Data terminal safety fuse (optional) = Drive safety fuse

= 250A

= Lifting safety fuse

= 200A

= 8A

Workshop literature 45408042303 EN 03/2007

¾ Remove the "twist lock" band to free the supply wire of the battery state indicator and hour counter instrument.

¾ Remove the connector from the battery state indicator and hour counter instrument.

¾ Remove the battery state indicator and hour counter instrument by unscrewing the 2 screws holding it to the anchorage bracket.

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

See figure above).

Workshop literature 45408042303 EN 03/2007

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

-11

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.

For recharge conditions with the to the truck system while recharging, (for example: battery charger installed on board) the reset voltage is equal to 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).

1

2

3

OM1272

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

Disconnect the battery outlet (3) from the relative plug.

Raise the battery compartment hood (1) by pressing pushbutton (2).

Follow the battery replacement instructions relative to the setup of your forklift (version

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Workshop literature 45408042303 EN 03/2007

without battery extraction rollers or version with battery extraction rollers) provided below.

B

7

6

5

6 A

OM1273

Loosen the nuts (5) of the battery holddowns and turn the holddowns upwards to release the battery.

Hook the battery in the two points (6) with a non-metallic cable (7) of an adequate size for the weight of the battery.

Lift the battery upwards " " 2-3 centimeters, using a suitably sized hoist, then extract it laterally towards direction " ".

Workshop literature 45408042303 EN 03/2007

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

-13

5

4

OM1274

Place the battery extraction roller unit (4) next to the forklift, on the side indicated in the figure (see the relative section for information on how to use the roller unit).

Loosen the nuts (5) of the battery holddowns and turn the holddowns upwards to release the battery.

Slide the battery on the roller unit (4).

-14

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

Workshop literature 45408042303 EN 03/2007

D

E

F

A

C 1

D B

E 2

There are two versions of stands for lateral battery extraction: - A stand for batteries between 624 mm and 835 mm long and between 170 mm and 284 mm wide.

- A stand for batteries between 835 mm and 1223 mm long and between 283 mm and 443 mm wide.

Height-adjustable supports both versions.

F

are supplied for

Remove the adjustable supports and insert the forks of a pallet truck between 200 - 240 mm wide in positions (1).

C OM0763

Place the appropriate battery extraction stand level with the battery extraction point.

Raise battery holddown .

Release the battery from its holddown and pull it out until reaching the first roller of the roller unit..

Lift the roller unit until the roller rests on the bottom of the battery.

If you are using a manual pallet truck, turn its tiller 90°.

Pull out the battery until reaching the mechanical stop of roller unit .

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

Insert the forks of a pallet truck between 520560 mm wide in positions (2).

Workshop literature 45408042303 EN 03/2007

-15

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

1

OM0874

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Workshop literature 45408042303 EN 03/2007

3

2

1

OM1266

Charge the battery with the forklift turned off and the ignition key removed.

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

Connect outlet (3) to the battery charger to begin charging.

Turn on the external battery charger.

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

Disconnect the outlet (3) from the battery charger.

Replace the battery caps (if removed previously).

Press pushbutton (2) to raise the battery compartment hood (1).

Reconnect the battery outlet (3) to the plug.

Lower the battery compartment hood (1).

Disconnect the battery outlet (3) from the plug of the forklift s electronic equipment.

Workshop literature 45408042303 EN 03/2007

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Workshop literature 45408042303 EN 03/2007

a

Workshop literature 45408042303 EN 03/2007

-1

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Workshop literature 45408042303 EN 03/2007

a

¾ After removing the motors compartment bonnet, using a cross screwdriver, unscrew the screw of the connector shown in the figure.

¾ Disconnect the connector.

¾ Unscrew and remove the 2 nuts holding the power wires to the hydraulic control unit.

¾ Unscrew and remove the hydraulic control unit supply pipe.

Workshop literature 45408042303 EN 03/2007

-1

¾ Unscrew the screw holding the control unit to the truck.

¾ Remove the screw that has just been unscrewed and all the components shown to the side.

¾ Remove the control unit. ¾ To replace the hydraulic control unit, repeat the above instructions in the opposite order.

-2

Workshop literature 45408042303 EN 03/2007

¾ The mobile platform accumulator is positioned in the motor compartment near the left swivelling wheel.

¾ Unscrew the connection between the accumulator and the electromagnetic valves group.

¾ Unscrew the pipe-holding block. ¾ After releasing the pipe, the accumulator can be pulled off from above.

Workshop literature 45408042303 EN 03/2007

-3

Check the hydraulic oil level by placing the forklift on a flat surface with the forks completely lowered.

Turn off the forklift and remove the keys.

Remove the motor hood as indicated in the " " section.

2

Visually check that the hydraulic oil level is level with notch (1); if necessary, top up by removing cap (2) and pouring oil into the tank.

1

Use the type of oil indicated in the supply table.

OM1269

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Workshop literature 45408042303 EN 03/2007

a

¾ Lift the fork to the maximum height, and insert support shims.

¾ Remove the spring near the rod.

¾ With the aid of a hammer and a punch, remove the pin holding the cylinder rod to the chassis. ¾ At this point the bushing can be removed.

Workshop literature 45408042303 EN 03/2007

-1

¾ Press the fork descent button on the tiller head and simultaneously press on the cylinder rod to retract it into the cylinder.

Use a wooden instrument in order to avoid damaging the rod.

¾ Remove the spacer washers on the cylinder head, and measure the thickness of this pack of spacer washers.

The thickness of the pack of washers must be measured in order to reproduce the same thickness in the reassembly stage.

¾ Loosen the coupling at the base of the cylinder.

-2

Workshop literature 45408042303 EN 03/2007

¾ Unscrew the 4 fixing screws of the cylinder. ¾ Unscrew the coupling in order to completely remove the cylinder.

¾ Raise the platform in order to have space to manoeuvre, and block with a support to prevent accidental descent.

¾ Removethe plastic cover facing the forks, unscrewing the 4 fixing screws.

Continue by freeing the pipe at the various anchorage points.

¾ Open the pipe-holding block beneath the platform, unscrewing the relative screw.

Workshop literature 45408042303 EN 03/2007

-3

¾ Disconnect the pipe coupling (1) on the truck electromagnetic valve group.

Another anchorage point is situated under the battery. Therefore, the battery must be removed before continuing.

¾ Unscrew the fixing block situated under the battery.

After freeing the pipe at the various anchorage points, the truck must be raised in order to have the necessary manoeuvring space to free the pipe.

¾ Hook the truck at the two lateral anchorage points and raise it using a bridge crane or a lifting instrument with an adequate capacity.

-4

Workshop literature 45408042303 EN 03/2007

¾ Rest the structure on wooden planks.

¾ At this point the pipe can be removed, pulling out the flexible part from beneath the truck, and manoeuvring the rigid part so that it can be pulled out through the opening.

Workshop literature 45408042303 EN 03/2007

-5

¾ With the appropriate button on the tiller handlebar, raise the platform to the maximum height. ¾ Disconnect the battery plug and socket. ¾ Remove the cover of the runners.

¾ Loosen the 2 screws inside the profiles that hold "the packed".platform runners .

¾ Insert the shims necessary to eliminate play between the mobile platform and the runners.

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Workshop literature 45408042303 EN 03/2007

¾ Retighten the screws previously loosened, that hold "the packed" runners.

¾ The platform stroke-end rubber buffers are shown at the side:

¾ To adjust and, if necessary, replace the buffers, adjust or unscrew the buffer fixing screw with a spanner.

Workshop literature 45408042303 EN 03/2007

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-8

Workshop literature 45408042303 EN 03/2007

Workshop literature 45408042303 EN 03/2007

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Workshop literature 45408042303 EN 03/2007

¾ Fit the lifting cylinder into the clamp for its own supports. Using a gas blowlamp, or preferably an electric hot air device, heat the cap to soften the thread-stop.

¾ Using a compass wrench, unscrew and remove the cylinder tube cap.

¾ If the resistance of the thread-stop is too great, use a tube-turner to unscrew the cap, holding it by the edge.

Workshop literature 45408042303 EN 03/2007

-11

¾ The cylinder cap is equipped with an O-ring. If it is broken, due to excessive crushing or because it is too rigid, replace the O-ring.

¾ Using the special extraction tool, screw it into the threaded hole at the base of the rod.

Pulling, applying pressure on the handle, and pushing the head of the rod, extract it from the tube. The tool is also useful to keep the rod in the runner, avoiding friction between the chromed surface and the inside of the tube.

¾ During extraction of the rod, support it with the hand. After extracting the rod, place it on a soft surface or on a wooden surface with a V depression.

¾ Tighten the rod in a clamp, placing two aluminium corners between the rod and the clamps. Using a pair of expander pliers, such as those used for the elastic safety washers, widen the stop ring and, sliding it onto the edge of the rod, extract it from its seat and from the rod itself.

-12

Workshop literature 45408042303 EN 03/2007

¾ Using a flat tipped screwdriver with rounded edges, raise the scraper and extract it from the tube.

¾ Lift and extract the O-ring located above the gasket.

¾ Lift and extract the gasket from its seat.

¾ After greasing the various components of the lifting cylinder, check the efficiency and replace those that are worn.

Workshop literature 45408042303 EN 03/2007

-13

¾ Before starting to assemble the lifting cylinders, check the internal surface of the tube.

There must be no cracking in the material, or scoring in the gasket support seats.

¾ Start by inserting the gasket, pressing it on the outer edge. In the case of excess rigidity, soften it in hot water.

¾ Insert the scraper, pressing it on its outer edge.

In the case of excess rigidity, soften it in hot water.

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Workshop literature 45408042303 EN 03/2007

¾ Using a file for thread renewal, with the same pitch as the cap thread, remove thread-lock residues. Blow with compressed air.

¾ Apply a thin layer of grease on the gaskets of the cylinder tube.

¾ Using a file for thread renewal, with the same pitch as the cap thread, remove thread-lock residues. Blow with compressed air.

¾ Apply a thin layer of grease on the O-ring seat inside the cap. Fit on the O-ring, making sure that it adheres to the surface. The grease helps the O-ring to adhere during assembly.

Workshop literature 45408042303 EN 03/2007

-15

¾ Before inserting the rod into the tube, fit the elastic steel ring. If necessary, using very fine sandpaper, smoothen the seat of the elastic ring on the rod, if this has been scratched during extraction of the rod.

¾ Screw up the rod insertion device into the threaded hole. Insert the rod into the tube, taking care to avoid violent friction with the tube.

When the rod is resting on the gaskets, hit on the handle of the device with small blows with the palm of the hand. During the operation, keep the rod axis in line with that of the tube.

The rod must slide into the gasket pack.

¾ Apply a medium thread-lock on the cap threads. Screw the cap onto the tube; unscrew it and screw it on again a few times to spread the thread-lock evenly.

¾ Using a compass wrench, screw the cap home onto the tube.

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Workshop literature 45408042303 EN 03/2007

¾ Hit the compass wrench with a soft surfaced hammer to seal the cap.

¾ When the operation is finished, remember to fit the supply pipe coupling.

¾ Free the hinged area of the platform lifting cylinder.

¾ Remove also the low battery charge indicator as indicated previously.

Workshop literature 45408042303 EN 03/2007

-17

¾ Remove the battery state indicator and hour counter instrument by unscrewing the 2 screws holding it to the anchorage bracket.

¾ Unscrew and remove the nut on the screw holding the cylinder rod to the platform. ¾ Reconnect the battery plug and socket. ¾ With the special button on the handlebar shaft, raise the platform to the maximum height.

¾ Hold and block the platform by inserting chocks between the floor and the bottom of the platform, or as shown in the figure using a pulley with an adequate capacity.

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Workshop literature 45408042303 EN 03/2007

¾ Extract the screw that anchors the cylinder rod. ¾ The rod must now be made to completely enter into the tube of the platform lifting cylinder tube: With one hand, press the specific button to lower the platform and simultaneously, with the other hand, push the cylinder rod until it reaches the "stroke-end." ¾ Switch off the truck power supply by disconnecting the battery plug and socket.

¾ Unscrew the 4 nuts and relative 4 screws holding the anchorage bracket of the cylinder tube.

¾ The cylinder tube bracket can now be removed.

¾ Unscrew the cylinder supply pipe.

Workshop literature 45408042303 EN 03/2007

-19

¾ Remove the cylinder ¾ To service the cylinder, follow the instructions given in the relative chapter, or simply replace the cylinder with a new one, carrying out the sequence of procedures in the opposite order. ¾ If the cylinder lock valve needs to be replaced, unscrew and remove the coupling " ".

¾ Unscrew and remove the cylinder lock valve from its seat, using a seeger wrench.

¾ For access to the platform cylinder supply pipe, raise the platform to the maximum height with the specific button on the tiller handlebar. ¾ Unscrew the pipe connector nut from the coupling fitted at the base of the platform cylinder. ¾ Unscrew and remove the motor compartment bonnet.

¾ Unscrew the pipe connector nut from the T coupling fitted on the lock valve.

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Workshop literature 45408042303 EN 03/2007

¾ Remove the pipe and replace it carrying out the sequence in the opposite order.

a

Workshop literature 45408042303 EN 03/2007

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Workshop literature 45408042303 EN 03/2007

Copyright by OM Carrelli Elevatori S.p.A. Viale De Gasperi, 7 I-20020 Lainate www.om-mh.com 45408042303 EN Edition 03/2007

Workshop literature

Workshop literature 45408042303 EN 03/2007

a

(*2)

(*1)

(*2)

(*1)

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45408020003 - 1/5 (14-07-06)

(*4) (*3)

WH

BU

OG

BN

blue orange

brown

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white

Electronic control of electrical drive Electronic drive control Electronic e-ABS control Tiller card Safety fuse (2A) Safety fuse (10A) Safety fuse (8A) Drive safety fuse (250A) Lifting safety fuse (200A) Steering safety fuse (30A) Horn safety fuse (2A) Fan safety fuse (5A) Bimetal switch Battery General contactor contact Drive contactor contact Lifting contactor contact Electrical drive relay contact Horn relay coil Reverse gear warning buzzer Drive motor 3000W (AC) Lift motor 2200W (DC) Electrical drive motor reducer 600W (DC) Fan B.S.I. + counter Data terminal Resistance Key Chain loosening micro Chain loosening micro Emergency pushbutton Dashboard closure micro Handlebar handle micro (right) Handlebar handle micro (left) Roll-over protection micro Side closure micro (optional) Side closure micro (optional) Pedal micro (dead man) Peak suppressor diode Diode Battery plug-socket 7-pin DUBOX connector MTA UNIVAL 8-way fuse holder

black

A1 A2 A3 A4 F1 F2 F3 1F1 2F1 3F1 4F1 9F1 9F2 G1 K1 1K1 2K1 3K1 4K1 4H1 1M1 2M1 3M1 9M1 6P1 9P1 3R1 S1 S2 S3 7S1 7S3 7S4 7S5 7S6 7S7 7S8 7S9 1V1 2V1 X1 X2 X3

X4 X5 X6 X7 X8 X9 X10 X11 X12 X13 X14 X15 X16 1S4 1S5 1S6 1S7 2S1 2S2 2S3 2S4 2S5 2S6 4L1 4H2 4H3 4S1 V1 7K1 7K2 Y1 2Y1 2Y2 1X1 1X2 1X3 1X4 1X5 2X1 2X2 2X3 2X7 2X8

Insulator terminal 25-pin AMP connector Black 10-pin SAAB connector Black 10-pin SAAB connector Grey 6-pin SAAB connector 35-pin AMP SEAL connector Grey 10-pin SAAB connector Light blue 10-pin SAAB connector Light blue 10-pin SAAB connector 12-pin MOLEX connector Black 10-pin SAAB connector Black 4-pin SAAB connector Grey 6-pin SAAB connector Handlebar-side gear micro Fork-side gear micro Zero micro Cab 400 mm micro Fork lifting handlebar pushbutton (right) Fork descent handlebar pushbutton (right) Fork lifting handlebar pushbutton (left) Fork descent handlebar pushbutton (left) Platform lifting handlebar pushbutton Platform descent handlebar pushbutton Snubber Diode-Led Horn Horn handlebar pushbutton Diode INTERLOCK relay contacts Handle 1 relay Electromagnetic brake Electromagnetic valve Proportional electromagnetic valve Drive motor terminals Black 4-pin ITT CANNON connector Black 2-pin SAAB connector Grey 2-pin SAAB connector Black 4-pin JPT connector 4-pin MOLEX connector 4-pin MOLEX connector 4-pin MOLEX connector Black 4-pin ITT CANNON connector DIN 43650 connector

2X9 3X1 3X2 3X3 3X4 3X5 3X6 4X1 4X2 6X1 6X2 6X3 6P2 6P3 7X1 7X2 7X4 7X5 7X6 7X7 7X8 7X9 7X10 9X1 1B1 1B2 2B2 3K1 3R2 3R3 1R1 (*1) (*2) (*3) (*4) (*5) (*6) (*7) (*8) (*9) (*10) (*11) (*12)

YE GY

grey

RD

VT

GN red yellow

violet

green

DIN 43650 connector Welded cables 25-pin AMP connector 6-pin MOLEX connector 4-pin DEUTSCH connector Black 6-pin SAAB connector 4-pin DEUTSCH connector WITTRIN connector for micro-relay 4-pin MOLEX connector 8-pin MOLEX connector 4-pin MOLEX connector Black 4-pin SAAB connector CURTIS system console LES system console 4-pin MOLEX connector 4-pin MOLEX connector WITTRIN connector for micro-relay WITTRIN connector for micro-relay Black 4-pin ITT CANNON connector Black 3-pin ITT CANNON connector Black 3-pin ITT CANNON connector Black 3-pin ITT CANNON connector Black 4-pin ITT CANNON connector 2-pin AMP-SuperSeal connector Drive motor encoder Drive motor temperature sensor PT1000 Cab lifting stop microswitch Electrical drive relay coil Steering potentiometer Drive wheel potentiometer Drive potentiometer Dashboard Motor compartment Diagnosis Auxiliaries Fork descent Fork lifting Cab lifting Cab descent 4Km/h speed reduction Lifting consent Lifting cab braking Diagnostics

(*13) (*14) (*15) (*16) (*17) (*18) (*19) (*20) (*21) (*22) (*23) (*24) (*25) (*26) (*27) (*28) (*29) (*30) (*31) (*32) (*33) (*34) (*35) (*36) (*37) (*38) (*39) (*40) (*41) (*42) (*43) (*44) (*45) (*46) (*47) (*48) (*49) (*50) (*51) (*52)

Workshop literature 45408042303 EN 03/2007

Handle 1 Handle 2 Gear on fork side Gear on handlebar side Drive potentiometer Horn Potentiometer (+) Potentiometer (-) Proportional driver Program Load pressure gauge Drive consent Gear consent on forks side Braking analog signal Forced activation Safety relay Driver 4 Free Console (rx) Console (tx) GND logic Analog output Drive motor temp. sensor Brake signal Channel A encoder Channel B encoder Speed reduction in curve Speed sensor Drive block Truck code Relay Steering potentiometer Steering position Horn Drive wheel potentiometer Pot. GND Dead man consent Double dead man consent Platform lifting Platform descent

Workshop literature 45408042303 EN 03/2007

(*2)

(*1)

(*1)

(*21)

(*22)

(*5) (*6) (*7) (*8) (*5) (*6) (*7) (*8)

(*9)

(*10) (*11) (*12) (*13) (*14)

(*15) (*16) (*17) (*18)

(*17) (*16)

-3

(*2)

(*1)

45408020003 - 2/5 (14-07-06)

(*15) (*19) (*20)

WH

BU

OG

BN

blue orange

brown

-4

BK

white

Electronic control of electrical drive Electronic drive control Electronic e-ABS control Tiller card Safety fuse (2A) Safety fuse (10A) Safety fuse (8A) Drive safety fuse (250A) Lifting safety fuse (200A) Steering safety fuse (30A) Horn safety fuse (2A) Fan safety fuse (5A) Bimetal switch Battery General contactor contact Drive contactor contact Lifting contactor contact Electrical drive relay contact Horn relay coil Reverse gear warning buzzer Drive motor 3000W (AC) Lift motor 2200W (DC) Electrical drive motor reducer 600W (DC) Fan B.S.I. + counter Data terminal Resistance Key Chain loosening micro Chain loosening micro Emergency pushbutton Dashboard closure micro Handlebar handle micro (right) Handlebar handle micro (left) Roll-over protection micro Side closure micro (optional) Side closure micro (optional) Pedal micro (dead man) Peak suppressor diode Diode Battery plug-socket 7-pin DUBOX connector MTA UNIVAL 8-way fuse holder

black

A1 A2 A3 A4 F1 F2 F3 1F1 2F1 3F1 4F1 9F1 9F2 G1 K1 1K1 2K1 3K1 4K1 4H1 1M1 2M1 3M1 9M1 6P1 9P1 3R1 S1 S2 S3 7S1 7S3 7S4 7S5 7S6 7S7 7S8 7S9 1V1 2V1 X1 X2 X3

X4 X5 X6 X7 X8 X9 X10 X11 X12 X13 X14 X15 X16 1S4 1S5 1S6 1S7 2S1 2S2 2S3 2S4 2S5 2S6 4L1 4H2 4H3 4S1 V1 7K1 7K2 Y1 2Y1 2Y2 1X1 1X2 1X3 1X4 1X5 2X1 2X2 2X3 2X7 2X8

Insulator terminal 25-pin AMP connector Black 10-pin SAAB connector Black 10-pin SAAB connector Grey 6-pin SAAB connector 35-pin AMP SEAL connector Grey 10-pin SAAB connector Light blue 10-pin SAAB connector Light blue 10-pin SAAB connector 12-pin MOLEX connector Black 10-pin SAAB connector Black 4-pin SAAB connector Grey 6-pin SAAB connector Handlebar-side gear micro Fork-side gear micro Zero micro Cab 400 mm micro Fork lifting handlebar pushbutton (right) Fork descent handlebar pushbutton (right) Fork lifting handlebar pushbutton (left) Fork descent handlebar pushbutton (left) Platform lifting handlebar pushbutton Platform descent handlebar pushbutton Snubber Diode-Led Horn Horn handlebar pushbutton Diode INTERLOCK relay contacts Handle 1 relay Electromagnetic brake Electromagnetic valve Proportional electromagnetic valve Drive motor terminals Black 4-pin ITT CANNON connector Black 2-pin SAAB connector Grey 2-pin SAAB connector Black 4-pin JPT connector 4-pin MOLEX connector 4-pin MOLEX connector 4-pin MOLEX connector Black 4-pin ITT CANNON connector DIN 43650 connector

2X9 3X1 3X2 3X3 3X4 3X5 3X6 4X1 4X2 6X1 6X2 6X3 6P2 6P3 7X1 7X2 7X4 7X5 7X6 7X7 7X8 7X9 7X10 9X1 1B1 1B2 2B2 3K1 3R2 3R3 1R1 (*1) (*2) (*3) (*4) (*5) (*6) (*7) (*8) (*9) (*10) (*11) (*12)

YE GY

grey

RD

VT

GN red yellow

violet

green

DIN 43650 connector Welded cables 25-pin AMP connector 6-pin MOLEX connector 4-pin DEUTSCH connector Black 6-pin SAAB connector 4-pin DEUTSCH connector WITTRIN connector for micro-relay 4-pin MOLEX connector 8-pin MOLEX connector 4-pin MOLEX connector Black 4-pin SAAB connector CURTIS system console LES system console 4-pin MOLEX connector 4-pin MOLEX connector WITTRIN connector for micro-relay WITTRIN connector for micro-relay Black 4-pin ITT CANNON connector Black 3-pin ITT CANNON connector Black 3-pin ITT CANNON connector Black 3-pin ITT CANNON connector Black 4-pin ITT CANNON connector 2-pin AMP-SuperSeal connector Drive motor encoder Drive motor temperature sensor PT1000 Cab lifting stop microswitch Electrical drive relay coil Steering potentiometer Drive wheel potentiometer Drive potentiometer Dashboard Motor compartment Diagnosis Auxiliaries Fork descent Fork lifting Cab lifting Cab descent 4Km/h speed reduction Lifting consent Lifting cab braking Diagnostics

(*13) (*14) (*15) (*16) (*17) (*18) (*19) (*20) (*21) (*22) (*23) (*24) (*25) (*26) (*27) (*28) (*29) (*30) (*31) (*32) (*33) (*34) (*35) (*36) (*37) (*38) (*39) (*40) (*41) (*42) (*43) (*44) (*45) (*46) (*47) (*48) (*49) (*50) (*51) (*52)

Workshop literature 45408042303 EN 03/2007

Handle 1 Handle 2 Gear on fork side Gear on handlebar side Drive potentiometer Horn Potentiometer (+) Potentiometer (-) Proportional driver Program Load pressure gauge Drive consent Gear consent on forks side Braking analog signal Forced activation Safety relay Driver 4 Free Console (rx) Console (tx) GND logic Analog output Drive motor temp. sensor Brake signal Channel A encoder Channel B encoder Speed reduction in curve Speed sensor Drive block Truck code Relay Steering potentiometer Steering position Horn Drive wheel potentiometer Pot. GND Dead man consent Double dead man consent Platform lifting Platform descent

(*24)

(*24)

Workshop literature 45408042303 EN 03/2007

(*2)

(*1)

(*23)

(*2)

(*4)

(*13)

(*13)

(*25)

(*28)

(*28)

(*27)

(*26)

(*26)

45408020003 - 3/5 (14-07-06)

-5

(*2)

(*2)

WH

BU

OG

BN

blue orange

brown

-6

BK

white

Electronic control of electrical drive Electronic drive control Electronic e-ABS control Tiller card Safety fuse (2A) Safety fuse (10A) Safety fuse (8A) Drive safety fuse (250A) Lifting safety fuse (200A) Steering safety fuse (30A) Horn safety fuse (2A) Fan safety fuse (5A) Bimetal switch Battery General contactor contact Drive contactor contact Lifting contactor contact Electrical drive relay contact Horn relay coil Reverse gear warning buzzer Drive motor 3000W (AC) Lift motor 2200W (DC) Electrical drive motor reducer 600W (DC) Fan B.S.I. + counter Data terminal Resistance Key Chain loosening micro Chain loosening micro Emergency pushbutton Dashboard closure micro Handlebar handle micro (right) Handlebar handle micro (left) Roll-over protection micro Side closure micro (optional) Side closure micro (optional) Pedal micro (dead man) Peak suppressor diode Diode Battery plug-socket 7-pin DUBOX connector MTA UNIVAL 8-way fuse holder

black

A1 A2 A3 A4 F1 F2 F3 1F1 2F1 3F1 4F1 9F1 9F2 G1 K1 1K1 2K1 3K1 4K1 4H1 1M1 2M1 3M1 9M1 6P1 9P1 3R1 S1 S2 S3 7S1 7S3 7S4 7S5 7S6 7S7 7S8 7S9 1V1 2V1 X1 X2 X3

X4 X5 X6 X7 X8 X9 X10 X11 X12 X13 X14 X15 X16 1S4 1S5 1S6 1S7 2S1 2S2 2S3 2S4 2S5 2S6 4L1 4H2 4H3 4S1 V1 7K1 7K2 Y1 2Y1 2Y2 1X1 1X2 1X3 1X4 1X5 2X1 2X2 2X3 2X7 2X8

Insulator terminal 25-pin AMP connector Black 10-pin SAAB connector Black 10-pin SAAB connector Grey 6-pin SAAB connector 35-pin AMP SEAL connector Grey 10-pin SAAB connector Light blue 10-pin SAAB connector Light blue 10-pin SAAB connector 12-pin MOLEX connector Black 10-pin SAAB connector Black 4-pin SAAB connector Grey 6-pin SAAB connector Handlebar-side gear micro Fork-side gear micro Zero micro Cab 400 mm micro Fork lifting handlebar pushbutton (right) Fork descent handlebar pushbutton (right) Fork lifting handlebar pushbutton (left) Fork descent handlebar pushbutton (left) Platform lifting handlebar pushbutton Platform descent handlebar pushbutton Snubber Diode-Led Horn Horn handlebar pushbutton Diode INTERLOCK relay contacts Handle 1 relay Electromagnetic brake Electromagnetic valve Proportional electromagnetic valve Drive motor terminals Black 4-pin ITT CANNON connector Black 2-pin SAAB connector Grey 2-pin SAAB connector Black 4-pin JPT connector 4-pin MOLEX connector 4-pin MOLEX connector 4-pin MOLEX connector Black 4-pin ITT CANNON connector DIN 43650 connector

2X9 3X1 3X2 3X3 3X4 3X5 3X6 4X1 4X2 6X1 6X2 6X3 6P2 6P3 7X1 7X2 7X4 7X5 7X6 7X7 7X8 7X9 7X10 9X1 1B1 1B2 2B2 3K1 3R2 3R3 1R1 (*1) (*2) (*3) (*4) (*5) (*6) (*7) (*8) (*9) (*10) (*11) (*12)

YE GY

grey

RD

VT

GN red yellow

violet

green

DIN 43650 connector Welded cables 25-pin AMP connector 6-pin MOLEX connector 4-pin DEUTSCH connector Black 6-pin SAAB connector 4-pin DEUTSCH connector WITTRIN connector for micro-relay 4-pin MOLEX connector 8-pin MOLEX connector 4-pin MOLEX connector Black 4-pin SAAB connector CURTIS system console LES system console 4-pin MOLEX connector 4-pin MOLEX connector WITTRIN connector for micro-relay WITTRIN connector for micro-relay Black 4-pin ITT CANNON connector Black 3-pin ITT CANNON connector Black 3-pin ITT CANNON connector Black 3-pin ITT CANNON connector Black 4-pin ITT CANNON connector 2-pin AMP-SuperSeal connector Drive motor encoder Drive motor temperature sensor PT1000 Cab lifting stop microswitch Electrical drive relay coil Steering potentiometer Drive wheel potentiometer Drive potentiometer Dashboard Motor compartment Diagnosis Auxiliaries Fork descent Fork lifting Cab lifting Cab descent 4Km/h speed reduction Lifting consent Lifting cab braking Diagnostics

(*13) (*14) (*15) (*16) (*17) (*18) (*19) (*20) (*21) (*22) (*23) (*24) (*25) (*26) (*27) (*28) (*29) (*30) (*31) (*32) (*33) (*34) (*35) (*36) (*37) (*38) (*39) (*40) (*41) (*42) (*43) (*44) (*45) (*46) (*47) (*48) (*49) (*50) (*51) (*52)

Workshop literature 45408042303 EN 03/2007

Handle 1 Handle 2 Gear on fork side Gear on handlebar side Drive potentiometer Horn Potentiometer (+) Potentiometer (-) Proportional driver Program Load pressure gauge Drive consent Gear consent on forks side Braking analog signal Forced activation Safety relay Driver 4 Free Console (rx) Console (tx) GND logic Analog output Drive motor temp. sensor Brake signal Channel A encoder Channel B encoder Speed reduction in curve Speed sensor Drive block Truck code Relay Steering potentiometer Steering position Horn Drive wheel potentiometer Pot. GND Dead man consent Double dead man consent Platform lifting Platform descent

Workshop literature 45408042303 EN 03/2007

(*29)

(*31) (*33) (*32) (*34) (*30) (*35) (*36)

(*37) (*38) (*39)

(*37) (*38) (*30) (*30)

(*40) (*40) (*41) (*42) (*43)

(*30) (*44) (*30) (*45) (*44) (*47) (*48) (*42) (*47)

-7

45408020003 - 4/5 (14-07-06)

(*30) (*32) (*31) (*33) (*42)

(*2)

(*2)

(*30)

WH

BU

OG

BN

blue orange

brown

-8

BK

white

Electronic control of electrical drive Electronic drive control Electronic e-ABS control Tiller card Safety fuse (2A) Safety fuse (10A) Safety fuse (8A) Drive safety fuse (250A) Lifting safety fuse (200A) Steering safety fuse (30A) Horn safety fuse (2A) Fan safety fuse (5A) Bimetal switch Battery General contactor contact Drive contactor contact Lifting contactor contact Electrical drive relay contact Horn relay coil Reverse gear warning buzzer Drive motor 3000W (AC) Lift motor 2200W (DC) Electrical drive motor reducer 600W (DC) Fan B.S.I. + counter Data terminal Resistance Key Chain loosening micro Chain loosening micro Emergency pushbutton Dashboard closure micro Handlebar handle micro (right) Handlebar handle micro (left) Roll-over protection micro Side closure micro (optional) Side closure micro (optional) Pedal micro (dead man) Peak suppressor diode Diode Battery plug-socket 7-pin DUBOX connector MTA UNIVAL 8-way fuse holder

black

A1 A2 A3 A4 F1 F2 F3 1F1 2F1 3F1 4F1 9F1 9F2 G1 K1 1K1 2K1 3K1 4K1 4H1 1M1 2M1 3M1 9M1 6P1 9P1 3R1 S1 S2 S3 7S1 7S3 7S4 7S5 7S6 7S7 7S8 7S9 1V1 2V1 X1 X2 X3

X4 X5 X6 X7 X8 X9 X10 X11 X12 X13 X14 X15 X16 1S4 1S5 1S6 1S7 2S1 2S2 2S3 2S4 2S5 2S6 4L1 4H2 4H3 4S1 V1 7K1 7K2 Y1 2Y1 2Y2 1X1 1X2 1X3 1X4 1X5 2X1 2X2 2X3 2X7 2X8

Insulator terminal 25-pin AMP connector Black 10-pin SAAB connector Black 10-pin SAAB connector Grey 6-pin SAAB connector 35-pin AMP SEAL connector Grey 10-pin SAAB connector Light blue 10-pin SAAB connector Light blue 10-pin SAAB connector 12-pin MOLEX connector Black 10-pin SAAB connector Black 4-pin SAAB connector Grey 6-pin SAAB connector Handlebar-side gear micro Fork-side gear micro Zero micro Cab 400 mm micro Fork lifting handlebar pushbutton (right) Fork descent handlebar pushbutton (right) Fork lifting handlebar pushbutton (left) Fork descent handlebar pushbutton (left) Platform lifting handlebar pushbutton Platform descent handlebar pushbutton Snubber Diode-Led Horn Horn handlebar pushbutton Diode INTERLOCK relay contacts Handle 1 relay Electromagnetic brake Electromagnetic valve Proportional electromagnetic valve Drive motor terminals Black 4-pin ITT CANNON connector Black 2-pin SAAB connector Grey 2-pin SAAB connector Black 4-pin JPT connector 4-pin MOLEX connector 4-pin MOLEX connector 4-pin MOLEX connector Black 4-pin ITT CANNON connector DIN 43650 connector

2X9 3X1 3X2 3X3 3X4 3X5 3X6 4X1 4X2 6X1 6X2 6X3 6P2 6P3 7X1 7X2 7X4 7X5 7X6 7X7 7X8 7X9 7X10 9X1 1B1 1B2 2B2 3K1 3R2 3R3 1R1 (*1) (*2) (*3) (*4) (*5) (*6) (*7) (*8) (*9) (*10) (*11) (*12)

YE GY

grey

RD

VT

GN red yellow

violet

green

DIN 43650 connector Welded cables 25-pin AMP connector 6-pin MOLEX connector 4-pin DEUTSCH connector Black 6-pin SAAB connector 4-pin DEUTSCH connector WITTRIN connector for micro-relay 4-pin MOLEX connector 8-pin MOLEX connector 4-pin MOLEX connector Black 4-pin SAAB connector CURTIS system console LES system console 4-pin MOLEX connector 4-pin MOLEX connector WITTRIN connector for micro-relay WITTRIN connector for micro-relay Black 4-pin ITT CANNON connector Black 3-pin ITT CANNON connector Black 3-pin ITT CANNON connector Black 3-pin ITT CANNON connector Black 4-pin ITT CANNON connector 2-pin AMP-SuperSeal connector Drive motor encoder Drive motor temperature sensor PT1000 Cab lifting stop microswitch Electrical drive relay coil Steering potentiometer Drive wheel potentiometer Drive potentiometer Dashboard Motor compartment Diagnosis Auxiliaries Fork descent Fork lifting Cab lifting Cab descent 4Km/h speed reduction Lifting consent Lifting cab braking Diagnostics

(*13) (*14) (*15) (*16) (*17) (*18) (*19) (*20) (*21) (*22) (*23) (*24) (*25) (*26) (*27) (*28) (*29) (*30) (*31) (*32) (*33) (*34) (*35) (*36) (*37) (*38) (*39) (*40) (*41) (*42) (*43) (*44) (*45) (*46) (*47) (*48) (*49) (*50) (*51) (*52)

Workshop literature 45408042303 EN 03/2007

Handle 1 Handle 2 Gear on fork side Gear on handlebar side Drive potentiometer Horn Potentiometer (+) Potentiometer (-) Proportional driver Program Load pressure gauge Drive consent Gear consent on forks side Braking analog signal Forced activation Safety relay Driver 4 Free Console (rx) Console (tx) GND logic Analog output Drive motor temp. sensor Brake signal Channel A encoder Channel B encoder Speed reduction in curve Speed sensor Drive block Truck code Relay Steering potentiometer Steering position Horn Drive wheel potentiometer Pot. GND Dead man consent Double dead man consent Platform lifting Platform descent

Workshop literature 45408042303 EN 03/2007

(*49)

(*46)

(*52)

(*51)

(*5)

(*6)

(*17)

(*16)

(*15)

(*50)

-9

45408020003 - 5/5 (14-07-06)

WH

BU

OG

BN

blue orange

brown

-10

BK

white

Electronic control of electrical drive Electronic drive control Electronic e-ABS control Tiller card Safety fuse (2A) Safety fuse (10A) Safety fuse (8A) Drive safety fuse (250A) Lifting safety fuse (200A) Steering safety fuse (30A) Horn safety fuse (2A) Fan safety fuse (5A) Bimetal switch Battery General contactor contact Drive contactor contact Lifting contactor contact Electrical drive relay contact Horn relay coil Reverse gear warning buzzer Drive motor 3000W (AC) Lift motor 2200W (DC) Electrical drive motor reducer 600W (DC) Fan B.S.I. + counter Data terminal Resistance Key Chain loosening micro Chain loosening micro Emergency pushbutton Dashboard closure micro Handlebar handle micro (right) Handlebar handle micro (left) Roll-over protection micro Side closure micro (optional) Side closure micro (optional) Pedal micro (dead man) Peak suppressor diode Diode Battery plug-socket 7-pin DUBOX connector MTA UNIVAL 8-way fuse holder

black

A1 A2 A3 A4 F1 F2 F3 1F1 2F1 3F1 4F1 9F1 9F2 G1 K1 1K1 2K1 3K1 4K1 4H1 1M1 2M1 3M1 9M1 6P1 9P1 3R1 S1 S2 S3 7S1 7S3 7S4 7S5 7S6 7S7 7S8 7S9 1V1 2V1 X1 X2 X3

X4 X5 X6 X7 X8 X9 X10 X11 X12 X13 X14 X15 X16 1S4 1S5 1S6 1S7 2S1 2S2 2S3 2S4 2S5 2S6 4L1 4H2 4H3 4S1 V1 7K1 7K2 Y1 2Y1 2Y2 1X1 1X2 1X3 1X4 1X5 2X1 2X2 2X3 2X7 2X8

Insulator terminal 25-pin AMP connector Black 10-pin SAAB connector Black 10-pin SAAB connector Grey 6-pin SAAB connector 35-pin AMP SEAL connector Grey 10-pin SAAB connector Light blue 10-pin SAAB connector Light blue 10-pin SAAB connector 12-pin MOLEX connector Black 10-pin SAAB connector Black 4-pin SAAB connector Grey 6-pin SAAB connector Handlebar-side gear micro Fork-side gear micro Zero micro Cab 400 mm micro Fork lifting handlebar pushbutton (right) Fork descent handlebar pushbutton (right) Fork lifting handlebar pushbutton (left) Fork descent handlebar pushbutton (left) Platform lifting handlebar pushbutton Platform descent handlebar pushbutton Snubber Diode-Led Horn Horn handlebar pushbutton Diode INTERLOCK relay contacts Handle 1 relay Electromagnetic brake Electromagnetic valve Proportional electromagnetic valve Drive motor terminals Black 4-pin ITT CANNON connector Black 2-pin SAAB connector Grey 2-pin SAAB connector Black 4-pin JPT connector 4-pin MOLEX connector 4-pin MOLEX connector 4-pin MOLEX connector Black 4-pin ITT CANNON connector DIN 43650 connector

2X9 3X1 3X2 3X3 3X4 3X5 3X6 4X1 4X2 6X1 6X2 6X3 6P2 6P3 7X1 7X2 7X4 7X5 7X6 7X7 7X8 7X9 7X10 9X1 1B1 1B2 2B2 3K1 3R2 3R3 1R1 (*1) (*2) (*3) (*4) (*5) (*6) (*7) (*8) (*9) (*10) (*11) (*12)

YE GY

grey

RD

VT

GN red yellow

violet

green

DIN 43650 connector Welded cables 25-pin AMP connector 6-pin MOLEX connector 4-pin DEUTSCH connector Black 6-pin SAAB connector 4-pin DEUTSCH connector WITTRIN connector for micro-relay 4-pin MOLEX connector 8-pin MOLEX connector 4-pin MOLEX connector Black 4-pin SAAB connector CURTIS system console LES system console 4-pin MOLEX connector 4-pin MOLEX connector WITTRIN connector for micro-relay WITTRIN connector for micro-relay Black 4-pin ITT CANNON connector Black 3-pin ITT CANNON connector Black 3-pin ITT CANNON connector Black 3-pin ITT CANNON connector Black 4-pin ITT CANNON connector 2-pin AMP-SuperSeal connector Drive motor encoder Drive motor temperature sensor PT1000 Cab lifting stop microswitch Electrical drive relay coil Steering potentiometer Drive wheel potentiometer Drive potentiometer Dashboard Motor compartment Diagnosis Auxiliaries Fork descent Fork lifting Cab lifting Cab descent 4Km/h speed reduction Lifting consent Lifting cab braking Diagnostics

(*13) (*14) (*15) (*16) (*17) (*18) (*19) (*20) (*21) (*22) (*23) (*24) (*25) (*26) (*27) (*28) (*29) (*30) (*31) (*32) (*33) (*34) (*35) (*36) (*37) (*38) (*39) (*40) (*41) (*42) (*43) (*44) (*45) (*46) (*47) (*48) (*49) (*50) (*51) (*52)

Workshop literature 45408042303 EN 03/2007

Handle 1 Handle 2 Gear on fork side Gear on handlebar side Drive potentiometer Horn Potentiometer (+) Potentiometer (-) Proportional driver Program Load pressure gauge Drive consent Gear consent on forks side Braking analog signal Forced activation Safety relay Driver 4 Free Console (rx) Console (tx) GND logic Analog output Drive motor temp. sensor Brake signal Channel A encoder Channel B encoder Speed reduction in curve Speed sensor Drive block Truck code Relay Steering potentiometer Steering position Horn Drive wheel potentiometer Pot. GND Dead man consent Double dead man consent Platform lifting Platform descent

Workshop literature 45408042303 EN 03/2007

-11

WH

BU

blue orange

VT

RD

YE

GY

red yellow

grey

-12

GN

violet

BN

brown green

OG

BK

white

Electronic control of electrical drive Electronic drive control Electronic e-ABS control Safety fuse (2A) Safety fuse (10A) Safety fuse (8A) Drive safety fuse (250A) Lifting safety fuse (200A) Steering safety fuse (30A) Fan safety fuse (5A) Bimetal switch Battery General contactor contact Drive contactor contact Lifting contactor contact Electrical drive relay contact Drive motor 3000W (AC) Lift motor 2200W (DC) Electrical drive motor reducer 600W (DC) Fan B.S.I. + counter Data terminal Resistance

black

A1 A2 A3 F1 F2 F3 1F1 2F1 3F1 9F1 9F2 G1 K1 1K1 2K1 3K1 1M1 2M1 3M1 9M1 6P1 9P1 3R1

S1 7S1 2V1 X1 X3 X4 X5 X6 X7 X8 X9 1X1 3X1 6X1 9X1 (*1) (*2) (*3) (*4) (*5) (*6) (*7) (*8)

Key Emergency pushbutton Diode Battery plug-socket MTA UNIVAL 8-way fuse holder Insulator terminal 25-pin AMP connector Black 10-pin SAAB connector Black 10-pin SAAB connector Grey 6-pin SAAB connector 35-pin AMP SEAL connector Drive motor terminals Welded cables 8-pin MOLEX connector 2-pin AMP-SuperSeal connector Dashboard Motor compartment Diagnosis Auxiliaries Forks descent Fork lifting Cab lifting Cab descent

(*9) (*10) (*11) (*12) (*13) (*14) (*15) (*16) (*17) (*18) (*19) (*20) (*21) (*22) (*23) (*24) (*25) (*26) (*27) (*28) (*29) (*30) (*31)

4Km/h speed reduction Lifting consent Lifting cab braking Diagnostics Handle 1 Handle 2 Gear on forks side Gear on handlebar side Drive potentiometer Alarm horn Potentiometer (+) Potentiometer (-) Proportional driver Program load pressure gauge Drive consent Gear consent on forks side Braking analog signal Forced activation Safety relay Driver 4 Free Console (rx)

(*32) (*33) (*34) (*35) (*36) (*37) (*38) (*39) (*40) (*41) (*42) (*43) (*44) (*45) (*46) (*47) (*48) (*49) (*50) (*51) (*52)

Workshop literature 45408042303 EN 03/2007

Console (tx) GND logic Analog output Drive motor temp. sensor Brake signal Channel A encoder Channel B encoder Speed reduction in curve Speed sensor Drive block Truck code Relay Steering potentiometer Steering position Horn Drive wheel potentiometer Pot. GND Dead man consent Double dead man consent Platform lifting Platform descent

Workshop literature 45408042303 EN 03/2007

-13

WH

BU

blue orange

VT

RD

YE

GY

red yellow

grey

-14

GN

violet

BN

brown green

OG

BK

white

Electronic control of electrical drive Electronic drive control Electronic e-ABS control Safety fuse (2A) Safety fuse (10A) Safety fuse (8A) Drive safety fuse (250A) Lifting safety fuse (200A) Steering safety fuse (30A) Fan safety fuse (5A) Bimetal switch Battery General contactor contact Drive contactor contact Lifting contactor contact Electrical drive relay contact Drive motor 3000W (AC) Lift motor 2200W (DC) Electrical drive motor reducer 600W (DC) Fan B.S.I. + counter Data terminal Resistance

black

A1 A2 A3 F1 F2 F3 1F1 2F1 3F1 9F1 9F2 G1 K1 1K1 2K1 3K1 1M1 2M1 3M1 9M1 6P1 9P1 3R1

S1 7S1 2V1 X1 X3 X4 X5 X6 X7 X8 X9 1X1 3X1 6X1 9X1 (*1) (*2) (*3) (*4) (*5) (*6) (*7) (*8)

Key Emergency pushbutton Diode Battery plug-socket MTA UNIVAL 8-way fuse holder Insulator terminal 25-pin AMP connector Black 10-pin SAAB connector Black 10-pin SAAB connector Grey 6-pin SAAB connector 35-pin AMP SEAL connector Drive motor terminals Welded cables 8-pin MOLEX connector 2-pin AMP-SuperSeal connector Dashboard Motor compartment Diagnosis Auxiliaries Fork descent Fork lifting Cab lifting Cab descent

(*9) (*10) (*11) (*12) (*13) (*14) (*15) (*16) (*17) (*18) (*19) (*20) (*21) (*22) (*23) (*24) (*25) (*26) (*27) (*28) (*29) (*30) (*31)

4Km/h speed reduction Lifting consent Lifting cab braking Diagnostics Handle 1 Handle 2 Gear on fork side Gear on handlebar side Drive potentiometer Horn Potentiometer (+) Potentiometer (-) Proportional driver Program load pressure gauge Drive consent Gear consent on forks side Braking analog signal Forced activation Safety relay Driver 4 Free Console (rx)

(*32) (*33) (*34) (*35) (*36) (*37) (*38) (*39) (*40) (*41) (*42) (*43) (*44) (*45) (*46) (*47) (*48) (*49) (*50) (*51) (*52)

Workshop literature 45408042303 EN 03/2007

Console (tx) GND logic Analog output Drive motor temp. sensor Brake signal Channel A encoder Channel B encoder Speed reduction in curve Speed sensor Drive block Truck code Relay Steering potentiometer Steering position Horn Drive wheel potentiometer Pot. GND Dead man consent Double dead man consent Platform lifting Platform descent

Workshop literature 45408042303 EN 03/2007

-15

WH

BU

blue orange

VT

RD

YE

GY

red yellow

grey

-16

GN

violet

BN

brown green

OG

BK

white

Electronic control of electrical drive Electronic drive control Electronic e-ABS control Safety fuse (2A) Safety fuse (10A) Safety fuse (8A) Drive safety fuse (250A) Lifting safety fuse (200A) Steering safety fuse (30A) Fan safety fuse (5A) Bimetal switch Battery General contactor contact Drive contactor contact Lifting contactor contact Electrical drive relay contact Drive motor 3000W (AC) Lift motor 2200W (DC) Electrical drive motor reducer 600W (DC) Fan B.S.I. + counter Data terminal Resistance

black

A1 A2 A3 F1 F2 F3 1F1 2F1 3F1 9F1 9F2 G1 K1 1K1 2K1 3K1 1M1 2M1 3M1 9M1 6P1 9P1 3R1

S1 7S1 2V1 X1 X3 X4 X5 X6 X7 X8 X9 1X1 3X1 6X1 9X1 (*1) (*2) (*3) (*4) (*5) (*6) (*7) (*8)

Key Emergency pushbutton Diode Battery plug-socket MTA UNIVAL 8-way fuse holder Insulator terminal 25-pin AMP connector Black 10-pin SAAB connector Black 10-pin SAAB connector Grey 6-pin SAAB connector 35-pin AMP SEAL connector Drive motor terminals Welded cables 8-pin MOLEX connector 2-pin AMP-SuperSeal connector Dashboard Motor compartment Diagnosis Auxiliaries Fork descent Fork lifting Cab lifting Cab descent

(*9) (*10) (*11) (*12) (*13) (*14) (*15) (*16) (*17) (*18) (*19) (*20) (*21) (*22) (*23) (*24) (*25) (*26) (*27) (*28) (*29) (*30) (*31)

4Km/h speed reduction Lifting consent Lifting cab braking Diagnostics Handle 1 Handle 2 Gear on fork side Gear on handlebar side Drive potentiometer Horn Potentiometer (+) Potentiometer (-) Proportional driver Program load pressure gauge Drive consent Gear consent on forks side Braking analog signal Forced activation Safety relay Driver 4 Free Console (rx)

(*32) (*33) (*34) (*35) (*36) (*37) (*38) (*39) (*40) (*41) (*42) (*43) (*44) (*45) (*46) (*47) (*48) (*49) (*50) (*51) (*52)

Workshop literature 45408042303 EN 03/2007

Console (tx) GND logic Analog output Drive motor temp. sensor Brake signal Channel A encoder Channel B encoder Speed reduction in curve Speed sensor Drive block Truck code Relay Steering potentiometer Steering position Horn Drive wheel potentiometer Pot. GND Dead man consent Double dead man consent Platform lifting Platform descent

Workshop literature 45408042303 EN 03/2007

-17

WH

BU

blue orange

VT

RD

YE

GY

red yellow

grey

-18

GN

violet

BN

brown green

OG

BK

white

Electronic control of electrical drive Electronic drive control Electronic e-ABS control Safety fuse (2A) Safety fuse (10A) Safety fuse (8A) Drive safety fuse (250A) Lifting safety fuse (200A) Steering safety fuse (30A) Fan safety fuse (5A) Bimetal switch Battery General contactor contact Drive contactor contact Lifting contactor contact Electrical drive relay contact Drive motor 3000W (AC) Lift motor 2200W (DC) Electrical drive motor reducer 600W (DC) Fan B.S.I. + counter Data terminal Resistance

black

A1 A2 A3 F1 F2 F3 1F1 2F1 3F1 9F1 9F2 G1 K1 1K1 2K1 3K1 1M1 2M1 3M1 9M1 6P1 9P1 3R1

S1 7S1 2V1 X1 X3 X4 X5 X6 X7 X8 X9 1X1 3X1 6X1 9X1 (*1) (*2) (*3) (*4) (*5) (*6) (*7) (*8)

Key Emergency pushbutton Diode Battery plug-socket MTA UNIVAL 8-way fuse holder Insulator terminal 25-pin AMP connector Black 10-pin SAAB connector Black 10-pin SAAB connector Grey 6-pin SAAB connector 35-pin AMP SEAL connector Drive motor terminals Welded cables 8-pin MOLEX connector 2-pin AMP-SuperSeal connector Dashboard Motor compartment Diagnosis Auxiliaries Fork descent Fork lifting Cab lifting Cab descent

(*9) (*10) (*11) (*12) (*13) (*14) (*15) (*16) (*17) (*18) (*19) (*20) (*21) (*22) (*23) (*24) (*25) (*26) (*27) (*28) (*29) (*30) (*31)

4Km/h speed reduction Lifting consent Lifting cab braking Diagnostics Handle 1 Handle 2 Gear on fork side Gear on handlebar side Drive potentiometer Horn Potentiometer (+) Potentiometer (-) Proportional driver Program load pressure gauge Drive consent Gear consent on forks side Braking analog signal Forced activation Safety relay Driver 4 Free Console (rx)

(*32) (*33) (*34) (*35) (*36) (*37) (*38) (*39) (*40) (*41) (*42) (*43) (*44) (*45) (*46) (*47) (*48) (*49) (*50) (*51) (*52)

Workshop literature 45408042303 EN 03/2007

Console (tx) GND logic Analog output Drive motor temp. sensor Brake signal Channel A encoder Channel B encoder Speed reduction in curve Speed sensor Drive block Truck code Relay Steering potentiometer Steering position Horn Drive wheel potentiometer Pot. GND Dead man consent Double dead man consent Platform lifting Platform descent

Workshop literature 45408042303 EN 03/2007

-19

WH

BU

blue orange

VT

RD

YE

GY

red yellow

grey

-20

GN

violet

BN

brown green

OG

BK

white

Electronic control of electrical drive Electronic drive control Electronic e-ABS control Safety fuse (2A) Safety fuse (10A) Safety fuse (8A) Drive safety fuse (250A) Lifting safety fuse (200A) Steering safety fuse (30A) Fan safety fuse (5A) Bimetal switch Battery General contactor contact Drive contactor contact Lifting contactor contact Electrical drive relay contact Drive motor 3000W (AC) Lift motor 2200W (DC) Electrical drive motor reducer 600W (DC) Fan B.S.I. + counter Data terminal Resistance

black

A1 A2 A3 F1 F2 F3 1F1 2F1 3F1 9F1 9F2 G1 K1 1K1 2K1 3K1 1M1 2M1 3M1 9M1 6P1 9P1 3R1

S1 7S1 2V1 X1 X3 X4 X5 X6 X7 X8 X9 1X1 3X1 6X1 9X1 (*1) (*2) (*3) (*4) (*5) (*6) (*7) (*8)

Key Emergency pushbutton Diode Battery plug-socket MTA UNIVAL 8-way fuse holder Insulator terminal 25-pin AMP connector Black 10-pin SAAB connector Black 10-pin SAAB connector Grey 6-pin SAAB connector 35-pin AMP SEAL connector Drive motor terminals Welded cables 8-pin MOLEX connector 2-pin AMP-SuperSeal connector Dashboard Motor compartment Diagnosis Auxiliaries Fork descent Fork lifting Cab lifting Cab descent

(*9) (*10) (*11) (*12) (*13) (*14) (*15) (*16) (*17) (*18) (*19) (*20) (*21) (*22) (*23) (*24) (*25) (*26) (*27) (*28) (*29) (*30) (*31)

4Km/h speed reduction Lifting consent Lifting cab braking Diagnostics Handle 1 Handle 2 Gear on fork side Gear on handlebar side Drive potentiometer Horn Potentiometer (+) Potentiometer (-) Proportional driver Program load pressure gauge Drive consent Gear consent on forks side Braking analog signal Forced activation Safety relay Driver 4 Free Console (rx)

(*32) (*33) (*34) (*35) (*36) (*37) (*38) (*39) (*40) (*41) (*42) (*43) (*44) (*45) (*46) (*47) (*48) (*49) (*50) (*51) (*52)

Workshop literature 45408042303 EN 03/2007

Console (tx) GND logic Analog output Drive motor temp. sensor Brake signal Channel A encoder Channel B encoder Speed reduction in curve Speed sensor Drive block Truck code Relay Steering potentiometer Steering position Horn Drive wheel potentiometer Pot. GND Dead man consent Double dead man consent Platform lifting Platform descent

Workshop literature 45408042303 EN 03/2007

(*1)

-21

45408020200 - 1/1 (13-05-06)

Cab lifting

Cab descent Cab lifting

-22

OFF* = Upon activation of the command the valve is in the ON mode; it then passes to OFF in a linear manner over a time interval of about 1 sec.

(*1)

ON OFF*

OFF

2Y2

ON

2Y1

Workshop literature 45408042303 EN 03/2007

ON

OFF

PUMP M.

Workshop literature 45408042303 EN 03/2007

(*1)

45408020201 - 1/1 (13-05-06)

(*2)

-23

Cab lifting Fork lifting

OFF*

OFF OFF ON

Cab lifting

Cab descent

-24

ON

OFF*

ON

2Y2

ON

2Y1

Forks descent Fork lifting

OFF* = Upon activation of the command the valve is in the ON mode; it then passes to OFF in a linear manner over a time interval of about 1 sec.

(*1) (*2)

2Y3

ON

ON

OFF

OFF

OFF

OFF

ON

ON

2Y4

Workshop literature 45408042303 EN 03/2007

OFF

ON

ON

OFF

PUMP M.

Workshop literature 45408042303 EN 03/2007

-25

45408042303 EN Edition 03/2007

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OM Carrelli Elevatori S.p.A. Viale De Gasperi, 7 I-20020 Lainate

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