STILL Saxby forklift EGV 14 EGV 16 Walk-high lift truck Workshop Manual

WORKSHOP MANUAL

Walk-high lift truck

available from Ser. Nr :

710304 xxxxxx 710306 xxxxxx 710244 xxxxxx 710246 xxxxxx

STILL & SAXBY S.A.R.L 26, rue des Frères-Lumière F- 77107 Meaux Tél : 01 64 36 33 00 4498984 - 05.00

EGV 14 EGV 16

STILL & SAXBY

Foreword

Instructions on Use of Manual Purpose of the manual The user will in future receive Workshop Manuals for every specific type of truck (in this case EGV 14/16 models).

These are meant to replace the service information bulletins formerly used.

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The Workshop Manual incorporates the following advantages: Easy to use : Easy, speedy and unerring use of the workshop manual, eliminating the need for time-consuming searching.

Reliable updating causing no problems : The break-down of the manual into single sheets results in the association of information, reducing errors to a minimum.

Updating Should single sheets or groups of sheets no longer correspond to the latest engineering design or know-how, updating sheets will be dispatched.

Due to organizational reasons this is feasible only within the STILL & SAXBY Organization.

must be filed directly behind page 6 which must be followed by page number 7 (e.g. in the case of additions or product improvements).

3. Supplements/repeated supplements Additional sheets which are valid from a given serial number or from a certain production date are printed on coloured paper, insuch a case the old sheets must remain inthe manual as they still remain valid for thefirst serial numbers (e.g. in the event of several product improvements).

Together with the updated sheets the addressee will in each case also receive instructions advising him how to file the new sheets and whether old sheets must be removed from file and if so, which ones.

If sheets must be replaced, the places which comprise the change with regard to the previous sheets will be identified with an asterisk (*).

Updating exists in the forms shown below: 1. Substituting a sheet You remove the previous sheet and substitute the new one (e.g. in the event of printing errors, changes in illustrations etc.)

2. Inserting additional sheets These sheets carry the page number of the page which must precede the sheets to be inserted. For example, the sheet with page numbers 6a and 6b

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I

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STILL & SAXBY

Foreword

Instructions on Use of Manual

Publisher :

When working with the present manual please observe the following :

STILL & SAXBY 26 rue des Frères Lumière

In this workshop Manual the standard designs of the corresponding truck models, as well as some widely used variants are dealt with.

F-77107 Meaux

Working in compliance with the instructions contained in this manual does not entitle to warranty claims. The STILL & SAXBY warranty conditions remain unaffected.

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STILL & SAXBY are constantly striving to improve their products and we therefore reserve the right to change truck specifications and design without notice.

Workshop Manual

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II

Group index

01 Chassis 03 Gear motor 04 Wheels 05 Driving controls 06 Steering All rights reserved. Any reproduction, even of extracts, is prohibited. copyright reserved.

07 Brake 08 Electrical system 09 Accessories 10 Hydraulics 11 Motors 20 Mast 22 Fork carriage 28 Built-in charger 32 Special tools

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III

Assembly 01

Chassis

Contents

Page

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General .................................................................................................................. 01-02 Housing .................................................................................................................. 01-03

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Assembly 01

Chassis

General

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The chassis of the EGV 14/16 is joint-welded.

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Assembly 01

Chassis

Housing

The housing is made up of three sub-assemblies : - Battery hood (1) - Brake hood (2) - Motor hood (3) To remove the battery hood, raise it, and remove the ring (4) so that you can pull the battery hood to one side.

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The brake hood is secured by a screw (M8x20) (5).

The motor hood is secured by 3 screws (M8x20) (6).

4

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Assembly 03

Gear motor

Contents

Page

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Removing the gearbox, reassembling the gearbox ............................................... 03-02 Changing the gearbox oil, checking the oil level.................................................... 03-03

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Assembly 03

Gear motor

Removing the gearbox

Note :

The drive motor must be removed before removing the gearbox.

When the drive motor is dismantled, the truck is not braked, so it must be chocked to prevent it from moving.

Locked with Loctite 243

1. Remove the battery plug.

2. Place the truck on chocks approximately 230 mm high (see page 04-02).

3. Remove the drive wheel.

4. Remove the drive motor (see page 11-04).

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Note : The leads must not be disconnected!

5. Drain the oil from the gearbox (see page 0303).

6. Block the gearbox securely.

7. Loosen the 6 remaining screws (1) and lower the gearbox carefully.

8. Remove the gearbox.

Note : Cover the gearbox orifice (2) to prevent dirt from entering it.

Assembly of the gearbox Assembly follows reverse order.

Note :

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Before assembling the gearbox, make sure that its ventilation and breather holes are clear.

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03-02

Assembly 03

Gear motor

Changing the gearbox oil

The first oil change must be carried out after approximately 50 - 100 hours’ service. All other oil changes must be carried out after approximately 2,000 hours’ service or once a year.

Note :

2

The oil in the gearbox must be drained at operating temperature.

Caution : Danger of scalding!

The maximum acceptable operating temperature is 80°C.

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Viscosity : 80W90EP.

Changing the oil 1. Set a 2l tank under the oil drain plug(1) 2. Unscrew the plug and drain the oil.

1

Caution : The temperature can reach 80°C. 3. Replace the oil seal and screw on the plug again 4. Fill in the gearbox with oil (1,5l) from the top of the gearbox(2)

Checking the gearbox oil level 1. Remove the battery plug.

2. Remove the tiller (see page 6-02) 3. Remove the drive motor (see page 11-04) (The power supply cables must not be disconnected!)

4. Check the oil level at the check plug (2).

The oil level is correct if the pinion (3) is approximately 1/3 covered by oil.

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Oil level

MA = 55 +10Nm

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Wheels

Assembly 04

Contents

Page

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Replacing the drive wheel .................................................................................... 04-02 Swivel rollers: adjusting, dismantling the castor .................................................... 04-03 Support rollers ....................................................................................................... 04-04

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Assembly 04

Wheels

Replacing the drive wheel (complete) New dimensions : 230 x 75 The drive wheel must be replaced if : - the running surface is badly damaged or out of round, - the diameter of the tyre has been worn down by 10% (minimum acceptable tyre diameter : 207 mm).

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Types of tyres :

230 mm

- Smooth polyurethane wheel - Treaded polyurethane wheel - Smooth rubber wheel - Treaded rubber wheel - Smooth natural rubber wheel - Treaded natural rubber wheel

Fig. 1

Removal 1. Remove the battery plug.

2. Place the machine on chocks and block it so that it cannot roll (raise by 230 mm) or like on fig. 1.

3. Turn the drive wheel (2) so that you can loosen the 5 wheel nuts (1).

4. Remove the wheel nuts.

5. Remove the drive wheel.

Assembly

1

1. Before assembling the drive wheel, clean the seat and make sure that it is in perfect condition.

2. Put the drive wheel in place and tighten all 5 nuts by hand.

3. Use a torque wrench to lock the nuts, tightening opposite nuts alternately.

2

Nut dimensions : A12x1,5 DIN 74361 Tightening torque for the nuts : 83 Nm.

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Assembly 04

Wheels

Swivel roller

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Adjusting the swivel roller (Fig. 1) 1. Release the clamping screw (1) on the roller support.

2. Remove the socket head screw (2).

3. Lower the two swivel rollers (4) until the distance between the chassis of the machine and the ground is 160 mm.

If necessary, raise the chassis with a hydraulic jack.

4. Tighten the screw (1) to a torque of 200 Nm. 5. Tighten the socket head screw with its washer (3) until the washer is clamped against the bearing housing.

Fig. 1 Note :

After assembling the rollers, you must check that they work properly.

When you change the travel direction, the supporting rollers must pivot by 180° after travelling a short distance.

Dismantling the castor (Fig. 2) - Remove the nut and bolt (1). The castor with the tincover and the collared spacers can then be removed.

The pivot is removed by unscrewing the setscrew (2). Since this screw is mounted using Loctite, it may be necessary to heat it beforehand.

- Then remove the washer (3).

- Remove the taper roller bearing (4) and the spacer (5). These two parts must be removed with a bearing extractor.

Reassembly follows reverse order.

Fig. 2

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Assembly 04

Wheels

Support rollers

1

General 4

The support rollers must be replaced - When they are damaged or out of round - When their diameter is worn down to 76.5 mm - When their bearings are faulty Depending on the customer’s requirements, the EGV may be equipped with two types of support rollers :

2

3

Single support rollers All rights reserved. Any reproduction, even of extracts, is prohibited. copyright reserved.

Removal : - Use chocks to securely raise the side to be replaced by approximately 100 mm.

- Drive out the pin (1) downwards.

- Drive out the shaft (2).

- If necessary, replace the roller (3) + bearings and rings(4).

Initial dimensions (mm) : 85x100 Reassembly is performed in reverse order.

Tandem support rollers Removal : - Use chocks to securely raise the side to be replaced by approximately 100 mm.

- Pivot the supports (5).

- Loosen then remove the screws (6).

- Extract both rollers ( 7) - If necessary, replace the rollers, bearings (8), shafts (9) and rings (10).

- Grease the bush (11).

Initial dimensions (mm) : 85x80 Reassembly : Reassembly is performed in reverse order, with a screw tightening torque of 70 Nm(6).

Note :

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After reassembly, you must check that the pivoting mechanism (5) works properly.

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04-04

Assembly 05

Driving controls

Contents

Page

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Tiller : general, arrangement of the components ................................................... 05-02 Dismantling and reassembling : tiller head, tiller circuit board block, butterfly handles..................................................................................................... 05-03 Operating principle................................................................................................. 05-04 Safety microswitch ................................................................................................. 05-05

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Assembly 05

Driving controls

Tiller

General The tiller head is composed of a moulded housing containing an electronic circuit board, 3 push-buttons (raise, lower and horn), 2 butterfly handles for traction and a safety microswitch with a push-button.

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If the tiller head malfunctions, the whole circuit board block must be changed.

When the butterfly handles are used, a combination of resistors is activated and causes the index value to vary according to the angle of rotation of the butterfly handles. The same applies to the 3 other push-buttons which render the functions (lift, lower) progressive according to the pressure applied.

Arrangement of the different components of the tiller head 1: safety microswitch.

2: circuit board.

3: butterfly handle for traction movements.

4: push-button for the horn.

5: push-button for lifting the forks.

6: push-button for lowering the forks.

7: tiller safety button.

8: push-button for lowering the basiclifting 9: push-button for lifting the basiclifting

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Assembly 05

Driving controls

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Dismantling the tiller head

- Unplug the battery.

- Remove the 4 BTR screws (DIN 912, M6x128.8) (1) on the tiller head housing and then the 2 small cross-head screws (2) holding in place the red tiller protection housing.

- Remove the housing (3).

- Since the safety button (4) is only pushed in, simply pull upwards to remove it.

- Disconnect the tiller circuit board plug (located at bottom), after first noting which way round it was connected.

- Then remove the second housing by loosening the 2 BTR screws (FHC M8xI2xI2) (5) and the BTR screw (DIN 912 - M8x12 - 8,8) (6).

3

7

9 4

2

8 1

Dismantling the tiller circuit board block - Remove the BTR screw (DIN 912, M6x20- 88) (7).

- Extract the tiller head pcb(9) secured on 3 studs located at the back of the block.

Dismantling the butterfly handles Pull hard, in a single movement, to extract each butterfly handle (8).

The butterfly handles can only be removed once the circuit board has been extracted from its housing.

Reassembly follows the reverse order.

Caution : When reassembling, the 2 butterfly handles must be clipped back onto the 2 positioning and securing studs.

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Assembly 05

Driving controls

Operating principle

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One side of the control circuit board is covered with a plastic film under which you can see several white areas,. These areas are conductive and each cover 2 strips which activate the functions (forward travel, reverse travel, lift lower and horn) when they come into contact.

The lift lower and horn control buttons are equipped with two small white plastic studs which press on the conductive areas and link the strips of the circuits controlling the different functions. Only the traction control butterfly handles are equipped with 4 white plastic studs (2 for travel direction and 2 for speed).

FWD

BACK Accelerator

Horn

Lifting - 2S2

Lowering - 2S1

Lifting - 2S80 (Basic lifting)

Lowering - 2S81 (Basic lifting)

Direction control

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Assembly 05

Driving controls

Safety microswitch

The tiller microswitch activated by the housing (1) is a safety device that must operate in accordance with accident prevention regulations.

This is why you must always check that it workscorrectly during each maintenance operation.

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When the safety microswitch is activated, the travel direction is overridden and changed to reverse. As soon as the microswitch is released, the machine remains at a standstill.

To restart the machine, there are only two possible solutions : 1. Turn the key switch to stop and then back to start.

2. Return the tiller to the braking position.

Travel direction

Backward direction

Forward direction

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Steering

Assembly 06

Contents

Page

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Dismantling and reassembling the mechanical assembly ..................................... 06-02 Dismantling and reassembling the spring.............................................................. 06-03

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Assembly 06

Steering

Dismantling the mechanical assembly

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Before doing anything else, remove the tiller cable.

- Disconnect the cable plug from the tiller circuit board.

- Slide the cable downwards inside the tiller arm.

- Unscrew the clamp (1) and remove it from the cable.

- Disconnect the two microswitch plugs after marking them.

- Remove the 6 BTR screws (DIN 912, M8x40, 8.8) (2) fastening the tiller assembly onto the motor. These are mounted using Loctite.

- Remove the mechanical assembly.

1

2

Reassembly follows reverse order.

Dismantling the microswitch - Remove the 2 microswitch power-supply plugs.

- Unscrew the 2 socket head screws and remove the microswitch support assembly (3).

- Unscrew the 2 screws (4) on the microswitch.

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Assembly 06

Steering

Dismantling the spring

Caution : The spring (2) located inside the tiller arm is under high pressure. When dismantling it, place the tiller in the neutral position.

- Loosen the nut (1) located on the tiller arm after removing its plastic cover.

- To remove the ball joint (3), use a screwdriver as a lever.

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Reassembly follows reverse order.

Caution : To reassemble the cylinder, do not tighten the barrel straight away so that it is easier to fit the ball joint.

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Assembly 07

Brake

Contents

Page

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General .................................................................................................................. 07-02 Removal - reassembly ........................................................................................... 07-03 Adjusting the air gap .............................................................................................. 07-04 Adjusting the braking force .................................................................................... 07-05

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Assembly 07

Brake

Mechanical disk brake

General The brake installed in this truck is a dead man brake.

The tiller is returned to the vertical position by a gas-filled spring and the brake is activated.

This brake is both a parking and service brake.

Fig. 1

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The operation of the brake can be optimized by a range of adjustments.

a = braking zone b = travel zone c = braking zone

Operation The cam (1) activates the brake by means of the lever (2) when the tiller is placed in the up or down position (fig. 1, a and c).

The lever (2) presses on the brake disk (5) by means of the socket head screw (4) and thus pushes the brake disk (6).

The travel control current is interrupted by the microswitch (3) and the brake is activated at the same time.

Fig. 2

Fig. 3

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07-02

Assembly 07

Brake

Mechanical disk brake

Note :

The truck is no longer braked when the brake has been removed, so the truck must be immobilized before dismantling the brake.

Removal

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1. Disconnect the battery plug.

2. Unscrew the 6 socket head screws (1) and remove the tiller.

3. Unscrew the 3 lock nuts (2) and the 3 nuts (3) and then remove the brake disk (6).

Reassembly follows reverse order The brake disk must be changed when it is less than 6 mm thick.

Thickness of new disk : 12 mm.

It may be necessary to change it earlier if the wear is asymmetrical.

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Assembly 07

Brake

Mechanical disk brake 5 1

Adjusting the air gap

4 3

1. Disconnect the battery plug.

2. Place the tiller in the travel position (see page 07-02).

3. Check the clearance between the brake disk (2) and the plate (1) at several points using a 0.4 mm gauge. If necessary, adjust the air gap by progressively tightening or loosening all 3 nuts (3).

4. Lock the adjusting nuts by means of the lock nuts (4) and then check the adjustment again.

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Note :

2

A difference in the adjustment of the various control points may lead to the brake disk jamming

5. Place the tiller in the braking position (see page 07-02) and check that the adjustment screw (5) is against the lever (7) when the cam (8) (see figure below) moves and, if not, adjust this screw.

Note :

8

7 11

After this adjustment, you must check the adjustment of the travel control microswitch andbraking efficiency.

10 9

Adjusting the travel control microswitch The adjustment of the microswitch (9) must be checked and, if necessary, modified each time the braking system is repaired.

Brake cam

1. Unscrew the lock nut (10).

2. Place the tiller in the travel position (brake off) (see page 07-02).

The microswitch must transmit a signal (24) to the variator (pin 15). If necessary, adjust the adjusting screw (11) until the microswitch is closed.

3. Tighten the lock nut (10).

4. Place the tiller in the braking position (see page 07-02).

5. Check that the microswitch (9) opens (no signal on pin 15 of the variator control).

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Brake lever

Brake off

Braking begins

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Assembly 07

Brake

Mechanical disk brake

Adjustment of the braking force As the setting of the braking force influences the length of the braking distance, it must be adjusted as follows.

Adjust the locknuts (1) and adjusting nut (2) until the end of the thread of the adjusting screw (3) and the locknuts are flush.

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Note : Turning the nuts increases the braking force.

Maintenance Wenn servicing the truck, the following procedure must be carried out or paid attention to : - Adjustment of the air gap and the braking force.

- Renew a spalled, unevenly worn or worn rotor (1).

- Check the setting of the brake switch Original rotor thickness : 12 mm Replace with : 6 mm The rotor (1) must move easily on the pinion gear (2).

25 Nm

- Remove any oil on the brake with a jet air.

- "Glazed" rotors can be roughened carefull with sand paper.

- Check the brake levers for ease of movment.

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Assembly 08

Electrical system

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Contents

Page

Traction control unit : General, technical characteristics .................................................................... 08-02 Power section connections .............................................................................. 08-03 Input / output signals........................................................................................ 08-04 Drive controller : Fault display ..................................................................................................... 08-06 Troubleshooting table ....................................................................................... 08-07 Hydac MVV 1000 lift controller : General ............................................................................................................ 08-08 Input / output signals........................................................................................ 08-09 Fault display ..................................................................................................... 08-10 Tiller head microswitch, induction sensor .............................................................. 08-11 Fuses, contactors................................................................................................... 08-12 Solenoid valves ...................................................................................................... 08-13 Location of electrical components, wiring diagrams, legend, Curtis parameters .. 08-14 Battery.................................................................................................................... 08-15

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Assembly 08

Electrical system

Traction control unit

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General The Traction Control Unit (Item. 1) is a unit controlled by a microprocessor using proven MOSFET technology.

The microprocessor has direct control on the input signal of the starting switch, for all signal processing, up to integration of current limitation.

To control the speed and power of the travel motor from 0 to 100%, the excitation of the transistor cadence is changed.

The direction contactors are fully controlled by excitation outputs so as to have commutation without sparking.

The control unit has internal and external safety monitoring, which stops the unit if an anomaly appears.

Fault diagnosis is simple to effect using a light emitting diode (LED) placed under the control section.

Control unit adjustment operations must be effected by the programmer or the Notebook.

To reach the control unit or any other electrical component, you must first remove the covers (see P. 01-03).

Technical Characteristics Voltage range : Low Voltage Limit : Voltage Limit : Casing Electrical Insulation : Output current :

24V - 36V 16V High 45V 500V 250A for 1 min

200A for 2 min 150A for 5 min 100A for 1 h Commutation Frequency : 15 kHz Commutation outputs : Max winding current 2A Ambient Temperature : -25°C to +50°C Dimensions : 165x122x60 (L x W x h) in mm Weight : 1.1 kg

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Assembly 08

Electrical system

Traction control unit

Power section - connections Terminal B+ (Item 1) Is connected to the positive pole of the battery and to the positive connection of the field winding. Internally, it is connected to the cathode of the “free wheel” diode.

Terminal B- (Item. 2)

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Is connected to the minus pole of the battery.

Internally, it is connected to the MOSFET power source and to the condensers.

Terminal A2 (Item. 3) Is connected to the connection between the armature and the field winding of the motor.

Internally, it is connected to the cathode of the armature diode.

Terminal M (Item. 4) Is connected the armature. Internally, it is connected to the power MOSFET drain, to the anode of the armature diode and to the anode of the “free wheel” diode.

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Assembly 08

Electrical system

Traction control unit

Input and output Signals

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The input and output signals are grouped on 16pole connector X1 that is directly inserted in the control section of the control unit (Item. 1).

Inputs Pin 16 :supply of +24V voltage through key switch. Initialise control in this way and an internal monitoring circuit starts up.

When the control is powered, follow the circuit sequence: key switch -> operating direction micro switch.

Pin 15 :Tiller Input micro +24V. Pin 14 : Operating Reduction Input (slow/fast speed setting) +24V, (option), modification of software required. +24V on Pin 14 = fast speed setting.

0V on Pin 14 = slow speed setting.

Pin 13 :Tiller Head Safety Input +24V. As long as this input is on circuit, the control takes the motor traction current to 60% of power and the operating direction changes.

Pin 12 :Operating Direction Input +24V (forward).

Pin 11 :Operating Direction Input +24V (reverse).

Inputs 12 and 11 activate the control unit power stage.

Voltage check: between terminals 8(+) and 7(-).

Flap at rest about 5.0V (between 4.8 and 5.0V) Flap at full setting about 0V (between 0 and 0.1V).

Pin 8 : Acceleration instruction (from 5 KOhm to 0 KOhm).

Pin 7 : Voltage supply 0 for ON switch.

Pin 6 : Input set value for potentiometer (option). Not used.

Pin 5 : Voltage supply 0 for potentiometer (option). Not used.

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Assembly 08

Electrical system

Traction control unit

Output

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Pin 10: Switch inspection output for tiller head safety.

Pin 9:

Not used.

Pin 4:

Controlled negative for line contactor (option). Not used.

Pin 3:

Controlled negative for forward controlled negative.

Pin 2:

Controlled negative for reverse controlled negative.

Pin 1:

Controlled negative for shunt section of the compound motor, when the ON switch is actuated.

Note : To eliminate the induction voltage at the direction contact coils two “free wheel” diodes are integral to the control unit.

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Assembly 08

Electrical system

Drive controller

Fault display If a fault is detected, a led (1) indicates the fault type by means of a flashing code.

The LED is on the front panel of the controller.

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The code flashes until the controller is reinitialised (turn off / on - the braking switch is sometimes sufficient), provided that the fault has been cleared.

1

Flashing fault code The following troubleshooting information is generated by the command. The troubleshooting LED, in the control unit section, flashes to indicate the diagnostic code.

Short Pause

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Long Pause

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08-06

Assembly 08

Electrical system

Drive controller Troubleshooting table The table below provides a key to the flashing codes.

Note : The last fault detected is always displayed. Under normal operation, the LED CODE is 1-0 activity CODE LED 1,2 1,3

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1,4

2,1

2,2 2,3

2,4

3,1

3,2 3,4

4,1

4,2 4,3

Issue :

MESSAGE ON PROGRAMMER SCREEN HW SAFE

MEANING

CAUSE OF FAULT

- Controller fault.

- Wiring problem.

M-FAULT - M - output short-circuit to ground.

- Travel direction contactor not connected.

- travel direction contactor response too slow.

- Short circuit in motor.

SRO SRO fault - Wrong switch-on sequence : ignition key / brake / travel direction selection.

- Incorrect SRO configuration.

- Brake circuit or travel selection circuit not made.

- Operating times too short.

THROTTLE Potentiometer - Accelerator / controller connection broken.

FAULT 1 cursor fault - Accelerator wiring short-circuit to ground or B+.

- Defective potentiometer.

- Incorrect potentiometer configuration on programmer.

EMR REV WIRING Tiller head - Tiller head safety circuit not made.

CHECK safety circ - Tiller head safety check circuit not made.

HPD High pedal safety - Wrong switch-on sequence : ignition key / brake / travel direction selection.

- Incorrect accelerator type configuration on programmer.

- Potentiometer needs adjusting (low point).

THROTTLE FAULT 2 Potentiometer low - Potentiometer low point circuit not made. point short-circuit - Potentiometer low point short circuit. or broken - Incorrect configuration of type of accelerator used.

CONT COLD / On current in - Direction contactor windings short circuit.

FIELD SHORT contactor or inducteur - Shunt winding short circuit. winding DIR CONT WELDED Travel direction - Travel direction contactors welved or short circuited contactors welved (power).

MISSING Shunt or contactor - Travel direction contactor winding circuit not made.

CONTACTOR winding missing - Travel direction contactor missing.

- Shunt winding circuit broken.

- Shunt or contactor wiring cut.

LOW BATTERY Low battery - Battery voltage < 16 Volts.

VOLTAGE voltage - Battery connections coroded - Voltage loss in battery terminals or controller.

OVERVOLTAGE Battery overvoltage - Battery voltage > 45 Volts.

- Charger connected to vehicle.

THERMAL Temperature too - Temperature > 85°C or < 25°C. CUTBACK high / too low - Vehicle overload.

- Controller installation incorrect.

- Operation in extreme environmental conditions.

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Hardware error M - output short circuit

Workshop Manual

EGV 14/16 Page :

08-07

Assembly 08

Electrical system

HYDAC MVV 1000 lift controller

General The power part of the pump motor is controlled by closing the contactor (2K1). The motor rotation speed is therefore always the same.

The lifting or lowering speed variation is modulated by means of proportional magnet valves (2Y20 and 2Y21), which are controlled by the MV 1000 controller (2A3).

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The lifting or lowering speed can be modulated by pushing the tiller head lift / lower pushbuttons (A2).

The basic lifting option operates according to the same principle, with its own magnet valve (2Y22).

The MVV 1000 controller also initiates the time clock.

Operating example : lifting Once 2S2 (lift microswitch) has been pressed, the 2A3 controller's X.1C7 terminal receives a +24 V signal from the tiller head.

The 2A3 controller initially provides a +24 V signal via its X.1A4 terminal, to power the 2K1 contactor winding (motor start-up).

In then checks the voltage from the potentiometer on its X.1C8 terminal (between at least 0.5 V (approx.) and approx. 4.5 V at full charge).

Depending on this voltage, it provides a positive signal (between at least 7 V (approx. ) and approx. 20 V at full charge) on its X.1C4 terminal, to power the 2Y20 proportional lifting magnet valve.

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08-08

Assembly 08

Electrical system

HYDAC MVV 1000 lift controller PN : 490350 index c*

Input / output signals X 1.A

1 2 3 4 5 6

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X 1.B

+24 V after contact (module power supply) +24 V after tiller microswitch (anti-inversion anode diode) +24 V after tiller microswitch (anti-inversion cathode diode) +24 V pump contactor power supply negative +24 V proportional magnet valve (lift-lower) power supply

1 2 3 for options 4,5 5,6

negative to magnet valve 2Y22 +24 V unlock lift limitation (input) +24 V lift limitation (input) +24 V basic lift +24 V connected together

X 1.C

5V power supply to potentiometer (approx. 4.6 V) negative power supply to proportional lowering magnet valve (max. lower approx. 20 V and min. lower approx. 9 V) power supply to proportional lifting magnet valve (max. lift approx. 20 V and min. lift approx. 7 V) +24 V basic lift (lift - lower) approx. +24 V in lowering function (input) approx. +24 V in lifting function (input) lifting - lowering potentiometer setting (approx. 0.5 V min. and approx. 4 V at full charge) +24 V if following functions : lift - lower - forward - reverse (clock meter) negative to potentiometer +24 V if rear operation for clock meter control +24 V if forward operation for clock meter control * after the following modifications on the cabling this controller can be replaced by the controller PN 4468869. to move the cable X1 - A4 to X1 - B4 (trucks with or without basic lift) to remove the bridge X1 - B5 / X1 - B6 (trucks with or without basic lift) to move the bridge X1 - B5 / X1 - B4 to X1 - B5 / X1 - B6 (trucks without basic lift)

1 2 3 4 5 6 7 8 9 10 11 12

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Assembly 08

Electrical system

HYDAC MVV 1000 lift controller PN : 468869 index b

Input / output signals X 1.A

1 2 3 4 5 6

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X 1.B

+24 V after contact (module power supply) +24 V after tiller microswitch (anti-inversion anode diode) +24 V after tiller microswitch (anti-inversion cathode diode) +24 V basic lift limitation (input) negative +24 V proportional magnet valve (lift-lower) power supply

1 2 3 for options 4 5,6

negative to magnet valve 2Y22 +24 V unlock lift limitation (input) +24 V lift limitation (input) +24 V pump contactor power supply +24 V basic lift

X 1.C

5 V power supply to potentiometer (approx. 4.6 V) negative power supply to proportional lowering magnet valve (max. lower approx. 20 V and min. lower approx. 9 V) power supply to proportional lifting magnet valve (max. lift approx. 20 V and min. lift approx. 7 V) +24 V basic lift (lift - lower) approx. +24 V in lowering function (input) approx. +24 V in lifting function (input) lifting - lowering potentiometer setting (approx. 0.5 V min. and approx. 4 V at full charge) +24 V if following functions : lift - lower - forward - reverse (clock meter) negative to potentiometer +24 V if rear operation for clock meter control +24 V if forward operation for clock meter control

1 2 3 4 5 6 7 8 9 10 11 12

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08-09bis

Assembly 08

Electrical system

HYDAC MVV 1000 lift controller

Fault display - LED flashing frequency : 1 pulse • One of the analogue inputs cut - LED flashing frequency : 2 pulses • One of the proportional magnet valves is short-circuited or cut

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- LED flashing frequency : 3 pulses • EEPROM memory fault - LED flashing frequency : 2 Hertz • Lift / lower pushbuttons pressed together (magnet valves do not operate) - LED always on • Unit powered up and operating correctly

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Assembly 08

Electrical system

Tiller head microswitch

Microswitch 1S3 is controlled by the tiller head position. When the tiller head is at rest (positions 1 and 3), traction is inhibited, but lifting is authorised.

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Traction is only possible in tiller head position 2, which releases the mechanical braking system.

Inductive sensor basic lifting If the unit is fitted with the basic lifting option, an inductive sensor (1) is placed on the chassis ; this sensor detects when the basic lifting cylinder is "up" and stops the pump motor.

1

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Assembly 08

Electrical system

Fuses

Position of fuses : power and control - 1F1 : travel motor power fuse = 100 A - 2F1 : pump motor power fuse = 200 A - F2 : main control fuse = 7.5 A - 6F20 : Curtis combi control fuse = 3 A

Contactors

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The coil of the line contactor -K1 has a resistance of about 51 Ohm. The coil of each direction contactor -1K11 and 1K12 has a resistance of about 29 Ohm. The coil of the pump contactor -2K1 has a resistance of about 19 Ohm.

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Assembly 08

Electrical system

Solenoid valves 1 Proportional solenoid valves : lift (2Y20) and descent (2Y21).

The proportional solenoid valve allows a different hydraulic flow (more or less), as the voltage sent to its terminals by module -2A3, increases.

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The winding resistance of the two proportional solenoid valves is 14.2 Ohms measured between pins 1 and 2.

A hole is installed (Item. 3) in the centre of the descent valve (2Y21) so as to lower the forks in case of electrical failure, using a 4-mm BTR wrench.

3

2

Caution however : The two proportional solenoid valves operate differently. The lift valve has a passage open at rest ; the descent valve has a closed passage.

They are therefore not interchangeable.

Valve 2Y23 (basic lift option) is an "open or closed" valve. Its winding resistance is about 16 Ohms.

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Assembly 08

Electrical system

All rights reserved. Any reproduction, even of extracts, is prohibited. copyright reserved.

Location of electrical components

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08-14

All rights reserved. Any reproduction, even of extracts, is prohibited. copyright reserved.

Assembly 08 Electrical system

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Assembly 08 Electrical system

Assembly 08

Electrical system

All rights reserved. Any reproduction, even of extracts, is prohibited. copyright reserved.

EGV 14/16

Legend to wiring diagram

Legende zum Schaltplan

A11 : Built-in charger

A11

: Einbauladegerät

A2 1A1 2A3 D10 D11 F2 1F1

A2 1A1 2A3 D10 D11 F2 1F1

: Deichselkopf : Steuerung : Hydraulisch Steuerung : Diode : Diode : Sicherung : Sicherung

: Tiller head : Drive controller : Hydraulic control module : Diode : Diode : Control circuit fuse : Drive motor fuse

2F1 : Pump fuse 6F20 : Instrument fuse G1 : Battery 4H1 : Horn K1 : Main contactor 2K1 : Pump contactor

2F1 : Sicherung 6F20 : Sicherung G1 : Batterie 4H1 : Hupe K1 : Hauptrelais 2K1 : Relais Pumpe

1K11 : Forward travel contactor 1K12 : Backward travel contactor 1M1 : Drive motor 2M1 : Pump motor 6P20 : Clock-meter / discharge indicator S1 : Ignition key S2 : Emergency stop

1K11 : Relais Fahrtrichtung Vorwärts 1K12 : Relais Fahrtrichtung Rückwärts 1M1 : Fahrmotor 2M1 : Pumpenmotor 6P20 : Curtis Combi-Controller S1 : Schaltschlüssel S2 : Not-Ausschalter

1S1 : Forward travel direction command 1S2 : Backward direction travel command 1S3 : Tiller switch 1S20 : Speed reduction switch 1S27 : Built-in charger switch off 1S30 : Tiller head safety 2S1 : Lower command

1S1 : Mikroschalter Fahrtrichtung Vorwärts 1S2 : Mikroschalter Fahrtrichtung Rückwärts 1S3 : Mikroschalter Deichsel 1S20 : Schalter Geschwindigkeitsbegrenzung 1S27 : Schalter Einbauladegerät 1S30 : Bauchschalter 2S1 : Mikroschalter Senken

2S2 : Lift command 2S26 : Lift limitation deactivation 2S46 : Lift limitation 2S61 : Inductive sensor (basiclift) 2S80 : Basiclifting lift command 2S81 : Basiclifting lower command

2S2 : Mikroschalter Heben 2S26 : Freigabe Endhubbegrenzung 2S46 : Hubbegrenzung 2S61 : Endkontackt mit Basishub 2S80 : Mikroschalter Heben Basishub 2S81 : Mikroschalter Senken Basishub

4S1 : Horn command 2Y20 : Proportional valve (lift) 2Y21 : Proportional valve (lower) 2Y22 : Magnet valve (basiclifting)

4S1 : Mikroschalter Hupe 2Y20 : Proportionalventil Heben 2Y21 : Proportionalventil Senken 2Y22 : Magnetventil Basishub

Assembly 08

Electrical system

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Parameter setting

Display

Parameters

EMR REV C/L THROTTLE TYPE RAMP SHAPE CREEP SPEED EMR REV SPEED SEQUENCING DLY VARIABLE PLUG HIGH PEDAL DIS SRO ANTI-TIEDOWN SHNT CONT DRVR BB CHECK QUICK-START M1-MAIN C/L M1-PLUG C/L M1-RAMP C/L M1-ACCEL RATE M1-MAX SPEED M2-MAIN C/L M2-PLUG C/L M2-RAMP C/L M2-ACCEL RATE M2-MAX SPEED NEUT BRAKE C/L NEUT BRAKE

Tiller safety limit current Type of accelerator used Instructions at mid-potentiometer Staring threshold Tiller safety reverse speed Time in sec (key, brake, select direction) Braking proportional to accelerator Pedal up safety Starting in neutral Staring in slow speed Shunt winding active Tiller safety test Fast start acceleration factor Limit current Braking limit current Uphill start limit current Acceleration ramp Maximum speed Limit current Braking limit current Uphill start limit current Acceleration ramp Maximum speed Neutral start limit current Neutral braking

A % % % s

A A A s % A A A s % A

EGV 14-16 100 1 50 10 60 1 on 2 0 off on on 1,4 150 80 140 1 100 150 70 140 1 50 70 on

Assembly 08

Electrical system

Battery

PzS battery (standard lead battery) Handling and maintenance - Preferable operating temperature is between 25°C and 40°C. To avoid permanent damage to the battery, the maximum permissible electrolyte temperature of 55°C should never be exceeded.

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- For heavy duty and when used at winter temperatures, the battery should be charge daily ; even if less than 80% of the standard capacity has been used.

- Always remove or open the tray lid or battery cover before charging and for intermediate charging.

- When charging the battery, a temperature increase of 10° - 12° may be expected. With heavely used batteries, the electrolyte temperature may increase to over 55°C. If this occurs, leave the battery to cool and interrupt the charging process.

- The cell plugs may remain in place during charging.

- Do not close the tray lid or battery cover until 0,5 hour after charging is completed.

- Always connect the charger correctly poled, otherwise the battery and charger may be irreparably damaged (+ to +).

- Only charge with direct current.

- To avoid leakage currents to chassis, always keep batteries dry and clean (Neutralospray).

- Poles and connectors should always be sprayed with pole spray in order to avoid oxidisation and sulphate formation.

- Unsuitable lifting gear may damage the battery (twisting of tray and damage to insulation).

- Protect the battery from contamination, e.g. metal dust, ammonia vapours.

- If in doubt, call the battery supplier's after-sales service.

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Assembly 08

Electrical system

PzS battery

Maintenance intervals Daily maintenance : Charging the battery.

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Weekly maintenance : Check the electrolyte level. If necessary : top up with distilled water towards the end of the charging process. If should always be topped up when the electrolyte level falls to the level of the baffle.

Monthly maintenance : Check all cells towards the end of the charging process for even gassing. Measure acid density and temperature after completion of charging and register any deviations from required values.

Quarterly maintenance : After termination of charging, measure the electrolyte temperature in all the cells. If one of the cells registers a substantial difference compared with its neighbours, check it separately.

Measure the battery's insulation resistance with a separate external circuit, as per VDE. 50 Ohm per V or rated voltage is the lowest limit.

The value must not, however, fall below 1 000 Ohms. If the insulation resistance is lower, clean the cells and the containers.

Half-yearly maintenance work : Ensure that the charger is working properly, particularly the level of the charging current when strong gassing begins (2.4 V per cell). Ensure that the plugs and connectors are working properly.

Note :

Issue :

Beyond these basic instructions, always comply with the battery manufacturer's instructions.

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Assembly 08

Electrical system

PzS Battery

Acid density measurement The acid density is an indication of a battery's charge condition, provided the acid is well mixed. However, the acid density only increases towards the end of the charging process. This is due to the gassing, which starts at approx. 2.4 V per cell.

Acid density is measured with an hydrometer (acid siphon (1)).

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During measurement, the float switch must not jam against the sides or knock the top.

The correct value for acid density is obtained by measuring around half an hour before the end of charging.

To ensure a correct reading, avoid measuring immediately after topping up with water, as the water and acid must be mixed.

The battery temperature must remain close to 30°C during measurement.

Acid density with fully charged battery Acid density with discharged battery

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1.27 kg/l 1.13 kg/l

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Assembly 08

Electrical system

PzS battery

Avoiding damage and accidents

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Working with batteries its not without its dangers. However, these can be avoided by following the procedures below : A)

Hazard : Charging gases can cause explosions.

Avoidance : Ensure good ventilation, avoid electric sparks or naked flames in battery rooms, no smoking.

B)

Hazard : Acid can cause injuries and corrosive damage to parts.

Avoidance : Wear protective acid-proof clothing and rubber gloves, as well as protective goggles, keep neutralisation agent close at hand. Keep water ready for rinsing eyes (in the event of accident, particularly to eyes, call a doctor immediately).

C)

Hazard : Voltages above 40 V can cause a health risk.

Avoidance : Never touch live parts and instruct staff accordingly.

Observe VDE 0100 and VDE 0105.

D)

Hazard : Lead and lead compounds are health hazards if absorbed by the human body.

Avoidance : Eating and drinking is not permitted at the battery charging station, always wash your hands after handling batteries.

E)

Hazard : Batteries can cause damage if tipped over or if they fall out of the lifting gear.

Avoidance : Only use suitable, safe lifting gear ; during transportation, provide necessary safeguards against tipping over or slipping off the transport vehicle's loading surface.

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Assembly 08

Electrical system

PzS Battery

Activation of unfilled battery, plates charged After removing the plugs, all components must be filled steadily with sulphuric acid with a density of 1.25 kg/l, up to the lower acid level marker (use a component filling system for a plastic sieve).

The filling acid must have a temperature of no less than 15°C. After a rest period of 5-6 hours, add some acid if necessary.

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Temperature increase must be measured using a thermometer dipped in electrolyte, in a component in the centre of the battery. If the temperature increase is less than 10°C, the battery may be connected to the charger for recharging.

Recharging time, until automatic stop by the charger control switch, is 6-12 hours. In the case of a "I-h" charging (without automatic stop), a longer charging time is required (up to 20 hours).

The temperature must be monitored during charging. It must not exceed 55°C ; otherwise the charging process must be suspended to let the battery cool.

At the end of the charging process, acid density must be 1.25 kg/l plus/minus 0.01 kg/l.

If not, continue charging until a uniform acid density of 1.27 kg/l is reached.

The battery is then ready to operate. If necessary, bring the electrolyte to reference level, using distilled water. If the acid density is too high, remove acid and add distilled water.

Note :

Issue :

If the electrolyte temperature increases by more than 10°C after filling, or the acid density used has dropped by more than 0.03 kg/l, it means that the material making up the plates has lost part of its charge following prior storage. A longer activation tile is then required. In addition to these instructions, the indications of the battery manufacturer must also be observed.

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Assembly 08

Electrical system

Replacing the battery

Removing the battery There are two possible ways of removing the battery :

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1) The battery must be removed using appropriate lifting tools and hooks with a sufficient lifting capacity, such as a crane).

Take into account the weight of the battery (indicated on the battery identification plate).

1

1. Open the battery compartment and lift the LH door (Item. 1) upward then remove it.

2. Attach the lifting cable (Item. 2) to the hooks fitted to both sides of the battery.

3. Attach the lifting device to the crane (insufficient capacity).

4. Lift the battery carefully.

2) The battery is mounted on rollers, so it is also possible to remove by the left side.

1. Open the battery compartment and lift the LH door upward then remove it (Item. 1).

2. After placing a trolley on this side to carry the battery, pull it out.

2

Refitting the battery To refit the battery, proceed in both cases as per removal, but in reverse order.

After refitting the side door, ensure that the upper and lower hooks are correctly positioned.

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08-20

Accessories

Assembly 09

Contents

Page

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"Curtis Combi 803" Controller: General ............................................................................................................ 09-02 Pin assignment ................................................................................................ 09-03 Voltage adjustment .......................................................................................... 09-04 Technical specifications ................................................................................... 09-05

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Assembly 09

Accessories

"Curtis Combi 803" controller

General The "Curtis Combi 803" controller operates according to the principle of continuous comparison of the battery voltage with a series of reference voltages defined internally.

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The 36-level reference voltage corresponds to the adjusted discharge voltage curve.

If the mean voltage of the battery dropped below the corresponding reference voltage, within a period of 46 seconds, the Combi 803 controller automatically compares with the next lowest reference voltage. This process continues from to voltage level.

When the voltage levels decreases, the DEL display (Item. 1) jumps from right to left. When the stop threshold is reached (end of discharge voltage), the two left LEDs (red) flash.

On the rear panel of the unit, the discharge characteristic may be adjusted to the utilisation case in presence (see P. 09-04).

A lithium battery (10 years) effects the memorisation of the discharge state of the battery ; the counter level is memorised in a EEPROM. The display (2) is able to indicate up to 99.999.9 hours.

When the tiller is moved to the working position, the meter stars running.

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Assembly 09

Accessories

"Curtis Combi 803" controller

Pin assignment (Fig. 1) Service voltages Pin 7 = B+ (24 V) Pin 5 = BFig. 1

Stop Function Pin 3/4 : stops when end of discharge voltage is reached, at 20% of the residual capacity of the battery.

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Note :

Stopping is effected by a thyristor.

This is why polarities must be observed on connection (logic positive / negative, (Fig. 3)).

Incorrect polarity may cause irreparable damage to the Curtis Combi 803 controller or the switching contact.

Fig. 2

Key switch Pin 2 : Powering the LED display Positive logical connection

Service Time Counter (Fig. 2)

Negative logical connection

Starting by application from B+ on Pin (6) or from B- on Pin (1)

Fig. 3

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Assembly 09

Accessories

"Curtis Combi 803" controller

Voltage adjustment End of discharge voltage (volt / element) may be adjusted using the potentiometer (Item. 1).

The battery manufacturer's recommendations for adjustment, must be observed (see table below).

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"Filling up" Voltage at beginning of gas discharge 2.35 V/ element during 6 min at least or Connection of the battery to a rest voltage of 2.09 V/element at least.

K L M N O P

Battery manufacturer

Battery type

Hoppecke Hagen

Wet cell Wet cell Maintenance-free : CWF, PWT, PZV Extended capacity : CSM Dryfit gel battery

Sonnenschein

1,57 1,63 1,68 1,73 1,78 1,82

Q R S T U

1,84 1,86 1,89 1,91 1,93

Voltage rating after discharge (V/Cell) 1,73 1,73 1,82 1,78 1,93

Adjustments recommended by the battery manufacturer for standard charging.

Note :

Issue :

In special cases of major charging (major current drain over a short period), the process may start too soon. In such cases, the correct adjustment must be determined through testing.

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Assembly 09

Accessories

"Curtis Combi 803" controller

Technical Specifications

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Battery discharge Indication : - 10 LEDs : 5 green, 3 yellow, 2 red.

- Lithium Accumulator.

- Reset to zero when the beginning of gas discharge voltage is 2.35 V/cell or the rest voltage 2.09 V/cell is reached.

- Stop by rest contact at self-maintenance.

- Adjustable Discharge Characteristic.

- Optical display, to warn at 25% of residual capacity.

- 3A switching current.

Identification plate

Service Time Counter : - 6 digit, liquid crystal display.

- Resolution 0.1 h.

- Flashing symbol display.

- Memory independant of energy by EEPROM. Basic Characteristics : - Service Voltage 24 V and 48 V. - Tolerance +/- 25% of the rated voltage.

- Service Temperature -40°C to +85°C. - Accuracy (max. deviation 2%).

- Protection Class (IP65).

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Assembly 10

Hydraulics

Contents

Page

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General information ............................................................................................... 10-02 Principle of operation : ascending movement ....................................................................................... 10-03 descending movement, removal of pump-motor.............................................. 10-04 Characteristics ....................................................................................................... 10-05 Pump : disassembly and reassembly .................................................................... 10-06 Maintenance of hydraulic system .......................................................................... 10-07

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Assembly 10

Hydraulics

General information

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The pump assembly is made up of the following components : 1. Pump motor 2. Gear pump 3. Suction filter 4. Distribution unit 5. Pressure limiter 6. Lifting electric valve 7. Lowering electric valve 8. Tank 9. Check valve

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Assembly 10

Hydraulics

Principle of operation

Ascending movement

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When the pump motor (Item. 1) is powered, it drives the pum (Item. 2) which immediately sends oil from the tank (Item. 3) to the steel pipe (Item. 6), while previously passing through the suction filter (Item. 4) and the chek valve (Item.

5).

The amount of oil sent to the steel pipe is controlled by the proportional electric valve 2Y20 and is directly in proportion to the pressure applied to the lift control button at the head of the tiller.

A hose is connected to this steel pipe which is itself connected to the "lift" jack.

If the pressure increases at the steel pipe (Item.

6), it also increases at the inlet of the relief valve (Item. 7) which then opens and enables return to the tank.

Calibration of the relief valve For EGV 14, the pressure limiter must be calibrated to 170 bar.

For EGV 16, the pressure limiter must be calibrated to 190 bar.

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Assembly 10

Hydraulics

Principle of operation

Descending movement

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1.

2.

3.

4.

5.

6.

7.

Pump motor Pump Tank Suction filter Check valve Coupling Relief valve

To lower the load, electric valve 2Y21 must be powered through the "lower" control button at the head of the tiller.

2Y21 being a proportional electric valve, the descent speed of the load is proportional to the pressure applied to the "lower" control button.

Removal of pump-motor assembly 1.

2.

3.

4.

5.

6.

7.

8.

Disconnect the battery connector.

Set the unit on chocks.

Remove cowlings.

Disconnect the pump power cables and the hydraulic hose and the electric valve power cables.

Unscrew the 4 nuts securing the pumpmotor assembly to the chassis (M8 DIN 985) (Item. 1).

Remove the panel above the pump-motor assembly if necessary.

Unscrew the 2 screws of the contactor and remove.

Lift the entire assembly to remove if from its position.

Assembly is effected in reverse order.

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Assembly 10

Hydraulics

Characteristics

Pump

P1-17RD6

Designation Capacity Rotation direction Service pressure Rotation speed

50264-00 3.3 cm3 Left 170 bar (EGV14) - 190 bar (EGV16) 2610 rpm

Distribution unit

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Max. pressure Connections

230 bar 2 x G3/8 (22Nm)

Tank Volume Oil Type

11.6 litres Din 51 624

Filter Filtration

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80 µ

Workshop Manual

EGV 14/16 Page :

10-05

Assembly 10

Hydraulics

Pump : diassembly and reassembly 1. Disconnect the battery connector and set the unit on blocks.

2. Unscrew the 4 securing screws (M8 x 16 DIN 912) of the motor (see Item 2 page 10-07).

3. Remove the motor-pump assembly.

4. Unscrew the 4 large securing screws (MC6 S8x90) (Item 1) of the pump (Item 2).

5. Disconnect the piping.

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Assembly is effected in reverse order.

Remark : Note for assembly : - Clean the suction filter.

- Remove impurities from the piping.

- Fill the oil pump.

- Screw tightening torque : • for the motor is 12Nm • for the pump : 22 Nm. When starting-up, the steel pipe should be loosened slightly for bleeding.

Note :

Issue :

Most premature gear pump failures are caused by polluted hydraulic oil.

This is why the clean-liness of the hydraulic system must be ensured and the filter replaced regularly. If the pump is noisy and the oil foams, check for leaks between the pump and the motor or at the hydraulic couplings.

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Workshop Manual

EGV 14/16 Page :

10-06

Assembly 10

Hydraulics

Maintenance of hydraulic system

Every 2000 hours or at least every two years.

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Caution : Hydraulic oil is a health hazard.

Observe the safety instructions for use of hydraulic oil.

- Place the truck on a horizontal surface.

- Lower the forks.

- Disconnect the battery connector and remove the motor cowling.

- Unscrew the 4 screws (Item. 2) of the pump motor (Item. 1) for removal.

- Suck out the hydraulic oil from the tank and discard it.

Caution : Discard waste oil according to instructions.

- Remove and replace the motor strainer.

- Mount the pump motor on the hydraulic tank.

- Unscrew the gauge (Item. 3) and fill the hydraulic oil tank OZ referring to the lubricant table until the gauge graduation (Item. 4) is reached.

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Workshop Manual

EGV 14/16 Page :

10-07

Assembly 11

Motors

Contents

Page

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Technical characteristics ........................................................................................ 11-02 Travel motor : General information, terminal strip................................................................... 11-03 Removal ........................................................................................................... 11-04 Assembly.......................................................................................................... 11-05 Replacing the brushes ..................................................................................... 11-06 Maintenance .................................................................................................... 11-07 Pump motor : Removal, assembly.......................................................................................... 11-09 Replacing the brushes ..................................................................................... 11-10 Maintenance .................................................................................................... 11-11

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Workshop Manual

EGV 14/16 Page :

11-01

Assembly 11

Motors

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Technical Characteristics

Designation Type of motor Service voltage (V) Amperage (A) Rated speed (rpm) Rated unladen speed (rpm) Power (kw) Service Protection Insulation Brushes • Dimensions (mm) • Wear limit (mm) • Number Ventilation

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Travel motor

Pump motor

3MB 80J Compound 24 53 1 850 3 500 1 S2 IP 20 class F H 100 10 x 40 x 32 12,5 4 forced ventilation

24MA42 - HSWA Compound 24 208 2 610 4 060 3 S3 15% IP 23 class F SO 266-00 9 x 30 x 27 14 4 ventilation

Workshop Manual

EGV 14/16 Page :

11-02

Assembly 11

Motors

Travel motor

General information These models are fitted with a compound travel motor (combined series-wound shunt-wound).

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The compound motor is fitted with a series winding and a parallel exciter winding. The latter is mounted in parallel on the armature and the series winding.

Compound motors have a lower starting torque than a series motor, but the torque remains much more stable in all speed ranges.

The direction of rotation of the motor is changed by reversing the polarity of the armature winding by means of a relay.

Travel speed depends on the control unit's duty ratio.

Compound motor

Terminal strip Designation on terminal strip A1 A2 D1 D2 E1 E2

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Designation on connector cable armature armature series winding series winding parallel winding parallel winding

Workshop Manual

EGV 14/16 Page :

11-03

Assembly 11

Motors

Travel motor

Removal Note :

When removing the travel motor, the truck is not braked ; it must be secured to prevent it from rolling.

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1.

2.

3.

4.

Disconnect the battery connector.

Remove the covers (see page 01-03).

Remove the steering stop (Item. 1).

Disconnect the power supply cables on the travel command microswitch (Item. 2).

5. Mark and disconnect the travel motor (Item.

3) connecting cables.

6. Remove the clamp (Item. 4).

7. Unscrew the 6 attchment screws (Item. 5) of the tiller and set the tiller to one side.

8. Unscrew the 3 attchment screws (Item. 6).

9. Remove the travel motor.

10. Cover the gearbox orifice.

6 (40 Nm)

1

2 5 (32 Nm)

3

4

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Workshop Manual

EGV 14/16 Page :

11-04

Assembly 11

Motors

Travel motor

Assembly Travel motor assembly is as per removal, but in reverse order of operations.

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The following conditions must, however, be fulfilled before assembly.

1. Clean the gearbox orifice (Item. 1) and the ventilation - slots (Item. 2).

2. bring the drive wheel to a straight position.

3. Install the travel motor in the gearbox, in the right position.

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EGV 14/16 Page :

11-05

Assembly 11

Motors

Travel motor

Replacing the brushes The brushes must be replaced when a residual length of 50% is reached.

New brushes 25 mm

Replace at 12,5 mm

Only complete sets of carbon brushes (4 units) should be replaced at any one time.

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Disassembly 1.

2.

3.

4.

Remove the battery connector.

Remove the travel motor cover.

Lift the brush spring (Item. 1) and hold it.

Remove the brush (Item. 2) using the connecting cable (pigtail).

5. Slowly release the brush spring.

6. Disconnect the connecting cable by removing the screw (Item. 3).

7. Clean the commutator area.

Note : Do not inhale carbon dust.

8. Fit new brushes Note : After replacing the brushes, the motor should not be brought to maximum speed ranges. the brushes are run-in fairly quickly under a light load.

Inspection of the brush springs Brush springs with insufficient pre-tension lead to commutator damage. Check that the spring move easily in their housing.

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EGV 14/16 Page :

11-06

Assembly 11

Motors

Travel motor

Maintenance The maintenance services between general overhauls consist of : - Cleaning.

- General visual inspection.

- Replacement of any defective component.

- Inspection of brushes and commutator.

- Replacement of brushes (if necessary).

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This work must be carried out every 500 hours or every quarter at the latest.

Caution : To prevent short-circuits or wounds, the battery must be disconnected before beginning any work on the motor.

Cleaning - Remove the brush cover from the motor and remove the brushes.

- Clean the motor using compressed air (do not inhale the dust use a mask).

- Clean the commutator and the brush holder using a petrolsoaked cloth (do not use wool), let dry properly.

Note :

Do not lift the brush springs any more than necessary and do not bend them on the side.

Visual inspection, replacing defective components : - Check the cleanliness of the gearbox ventilation channels (Item. 1). Dirt reduces the circulation of air and causes heating of the motor which may damage it.

- Check for signs of overloading (overheating) on the field windings and the armature : dark colour, brittle or burned insulation, unsoldered commutators.

Motors with these signs must be replaced immediately.

- If oil or grease is found in the motor (mostly a paste of oil, oil vapour with dust and dirt and carbon deposits), determine the cause at once. Clean the motor thoroughly.

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Remark : Rapid wear of the brushes or the commutator mainly due to oil.

The oil or grease burns in the brush box and leaves an abrasive residue.

This is why the brushes can be worn down below the limit before the routine maintenance interval.

Workshop Manual

EGV 14/16 Page :

11-07

Assembly 11

Motors

Travel motor

Maintenance (cont.)

Checking the brush unit, changing the motor brushes : When the brush unit has been cleaned, the brushes must move easily in their guides, once their springs have been raised.

If one or more brushes stick, they must not be rubbed with emery paper or any other abrasive material.

The complete brush set must be changed to prevent overheating.

The brushes must not be broken or anormally worn on the friction surface.

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Notes :

- Always replace the entire set of brushes ; the shortest brush determines whether a replacement is required.

- Only fit genuine replacement brushes (refer to spare parts list)!

- Take care not to let the springs drop down while fitting the brushes.

- Change the brushes even if they are not yet down to the minimum length. The remaining duty period may be less than the time to the next inspection.

- The motor should undergo a general overhaul after 3 sets of brushes have been changed. (specialist workshop)

Commutator The commutator's running surface should be evenly smooth and appear grey-black.

The commutator should not be run-in, scoured or untrue.

Minimum dimension : 62-0,2.

Do not rework it with a file, emery paper or similar objects.

Bearings The ball bearings do not have to be lubricated. The grease packing is sufficient for the maintenance period between general overhauls.

The bearings must be inspected : - At each general overhauls.

The bearings must be replaced : - After a maximum operating period of 2,000 service hours.

- Not more than every five years.

Only fit the bearings specified in the spare parts list.

Note on the risk of overloading with discharged batteries : If the RPM level of the motor drops noticeably, stop work immediately and check the battery charge without delay.

Do not drive with undervoltage.

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Workshop Manual

EGV 14/16 Page :

11-08

Assembly 11

Motors

Pump motor

Removing the pump motor 1.

2.

3.

4.

5.

6.

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7.

8.

Disconnect the battery connector.

Place the unit on a stand.

Remove the covers.

Disconnect the power cables for the pump motor and for the two electric valves.

Remove the hydraulic hose.

Remove the panel. Mark the location on the motor casing and another facing the motor base.

Remove the 4 screws (M8 x 16 DIN 912) (Item. 1).

Unscrew the four attachment screws for the pump and the motor.

Caution : Lift the motor using the shaft so as to remove the entire unit.

Assembly Assembly is in the reverse order of removal.

Check that the motor is positioned in the proper way by checking the position of the two markings.

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EGV 14/16 Page :

11-09

Assembly 11

Motors

Pump motor

1

Replacing the brushes 1. Disconnect the battery connector.

2. Remove the brush cover.

3. remove the brush and its holder (Item. 1).

Caution : The brushes must be replaced once they reach a residual length of 14 mm, which corresponds to 50% wear.

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4. Undo the ring braid.

Caution : Unscrew, replace and tighten the brushes one by one to avoid dropping the shunts.

5. Clean the commutator area.

Caution : Do not inhale the carbon dust.

Brush springs Make sure the brushes move easily in their housing. Insufficiently stressed brush springs damage the commutator.

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EGV 14/16 Page :

11-10

Assembly 11

Motors

Pump motor

Maintenance Inspection of brush holder assembly (replacement of brushes) See page 11-10 Commutator

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The contact surface of the Commutator must be perfectly smooth and grey-black in colour.

The commutator must not be worn, scratched or off centre.

The commutator must be overhauled if it shows one of these signs.

Minimum dimension reached : 46.3 mm.

In any case, do not work on the commutator with a file, glass paper or similar tools.

Bearings Ball bearings must not be lubricated. The amount of lubricant is sufficient for the operating period between two general overhauls.

Bearings must be checked : - At each general overhaul.

Bearings must be changed : - After no more than 2000 hours in service.

- At the latest every five years.

Only mount bearings as per the spare parts list.

Remarks on risks of overload in case of battery discharge : Stop work immediately and check the battery charge if the motor rpm drops significantly.

Never drive the truck with undervoltage!

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Workshop Manual

EGV 14/16 Page :

11-11

All rights reserved. Any reproduction, even of extracts, is prohibited. copyright reserved.

Assembly 20

Mast

Contents

Page

Technical specifications ......................................................................................... 20-02 Type of masts : telescopic, full freelift........................................................................................ 20-03 Triplex............................................................................................................... 20-04 Mast removal and assembly .................................................................................. 20-05 Telescopic mast : Principle of operation ....................................................................................... 20-06 Hydraulic system.............................................................................................. 20-07 Full free lift mast : Principle of operation ....................................................................................... 20-08 Hydraulic system.............................................................................................. 20-09 Triplex mast : Principle of operation ....................................................................................... 20-10 Hydraulic system.............................................................................................. 20-11 Adjustment of lift chains......................................................................................... 20-12 Guide rollers........................................................................................................... 20-13 Lift cylinders : Removal of the telescopic mast....................................................................... 20-14 Removal of outer cylinders .............................................................................. 20-15 Centre cylinder................................................................................................. 20-16 Automatic lock valve : operation ...................................................................... 20-17 Damping system, operation ............................................................................. 20-18 Initial lift .................................................................................................................. 20-19

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20-01

Assembly 20

Mast

Technical specifications

Lifting mast Mast securing bolts Guide roller bolts Automatic locking valve Chain

Torque = 20 Nm (+/- 2 Nm) Max. tolerated extension : 3% (as per regulations governing occupational accidents) Max. authorized = 0,6 m/s

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Lowering speed

Torque = 200 Nm Torque = 80 Nm

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Workshop Manual

EGV 14/16 Page :

20-02

Assembly 20

Mast

Type of masts

Telescopic

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During lifting, the inner channel exceeds the clearance of the fixed mast. In low-ceilinged areas, keep this in mind.

Full free lift The design of this type of mast permits movement of the carriage inside the inner channel without exceeding the mast clearance (closed height).

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EGV 14/16 Page :

20-03

Assembly 20

Mast

Type of masts

Triplex

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Similar to the full free lift mast, but with considerable lift height, without increase of closed height. For work in low-ceilinged areas, no need to take into account the channel lift.

All masts have total visibility. The mast beams are I-beam sections. The fork carriage and the mast beams are guided by rollers which also absorb lateral thrust.

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Workshop Manual

EGV 14/16 Page :

20-04

Assembly 20

Mast

Removing the lifting mast

1.

2.

3.

4.

5.

6.

Remove the carriage (see page 22-02).

Lower the mast completely.

Disconnect the battery.

Remove the lift-cylinder supply hose from the main block.

Sling the mast correctly.

Loosen by one turn the mast's lateral adjustment screws (as the same height as the middle bar).

7. Remove the 2 setscrews at the foot of the mast.

Be careful with the shims (note their position and quantity).

8. remove the mast.

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Caution : For the triplex mast, remove the fork carriage from above.

Installation of the mast Installation is in the reverse order of removal.

Caution : - be carefull with the mast adjustment shims.

- drain the lift cylinders.

Check the chain tension.

Torque for fixing mast : 200 Nm.

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Workshop Manual

EGV 14/16 Page :

20-05

Assembly 20

Mast

Telescopic mast

Principle of operation The two lift cylinders on the outer masts are integral to the mast sections.

They are supplied with hydraulic oil through a hose.

The two cylinders are connected at the top of the crossmember of the inner channels.

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As soon as the cylinders are supplied with pressurised oil, the two pistons extend simultaneously lifting the inner channel.

The stop is located between the lift cylinder and the piston.

The lift chains are secured on the outer mast and then transferred to the inner channels by chain pulleys. At the other end, the chains are connected to the fork carriage.

The lift mast thus lifts with respect to the fork carriage with a ratio of 1/2.

A descent lowering valve integral to the cylinder ensures a maximum descent speed of 0.60 m/s.

A stop (Item. 1) prevents the fork carriage from falling out onto the ground.

There is a minimum clearance of 2 mm between the carriage stop and the mast stop.

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EGV 14/16 Page :

20-06

Assembly 20

Mast

Telescopic mast

Hydraulic circuit in the lifting mast

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The oil enters via a rigid pipe, towards the lift cylinders. A lowering valve (1) is fitted inside the RH lift cylinder.

1

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Workshop Manual

EGV 14/16 Page :

20-07

Assembly 20

Mast

Full free lift mast

Principle of operation This mast is fitted with 3 lift cylinders.

It is the position of the centre cylinder which lifts inside the inner telescopic channels which provides the great free lift height, i.e. the maximum fork lift height, without increasing the closed height of the mast.

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The two lift cylinders located along the outer masts are integral to the outer mast I-beams.

The pistons of these cylinders are secured to the mobile intermediate channels.

As soon as the cylinders are supplied with pressurised oil, the centre cylinder lifts first thanks to the use of pistons with different diameters.

Then, it is the two outer cylinders that lift simultaneously while raising the inner channels.

A lowering valve integral to the right-hand cylinder ensures a maximum descent speed of 0.60 m/s.

A stop (Rep. 1) prevents the fork carriage from falling out onto the ground.

There is a minimum clearance of 2 mm between the carriage stop and the mast stop.

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Workshop Manual

EGV 14/16 Page :

20-08

Assembly 20

Mast

Full free lift mast

Hydraulic system A gear pump sends the pressurised oil to the solenoid valve group from where it is sent to the two lateral lift rams through piping.

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On the full free lift mast, the oil is delivered to the centre cylinder through the right hand lateral lift cylinder through a pipe.

Using pistons with different diameters, it is the centre cylinder that lifts first.

- Lift sequence 1 raises only the fork carriage (without lifting the inner channels).

- Lift sequence 2 enables the telescopic lifting of the inner channels.

The automatic lock valves integral to the cylinders prevent any sudden drop of the load in case of piping break.

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Workshop Manual

EGV 14/16 Page :

20-09

Assembly 20

Mast

Triplex mast

Operating principle

1

This mast is equipped with 3 lift cylinders.

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The position of the central lift cylinder, which is lifted inside the internal telescopic supports, provides an exceptionally high free-lift height, i.e. maximum fork-lift height, without having to increase the height excluding the mast.

The two lift cylinders located along the external supports are incorporated into the I-sections on these supports. The plunger pistons in these lift cylinders are secured to the intermediate mobile supports.

The chains for lifting sequence 2 are secured to the upper end of the external supports and to the lower end of the internal supports.

When oil under pressure is pumped into the cylinder, the central lift cylinder is lifted first, by means of pistons with different sections.

The two lateral lift cylinders are then extended, raising the intermediate mobile supports. The chain link mechanism raises the internal supports by a ratio of 1/2.

A lowering valve bolted to the connection block limits the descent rate to 0.60 m/s.

A stop (1) prevents dislocation of the fork carriage when it is raised to maximum height.

The minimum clearance between the fork carriage stop and the mast stop is 2 mm.

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Workshop Manual

EGV 14/16 Page :

20-10

Assembly 20

Mast

Triplex mast

Hydraulic system The oil enters via a hose, flowing towards the two outer lift cylinders.

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The oil from the RH lift cylinder (hollow cylinder rod) is sent through a hose to the central lift cylinder, pushing the piston rod as far as the stop. The two side lift cylinders are then extended simultaneously.

- Lifting sequence 1 only raises the fork carriage (without extending the inner channels).

- The inner channels are raised during lifting sequence 2.

The hose failure valve (1) incorporated in the RH lift cylinder prevents the load from falling abruptly in the event of a burst hose or pipe.

1

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20-11

Assembly 20

Mast

Adjustment the lifting chains

Telescopic, full free-lift and triplex masts External chains : The external lifting chains are retightened uniformly by means of the adjusters (1) until all three mast section bars are lined up.

Central chains (only for full free-lift and triplex masts) :

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The lifting chains are retightened uniformly by means of adjusters (2).

Extend the mast as far as it will go. In this case, the centre of the upper rollers on the fork carriage must be 10 mm away from the top of the mast range (see fig. 3) When adjusting the lifting chains, make sure the clearance between the fork carriage stop and the stop on the support is at least 2 mm.

Important : The condition of the lifting chains in terms of wear and stretching (3% maximum) must be checked in accordance with the regulations governing the prevention of occupational accidents.

"X" Dimension EGV 14 : X = 10 mm EGV 16 : X = 10 mm

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20-12

Assembly 20

Mast

Guide rollers

Assembly

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Roller diam.

75,3 75,6 75,9 76,2

Dim. “A” greater than 76,4 76,7 77

Dim. “X” to 76,4 76,7 77 -

1,1 1,1 1,1

Remark : Dimension "A" must be measured where the slide coincides with the radius.

1 : Guide rollers 2 : Adjusting shim 3 : Countersunk screw tightening torque = 140 Nm (+ or - 15 Nm)

Side clearance Side clearance

Fork carriage - inner mast 0.3 mm mini, 1.3 maxi on the narrowest section, otherwise 1.8 mm maxi.

Inner mast - (central column) - outer mast Upper roller : 0.3 mm mini, 1.3 on the narrowest section, otherwise 1.8 mm maxi.

Lower roller : 0.3 mm mini, 1.3 on the narrowest section, otherwise 1.8 mm maxi.

Fork carriage

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EGV 14/16 Page :

20-13

Assembly 20

Mast

Lifting cylinders

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Removal of cylinder fitted to the telescopic mast - Removal of mast (see page 20-05).

Lay the mast on the ground.

- Remove the upper piston attachment circlips.

- Pull on the inner channel to free the pistons.

- Place a piece of squared wood between the upper crossbeam of the outer mast and the upper crossbeam of the inner channel, for safety.

- Release the lower hydraulic coupling.

- Remove the attachment clamp.

Changing the seals - Tighten the cyl. in a vice.

- Unscrew the cyl. head using a chain pipe wrench.

If the cyl. head does not move, heat it with a blow-torch.

The cyl. head is locked using Loctite 242 (applied to 3 points, enabling it to spread around the periphery).

1 : double scraper 2 : slotted lining 3 : cyl. head 4 : drain screw 5 : O-ring 6 : guide ring 7 : piston cover 8 : piston 9 : cylinder (cylinder body) The piston cover is locked using Loctite 275.

Tightening torque = 150 Nm (+ 30 Nm).

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20-14

Assembly 20

Mast

Lifting cylinders

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Removal of outer cylinders (free lift masts) - Mast removal (see page 20-05).

- Place the mast on the ground.

- Remove the upper piston attachment circlips.

- Pull on the intermediate channel to free the pistons.

- Place a piece of edged wood between the upper croosbeam of the outer masts and the upper crossbeam of the inner channell or, for the triple mast, between the upper outer - mast crossbeam and the upper croosbeam of the intermediate channels, for safety.

- Loosen the upper and lower hydraulic couplings.

- Remove the attachment clamp.

Remark : Loctite 243 was uses for locking and sealing (Item. 1).

Tightening torque = 30 Nm. The cyl. head (Item. 2) is mounted using Loctite 243 applied to three 3 points, allowing it to be spread around the periphery.

The piston cover (Item. 3) is cotaed with Loctite 275 (P/N 524199) on the entire surface.

The piston end block must be tightened using the appropriate torque, which varies according to the diameter of the piston i.e. : diam. 26 mm : Tightening torque = 30 Nm (+ 10 Nm) diam. 37 mm : Tightening torque = 150 Nm (+ 30 Nm) If the packing is changed, do not remove the piston end block!

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EGV 14/16 Page :

20-15

Assembly 20

Mast

Lifting cylinders

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Centre cylinder (free lift and triplex masts) The cyl. is a single acting type with plunger.

The cylinder (cylinder body) and the bottom or base of the cylinder are a welded assembly.

The cylinder head is bonded using Loctite 243 on the cylinder.

Sealing between the cylinder and the cyl. head is ensured by an O-ring, and between the cyl. head and the plunger by a grooved packing.

A cover screwed using Loctite 275 in the piston rod is used as a stop to the lifting movement.

An automatic lock valve screwed in the cylinder base stops any sudden load drop in case of pipe failure.

Diassembly of the centre cylinder - Lift the fork carriage sufficiently to placed and edged piece of wood underneath. Then lower the fork carriage an unhook the carriage lifting chains.

Remove the hydraulic coupling at the base of the cylinder.

- Remove the cylinder attachment clamp.

- Remove the lifting cylinder.

- Tighten the cylinder in a vice (by the base and not the body, to prevent any risk of cylinder deformation).

- Unscrew the cyl. head using a chain pipe wrench.

If the cylinder head does not move, heat it with flame.

- Tighten the piston in a vice fitted with clamping jaws. Unscrew the cylinder pulley bracket (clevis).

The clevis is locked using Loctite 243.

- Remove the piston cylinder head.

Remark : If the seals are changed do not remove the piston cover, which is locked using Loctite 275 applied all over the surface, also ensuring sealing.

Tightening torque = 1 000 Mn (+ 200 Mn).

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Workshop Manual

1 : double scraper 2 : grooved lining 3 : cyl. head 4 : drain screw 5 : O-ring 6 : guide ring 7 : piston cover 8 : cylinder (cylinder body) 9 : piston cover

EGV 14/16 Page :

20-16

Assembly 20

Mast

Lifting cylinders

Automatic lock valve or flap (safety in case of pipe break) The figures show the position of this valve at the base of the cylinder and adapter.

Tightening torque : 20 Nm (+ or - 2 Nm).

Operation

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The purpose of the safety valve is to prevent a sudden, uncontrolled drop in load as a result of a break in piping.

It is a flap-type valve whose main closing element is, at rest, held away from the seat by a spring and allows a variable-width opening.

A load loss and build up of pressure on the flap in the B to F flow direction (triggering direction) are lower than the force of the spring in normal use : the valve remains open. If a rupture occurs in the hydraulic system, the oil flow increases because of load dynamics, the load loss becomes greater than the spring strength and the valve closes immediately.

The closing flap is fitted with a calibrated orifice that admits a flow according to load, from B to F, permitting a slow descent to the ground.

1 : piston cover 2 : cylinder base 3 : safety valve 4 : closing flap

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20-17

Assembly 20

Mast

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Lifting cylinders

Hydraulic cylinder cushioning device On the full free-lift and triplex masts, there is a cushioning device which is used (during the transition from lifting sequence 2 to lifting sequence 1) to hydraulically slow down or cushion the travel of the lateral lift cylinder rod equipped with this cushioning system just before it arrives at the stop when the mast is lowered fully. This devices slows the rapid movement of the piston at the end of its travel to reduce to a minimum the effect of impact on the cylinder.

Operation : When oil under pressure is pumped into the lift cylinder, during the lifting operation the spring (4) pushes the piston (2) is moved toward the bottom of the cylinder until the spring ring (5) stops up against the piston cover (1). The oil flow through the hole in the restrictor (3) continues to pass through chamber A and then out into chamber B until equilibrium is achieved.

When the load is lowered, before the lift cylinder rod reaches the end-of-travel position, the piston (2) first comes into contact with the bottom of the cylinder. The piston (2) is pushed towards the cylinder rod and the oil under pressure is sent via chamber B, through the restrictor hole (3) to chamber A. This balance in pressure brings about a hydraulic deceleration of the lifting mast.

1 : piston cover 2 : piston

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3 : nozzle 4 : pressure spring

Workshop Manual

5 : spring ring

EGV 14/16 Page :

20-18

Assembly 20

Mast

Removing the initial lift cylinder

Attention :

If the supports are not put in place, truck stability will be reduced, resulting in a higher risk of accidents.

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Securiting the mast 1. Set the initial lift device to the lower position.

2. Lift the mast until easy access for the work is ensured.

3. Secure the mast with a fastening chain.

4. Remove the top yoke of the gas-filled cylinder after first removing the clip.

5. Remove protective covers at the side of the cylinders.

6. Using a hydraulic jack located about 100 mm from the front end of the frame, raise on side of the truck until a 90 x 90 mm support can be placed under this side of the truck (see illustration below).

Support 50 mm Support 55 mm

Hydraulic jack Support 90 x 90 mm

7. Perform the same procedure for the opposite side of the truck. After supporting the truck with blocks, leave the jack in place with a low pressure.

8. Put supports 55 mm thick under the rear of the truck.

9. Put a support about 50 mm thick under the forks of the initial lift device.

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EGV 14/16 Page :

20-19

Assembly 20

Mast

10. First remove the clamping screws (1), then the two cylinder mounting pins (2) at the cylinder head.

11. Lift the truck with a jack to separate the frame and the initial lift device. This procedure must make enough room for the removal of the cylinder.

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Attention :

Do not exceed the opening angle indicated in the picture.

12. Remove the cylinder connections.

13. Remove the lift limiting switch (the switch hinders the removal of the cylinders).

14. Remove the cylinder and replace it with a new one.

(1) Clamping screw

(2) Cylinder mounting pin

Removal of the cylinder

Installing the initial lift cylinder Installation is in the reverse order of removal.

Ensure that the underside of the lift limiting switch is installed 170 mm from the top edge of the cylinder tube.

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EGV 14/16 Page :

20-20

Assembly 20

Mast

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Removing the wheel mounts and tie rods Attention :

If the supports are not put in place, truck stability will be reduced, resulting in a higher risk of accidents.

Attention :

If it is necessary to renew the wheel mounts and tie rods on both sides of the truck, perform the work on each side separately and follow the procedure described below each time.

1. Lift the mast until easy access for the work is ensured.

2. Secure the mast with a fastening chain.

3. Fully lower the initial lift device.

4. Remove the retaining pin (1) from the wheel mounting pin on the side in question with a drift punch of sufficient size.

Securing the mast

(1) retaining pin to be removed (visible between battery frame and initial lift device) 5. Refit the complete initial lift device.

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EGV 14/16 Page :

20-21

Assembly 20

Mast

6. Install a support about 170 mm thick under the mast on the opposite side.

Hydraulic jack, 5 tonnes Support 135 mm midway under wheel arm

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Truck side to be repaired

Maintenance support (170 mm thick)

7. Install two safety supports (about) 45 mm thick).

8. Install a hydraulic jack on the side to be worked on and lift the truck until a support 135 mm thick can be placed about midway under the wheel arm.

9. Lower the jack.

10. Fully lower the initial lift.

11. Check that the truck is supported well and is in a stable position.

12. Check that the wheel mount/tie rod unit is not attached (the wheels should not touch the ground).

13. Scribe the tie rod pin on the frame side in order to mark its angle (this will facilitate the later installation of the pin).

Support 135 mm midway under wheel arm Tie rod

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EGV 14/16 Page :

20-22

Assembly 20

Mast

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14. Remove the tie rod pin on the frame side and keep the washers. As the pin was not installed with force, it is sufficient to move the tandem wheels a little to remove the pin easily.

15. Remove the retaining pin and wheel mounting pin from the wheel mount.

16. Remove the retaining pin and tie rod/wheel mount pin. Keep the spacer and washers.

17. Measure the dimension indicated in the picture on the old wheel mount and grind the new part to exactly the same dimension.

Removal of the tie rod/wheel bogie pin

Surfaces to be ground for fitting

Dimension required for new part

18. Install the tie rod pin and then the pin in the wheel mount.

19. Install the pin connecting the fork and clevis of the wheel mount along the spacer and the washers, then insert the pin using a wheel mounting pin bevelled on one end.

Self-made installation tool

20. Insert the tie rod pin on the frame side, installing the washers in their original position and the cotter pin from below.

21. Remove the supports in the reverse order of installation.

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EGV 14/16 Page :

20-23

Assembly 20

Mast

Removing the complete initial lift device Attention :

If the supports are not put in place, truck stability will be reduced, resulting in a higher risk of accidents.

Remarque : This work can be not carried out at the customer’s if a crane or another suitable lifting device is not available.

Set the initial lift device to the lower position.

Remove the battery and the mast (see page 20-05).

Remove the top end of the gas-filled cylinder after removing the clamp.

Remove the cylinder side covers.

Lift the truck on one side with a hydraulik jack to allow a 90 x 900 mm thick support to be placed under this side of the truck (see illlustration).

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1.

2.

4.

5.

6.

90 mm thick support 7. Proceed similarly as for the other side of the truck.

8. Put a hydraulik jack under the initial lift unit between the forks as a light support. The tandem wheels of the initial lift device must still contact the ground.

9. First remove the clamping screws, then the two cylinder mounting pins on the cylinder head (see page 20-20).

10. Remove the split pins and pins on that part of the initial lift device located in the battery compartment ; do not discard the washers.

11. The initial lift device is now separated from the frame.

Installation is in the reverse order of removal. Do not forget to install the washers in their original position. If new adjusting cams must be installed, they must be installed with Loctite and tightened with a 32 mm key having a thickness of no more than 4 mm. This adjustment must be carried out in such a way that the pins can be installed without the use of force.

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EGV 14/16 Page :

20-24

Assembly 20

Mast

Repairing the initial lift cylinders

First remove the cylinder to be repaired from the truck as described on page 20-19.

Removal of the cylinder :

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1. Withdraw the piston rod until the snap ring (1) is opposite for the hydraulic fitting.

2. Using a small lever, pry the snap ring into the adjacent groove (3) through the opening for the fitting.

3. Fully remove the piston rod.

4. The seals can be removed with a small screwdriver.

Legend 1 : Snap ring 2 : Piston rod 3 : Groove 4 : Wiper ring 5 : Guide rings 6 : Sealing ring

Installation of the cylinder : 1. The snap ring must be fully seated in the groove, otherwise there is a risk of the cylinder canting.

2. Insert the piston rod until the snap ring can be accessed through the opening for the hydraulic fitting.

3. Position the snap ring in the groove.

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Initial lift cylinder

EGV 14/16 Page :

20-25

Assembly 22

Fork carriage

Contents

Page

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Telescopic mast : removal, assembly .................................................................... 22-02 Triplex mast : removal, assembly ........................................................................... 22-03

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EGV 14/16 Page :

22-01

Assembly 22

Fork carriage

Telescopic mast 2

3

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Removal 1. Lift the carriage to reach the stop screw (Item. 1).

2. Unscrew the screws (Item. 1).

3. Place 2x 10cm wooden shims on the two 2 longitudinal sections.

4. Rest the carriage on the shims and check its stability.

5. Disconnect the battery.

6. Remove the lift chains.

7. Remove the two screws(Item2) of the support plates of the mast roller.

8. Remove the 2 mast rollers (Item. 3).

9. Connect the battery.

10. Lift the mast to free the carriage (3-point sling).

1 (80 Nm)

Assembly Assembly is effected in the reverse order.

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EGV 14/16 Page :

22-02

Assembly 22

Fork carriage

Triplex mast Bumper

Removal - Lift the carriage to a height sufficient to remove the chain safety screws.

- Prop the carriage at this height.

- Lower the jack to give the chains slack.

- Disconnect the battery.

- Remove the chains.

- Remove the carriage by the top.

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Assembly

Stop

Re-assemble as per Removal, in reverse order of operations.

Bumper (max. mast deployment)

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EGV 14/16 Page :

22-03

Assembly 28

Built-in charger

Contents

Page

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IES Charger : General ............................................................................................................ 28-02 Technical data .................................................................................................. 28-03

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EGV 14/16 Page :

28-01

Assembly 28

Built-in charger

IES built-in battery charger

General

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The EGV 14/16 can (option) be equipped with an IES built-in battery charger (1).

If there is a charger, it is mounted on the righthand side of the motor chassis, as shown opposite.

In its standard version, this charger is only designed to operate with conventional batteries.

However, chargers that operate with GEL batteries can be supplied as an option.

1

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EGV 14/16 Page :

28-02

Assembly 28

Built-in charger

IES built-in battery charger

Technical data 1. General

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These specifications characterise a charger developed by IES. The charging curve, entirely controlled by micro-controller, adapts automatically to batteries of 160 to 300 Ah capacity, even those subjected to high-intensity uses.

The length of charge depends on the capacity of the battery to charge : 15 hours for 300 Ah capacity batteries 12 hours for 240 Ah capacity batteries 8 hours for 160 Ah capacity batteries Energy conversion uses a breakdown diagram operating at 80 kHz. 2. General Conditions of Utilisation Charger fitted continuously connected to travel battery.

Storage Temperature ...................................................................................-10 to +50°C Operating Temperature ..................................................................................0 to +40°C Relative Humidity ......................................................................................................90% Weight ....................................................................................................................2.2 kg Volume................................................................................................................1.6 litres 3. Electrical characteristics 3.1. Input characteristics Rated input voltage ....................................................................Mains 230 V +10/-15% Mains frequency ..........................................................................................50 Hz +/-1% Feeder current (connection to mains) ......................................................limited by CNT 3.2. Output characteristics Max. output power ..................................................................................720 W +/-3% Max. output current..................................................................................30 A +/-2% Rated battery voltage ..............................................................................................24 V U bearing voltage tolerance (see 5.2) ........................................................................1% 4. Mechanical characteristics Air input via fan, with protective grid on top of charger.

Air output at rear.

Unit fastened to baseplate by means of three 6 mm studs.

2.5 m mains lead on front panel.

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Assembly 28

Built-in charger

IES built-in battery charger

Technical data (cont'd) 5. Discharge Curves 5.1. Charging start

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Connecting the charger to the mains triggers the start of charging.

The phase parameter values are independent of mains fluctuations.

The charging operation does not start if the battery voltage is lower than 9 V (for a battery with a rated voltage of 24 V) 5.2. Charging phases Completion of phases in I1-P-U-I2 as per drawing opposite : First phase I1 with constant current (maximum current) is maintained as long as battery voltage is lower than 24 V. The next phase P is a phase where the output power of the charger is maintained constant, the current decreasing slightly while the battery voltage increases. The power value equals the rated power of the charger. This phase is over when the battery voltage reaches the voltage value of the following phase.

Phase U maintains the battery voltage constant, the current accepted by the battery in this phase decreases progressively.

The value of the voltage threshold is 29 V in charger output.

The last phase I2 is made up of one constant current phase whose role is to provide overcharge, required for proper mixing of the electrolyte. At the end of charging, the voltage is limited to 34 V (2.83 V/cell).

Tension

Courant

Phase U

29V phase I1

30A 24V

Phase P

phase I2 (surcharge)

I2 in A

The current amplitude of this phase I2 is determined by the charge injected during the first phases I1 and P. The law giving the current as a result of the charge is shown in the graph opposite : Issue :

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Workshop Manual

Temps

Arrêt

Ah en Phase I + P

EGV 14/16 Page :

28-04

Assembly 28

Built-in charger

IES built-in battery charger

Technical Data (cont.)

The duration of the final I2 phase is determined so that the charge quantity in this phase represents 17% of the total charge injected in phases I1-P-U beforehand, in order to ensure an overcharge coefficient of 1.15.

If topping up is used, charging is stopped by the user before it has ended.In this case, the ampere-hours injected during phases I1, P and U are stored in the memory.

They will be added to ampere-hours of the I1-P-U phases in the next charge operation, to determine the overcharge time. They are cumulated until a charge operation ends with complete overcharge. The overcharge current is determined by the above law, on the basis of the total number of ampere-hours.

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Note :

The first charge operation following connection of the charger leads to an overcharge of at least one hour. This characteristic enables sulphate removal from new batteries which may have been stored for several months.

6. Other charging characteristics 6.1. Maintenance charging If the charger remains connected to the mains, it restarts a charge cycle every 48 hours after the end of the previous charge operation, to compensate for self-discharge.

6.2. Partial recharge The CHARIS HF is built to adapt automatically to battery discharge situations and can therefore be used for any type of partial charging (topping up).

The overcharge calculation takes into account any partial charges. The circulation is always sufficient, without pointless water consumption, thus avoiding prematurely wearing out the batteries (often due to excessive overcharge) and reducing maintenance.

6.3. Equalizing charge and sulphate removal This charge operation begins automatically after the end of each full charge. It is performed at half the overcharge current. It stops when the battery's voltage stabilizes (variation less than 60 mV/hour).

This type of charge also prevents sulphating and equalizes the twelve 2 V elements that constitute a 24 V battery.

7. Protections 7.1. Charge too long Charging stops if the charge duration I1+P is longer than 12 hours. This fault occurs when an element in the battery fails (short circuit).

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EGV 14/16 Page :

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Assembly 28

Built-in charger

IES built-in battery charger

Technical data (cont.)

7.2. Mains micro-cut protection In the event of a mains power cut, all the current charge parameters are stored in the memory for 13 minutes. As soon as the main supply is re-established, charging resumes at the point (I,U) where the power cut occurred, while memorizing the number of amperehours already injected.

If the power cut lasts longer than 13 minutes (the truck may have been used), a complete charge cycle is initialized.

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7.3. Temperature safety system The charger is cooled by ventilation, so the air inlets and outlets must not be obstructed.

The ventilator starts running as soon as the mains power is connected. It stops when the mains supply is disconnected.

The charger delivers reduced power if the ambient temperature is outside the temperature range for use, in order to protect itself.

The charger stops if the micro-controller detects a temperature measurement fault.

8. Electrical safety Galvanic insulation : 1500 V RMS Protection against battery polarity inversion : two 25 A automobile-type fuses on output.

9. LED indicators The CHARIS 24V 30A STD battery charger is delivered with two LED indicators (diameter 5 mm) mounted on the ends of two cables.

9.1. Normal operation The green LED indicates that a mains supply is present.

The yellow LED indicates the current charge status : - it is on during phases I1 and P. - it flashes quickly in phase U. - it flashes slowly in the final overcharge phase.

- it comes on periodically between the end of overcharging and the end of the equalization phase.

- it goes off after charging.

9.2. Fault indication In the event of a charge duration fault (abnormal duration of I1+P phase), the green light flashes.

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EGV 14/16 Page :

28-06

Assembly 32

Special tools

Contents

Page

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Adaptater and cabel for connection to controller Curtis ........................................ 32-02 Tool to remove the automatic lock valve or flap..................................................... 32-03

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EGV 14/16 Page :

32-01

Assembly 32

Special tools

Photo 1 : Adapter cable PC (with windows 3.1) to controller (P/N : 4498906) Adapter cable PC (with windows 95) to controller (P/N : 4498916)

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Photo 1

Photo 2 : Cable for connection to controller 1207 P/N : 5456483

Photo 2

Photo 3 : Cable for connection to controller 1207A and 1243 P/N : 5456433

Photo 3

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EGV 14/16 Page :

32-02

Assembly 32

Special tools

Photo 1 : Tool to remove the automatic lock valve or flap (EGV 14/16).

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P/N : 1675075

Photo 1

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EGV 14/16 Page :

32-03