STILL SAXBY Walk-high lift truck EGV 10 EGV 12 WORKSHOP MANUAL

WORKSHOP MANUAL

Walk-high lift truck

Available from Ser. Nr :

710300 xxxxxx 710302 xxxxxx 710240 xxxxxx 710242 xxxxxx

STILL & SAXBY S.A.R.L 26, rue des Frères-Lumière F- 77107 Meaux Tél : 01 64 36 33 00 4498981 - 05.00

EGV 10 EGV 12

STILL & SAXBY

Introduction

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 10/12 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 timeconsuming 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.

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 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, in such a case the old sheets must remain in the manual as they still remain valid for the first 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.)

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Workshop Manual

EGV 10/12 Page :

I

STILL & SAXBY

Introduction

Instructions on Use of Manual When working with the present manual please observe the following : In this workshop Manual the standard designs of the corresponding truck models, as well as some widely used variants are dealt with.

STILL & SAXBY 26 rue des Frères Lumière ZI - B.P. 225 F-77107 Meaux STILL & SAXBY are constantly striving to improve their products and we therefore reserve the right to change truck specifications and design without notice.

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

Publisher :

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II

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Group index

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01

Chassis

03

Gear motor

04

Wheels

05

Driving controls

06

Steering

07

Brake

08

Electrical system

09

Accessories

10

Hydraulics

11

Motors

20

Mast

22

Fork carriage

28

Built-in charger

32

Special tools

Workshop Manual

EGV 10/12 Page :

III

Assembly 01

Chassis

CONTENTS

Page

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General, housing.................................................................................................... 01-02

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Assembly 01

Chassis

General The chassis is made of sheet metal and the section is welded to an integrated mast.

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Housing To remove the housing in order to gain access to the contactors panel, please do as follows : - Open the hatch (1).

- Disconnect the plug (2).

- If necessary (charger option), disconnect the black connector (3).

- Lower the tiller and then remove the screw from the housing (4).

- Remove the screws (6).

- If necessary (charger option), disconnect the mains plug (7).

- Remove the housing (5) from above.

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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 :

To remove the gearbox, you must first remove the drive motor. The truck will then no longer be braked, so you must block it to stop it moving.

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1.

2.

3.

4.

Disconnect the battery.

Remove the housing (see page 01-02).

Remove the battery (see page 08-23).

Place blocks under the truck on the drive wheel side (approximately 230 mm above ground level (see page 04-02)).

5. Remove the drive wheel (see page 04-02).

6. Remove the drive motor (see page 11-04) and put it to one side. It does not have to be disconnected.

7. Drain the oil from the gearbox.

8. Block the gearbox securely.

9. Loosen and remove the 6 screws (M 10x30 8,8) (1) and carefully lower the gearbox.

10. Remove the gearbox from below.

Note :

1

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

Reassembling the gearbox To reinstall, follow the same procedure in reverse order.

Note :

2

Before assembling the gearbox, make sure that its intake and ventilation holes are clean.

Replace the lip seal (2).

The 6 screws (1) must be remounted using a Loctite, with a torque of 90 Nm. Refill the gearbox before reinstalling the motor.

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Assembly 03

Gear motor

Changing the gearbox oil The first oil change must be carried out after approximately 50 - 100 hours’ service.

After this, the oil must be changed every 2,000 hours’ service or once a year.

Note :

3

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

Caution : Danger of scalding!

The maximum acceptable operating temperature is 80°C. Viscosity : 80W90EP.

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Capacity : 0,7 litre.

Changing the oil 1. Remove the battery.

2. Place the machine on blocks on the drive wheel side.

3. Place an oil pan with a capacity of 2 litres under the oil drain plug (2).

4. Turn the tiller until it reaches the stop so that the fill plug (1) is opposite the opening (3) provided in the chassis for this purpose.

5. Unscrew the drain plug (2) to allow the oil to drain out.

6. Replace the plug (2) after fitting a new seal.

7. Then fill through the hole (1) using an oil gun until the oil overflows and then refit the plug.

Checking the oil level

1

2

The battery must be removed to allow access to the level-check plug through the opening provided in the chassis for this purpose.

Unscrew the level-check plug (1).

The oil must be level with the bottom of the plug hole.

If this is not the case, fill with an oil gun.

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Assembly 04

Wheels

CONTENTS

Page

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Replacing the drive wheel...................................................................................... 04-02 Swivel roller : adjustment, removing the castor ..................................................... 04-03 Support rollers : single and tandem support rollers............................................... 04-04

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Assembly 04

Wheels

Replacing the drive wheel (complete) New dimension : 230 x 75 mm 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 : - Smooth polyurethane wheel.

- Treaded polyurethane wheel.

- Smooth rubber wheel.

- Treaded rubber wheel.

- Smooth natural rubber wheel.

- Treaded natural rubber wheel.

Removal 1. Disconnect the battery.

2. Place the machine on blocks (Fig. 1) and wedge it so that it cannot roll.

3. Remove the battery (see page 08-23).

4. Turn the drive wheel (2) so that you can unscrew the wheel nut (1).

5. Remove the drive wheel.

Fig. 1

To reinstall, follow the same procedure in reverse order.

1

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

2. Reinstall the drive wheel and tighten the nut (1) with a torque of 300 Nm.

2

Fig. 2

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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. Unscrew the socket head screw (2) and remove the washer (3).

3. Lower the roller (4) until the distance between the machine’s chassis and the ground is 160 mm. If necessary, raise the chassis using a hydraulic jack.

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

Note :

4

3

2

1

Fig. 1

After reassembling the roller, check that it is working satisfactorily. When you change direction, the roller should swivel by 180° after travelling a short distance.

2

Removing the castor (Fig. 2)

3 4

- Remove the socket head screw (8). The castor with the tin-cover and the collared spacers can then be removed.

The pivot is removed by unscrewing the setscrew (5).

Since this screw is mounted using Loctite, it may be necessary to heat it beforehand.

5

1

- Then remove the washer (6).

- Remove the spacer (7) with a bearing extractor.

Reassembly follows reverse order.

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Assembly 04

Wheels

Support rollers General Depending on the customer’s requirements, the EGV may be equipped with two types of support rollers :

Replacing support rollers Dimensions initiales (mm) : 85x47x80.

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

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Singles support rollers (Fig. 1) Removal : - Use chocks to securely raise the side to be replaced by approximately 100 mm.

- Drive out the pin (1) downwards.

- Then drive out the shaft (2).

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

New dimensions(mm) : 85x100 Reassemble in reverse order.

Tandem support rollers (Fig. 2) 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 pivoting supports (11).

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

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

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Assembly 05

Driving controls

CONTENTS

Page

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

2.

3.

4.

5.

6.

7.

8.

Safety microswitch.

Circuit board.

Butterfly handle for traction movements.

Push-button for the horn.

Push-button for lifting the forks.

Push-button for lowering the forks.

Tiller safety button.

Push-button for lifting and lowering with basic (only with EGV 14/16).

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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, M6x12- 8.8) (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).

- The tiller head is now dismantled.

Dismantling the tiller circuit board block - Remove the BTR screw (DIN 912 M6x20 - 8.8) located at the bottom of the block.(7) - Extract the tiller head pcb (9) which is fixed onto 3 studs.

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

5

6

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

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

To reinstall, follow the same procedure in reverse order.

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Assembly 05

Driving controls

Operating principe 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.

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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

Basic lifting (only for EGV 14/16 lifting 2S80)

Basic lifting (only for EGV 14/16 lowering 2S81)

direction control buttons

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Assembly 05

Driving controls

Safety microswitch The tiller microswitch (1) activated by the housing (2) is a safety device that must operate in accordance with accident prevention regulations.

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

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.

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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

Forward direction

Backward direction

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Assembly 06

Steering

CONTENTS

Page

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Mechanical assembly : removal and reassembly .................................................. 06-02 Gas-filled cylinder : removal and reassembly........................................................ 06-03

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Assembly 06

Steering

Mechanical assembly Removal

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- Remove the housing of the tiller unit (1).

- Disconnect the tiller cable connector plugged into the circuit board (2).

- Slide the cable downwards inside the tiller arm.

- Unscrew the cable clip (3).

- Remove the brake unlocking clamp (4).

- Remove the two plugs from the microswitch (5).

- Remove the 4 screws at the (M8x20 - 8,8 - 23 Nm) (6) at the base of the tiller.

Reassembly follows reverse order.

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Assembly 06

Steering

Gas-filled cylinder

Removal 1. Drive out the pin (1) of the tiller (3).

2. Drive out the pin (2) of the tiller support (4).

3. Remove the gas-filled cylinder (5).

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To reinstall, follow the same procedure in reverse order.

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Assembly 07

Brake

CONTENTS

Page

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Function - removal - reassembly ........................................................................... 07-02 Instruction for adjustment of the air gap ................................................................ 07-03 Checking the braking force .................................................................................... 07-04

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Assembly 07

Brake

Electromagnetic brake

Function 5

1

The drawing opposite shows the brake idle, i.e. in the braking position.

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The pressure springs (1) clamp the brake backing plate (2) axially against the brake lining (3) which is clamped against the plate (4) fixed on the motor.

If the tiller is moved from the neutral position to the travel position, the braking switch 5 ( see page 06-02) is activated by means of an actuating cam. The coil of the magnetic brake is excited by a DC current and the magnetic circuit between the brake backing plate (2) and the magnetic part (5) closes.

6

2

4

The brake backing plate (2) moves axially in the direction of the fixed magnetic part, air gap "a" becomes "nill" and the brake lining (3) is freed.

3

6

Removal 1. Unplug the battery.

2. Block the machine to stop it rolling.

3. Disconnect the power cable from the electromagnetic brake.

4. Dismantle the unlocking system.

Dismantle the tiller arm (see page 06-02).

Unscrew the 3 socket head screws (6).

5. Remove the brake unit.

a

To reinstall, follow the same procedure in reverse order.

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Assembly 07

Brake

Electromagnetic brake 7

Instructions for adjustment of the air gap General Correct adjustment of the electromagnetic brake should ensure a minimum travel to free the lining and should allow the greatest possible wear on the lining.

a

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Dimension “a” indicates the air gap which must be set to 0.4 mm when it is readjusted (travel of brake).

Adjustment procedure 1. Using the adjustment screws (7), adjust dimension “a” to 0.4 mm.

2. Use the thickness gauge to check dimension “a” at three points (next to the screws (7)).

Note :

Every time the lining is changed, check its mobility on the hub.

Replace when the residual thickness is : 4.5 mm.

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Assembly 07

Brake

Electromagnetic brake Checking the braking force - Load the truck with the nominal load.

Caution : Keep the braking track clear and ensure that there is a sufficient safety distance.

- Drive the truck at 5 km/h.

- Apply the brake and measure the braking distance.

Max. braking distance : 1.05 m.

- The brake must be replaced if the distance is any longer.

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Caution: Never drive the truck with a faulty brake.

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Assembly 08

Electrical system

CONTENTS

Page

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Traction control unit :

general, contactor panel................................................... 08-02 power connections............................................................ 08-03 input/output signals........................................................... 08-04 technical chatacteristics.................................................... 08-05 fault display....................................................................... 08-06 fault codes ........................................................................ 08-07 Lift control unit : general ........................................................................................ 08-08 Smiths unit connections ......................................................................................... 08-09 Tiller microswitch, magnet valves : simplex version ............................................ 08-10 duplex version - duplex (full free lift) version ... 08-11 Fuses ..................................................................................................................... 08-12 Contactors.............................................................................................................. 08-13 Location of electrical components, electrical diagram, 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 ne effected by the programmer or the Notebook.

To reach the control unit or any other electrical component, you must first remove the covers (see page 01-02).

Contactor panel To gain access to the contactor panel, you must first remove the housing (see page 01-02).

To work on the contactor panel, it is possible to raise it above the chassis. To do so, you must : - Remove the housing.

- Disconnect the battery.

- Cut the clips (2) to remove the pump-motor power cables.

- Pull the whole contactor panel upwards until the hooks on the bottom (4) can be positioned on the bar (5).

- For the versions with an integrated charger, you must first remove the electromagnetic brake unlocking system (see page 06-02), then remove the 4 screws fixing the tiller onto the drive motor (see page 06-02), disconnect the 200 V plug from the charger and place it to one side so that you can raise the panel.

- To reinstall, follow the same procedure in reverse order.

The four screws of the tiller support are mounted using a Loctite 243.

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Workshop Manual

Fig. 1

5

2

3

Fig. 2

EGV 10/12 Page : 08-02

Assembly 08

Electrical system

Traction control unit

Power 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.

4

2

1

3

Terminal A2 (Item 3) is connected to the liaison 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 / output signals 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).

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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. +24 V on Pin 14 = fast speed setting.

0 V 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 (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 Input/output signals Outputs 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.

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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 integrated to the control unit.

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

Commutation Frequency : Commutation outputs : Ambient Temperature :

24 - 36V 16V 45V 500V 250A for 1 min 200A for 2 min 150A for 5 min 100A for 1 h 15 kHz Maximum Winding Current 2A -25°C to +50°C

Mechanical characteristics Dimensions : Weight :

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165x122x60 (L x W x h) in mm 1.1 kg

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Assembly 08

Electrical system

Traction control unit

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.

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

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1

Flashing fault code (see page 08-07) The following troubleshooting information is generated by the command. The troubleshooting LED, in the control unit section, flashes to indicate the diagnostic code.

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short pause

long pause

EGV 10/12 Page : 08-06

Assembly 08

Electrical system

Traction control unit Fault codes The table below provides a key to the flashing codes.

Note :

1,2

MESSAGE ON PROGRAMMER SCREEN HW SAFE

1,3

M-FAULT

1,4

SRO

2,1

THROTTLE FAULT 1

2,2 2,3

EMR REV WIRING CHECK HPD

2,4

THROTTLE FAULT 2

3,1 3,2

CONT COLD/FIELD SHORT DIR CONT WELDED

3,4

MISSING CONTACTOR

4,1

LOW BATTERY

4,2

OVERVOLTAGE

4,3

THERMAL CUTBACK

LED CODE

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The last fault detected is always displayed. Under normal operation, the LED CODE is 1-0.

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MEANING

CAUSE OF FAULT

Hardware error

- Controller fault - Wiring problem M-output short-circuit - M-output short-circuit to ground.

- Travel direction contactor not connected.

- Travel direction contactor response too slow.

- Short circuit in motor.

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.

Potentiometer cursor - Accelerator/controller connection broken. fault - Accelerator wiring short-circuit to ground or B+.

- Defective potentiometer.

- Incorrect potentiometer configuration on programmer.

Tiller head safety circuit - Tiller head safety circuit not made.

- Tiller head safety check circuit not made.

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

- Incorrect accelerator type configuration on programmer.

- Potentiometer needs adjusting (low point).

Potentiometer low point - Potentiometer low point circuit not made. short-circuit or broken - Potentiometer low point short circuit.

- Incorrect configuration of type of accelerator used..

On current in contactor - Direction contactor windings short circuit. or inductor winding - Shunt winding short circuit.

Travel direction contactors - Travel direction contactors welded or short welded circuited (power) Shunt or contactor - Travel direction contactor winding circuit not winding missing made.

- Travel direction contactor missing.

- Shunt winding circuit broken.

- Shunt or contactor wiring cut.

Low battery voltage - Battery voltage < 16 Volts.

- Battery connections corroded.

- Voltage loss in battery terminals or controller.

Battery overvoltage - Battery voltage > 45 Volts.

- Charger connected to vehicle.

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

- Controller installation incorrect.

- Operation in extreme environmental conditions.

Workshop Manual

EGV 10/12 Page : 08-07

Assembly 08

Electrical system

Lift control unit General The pump motor is controlled by closing the contactor (2K1). The motor rotation speed is therefore always the same..

Attention :

There are two tiller-head references.

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For the EGV 10 SIMPLEX: the tiller head and the SMITHS unit are "all or nothing" devices.

For the EGV 10 DUPLEX, 12 DUPLEX or DUPLEX LLT : the tiller head and unit are "proportional".

On the EGV 10 SIMPLEX version, the lifting and lowering speeds are fixed.

On the EGV 10 DUPLEX, 12 DUPLEX and DUPLEX LLT versions, the lifting and lowering speeds can be varied, using a proportional magnet valve controlled by the SMITHS controller.

Example of operation Lifting (EGV 12 DUPLEX) After pressing 2S2 (lift microswitch), the 2A3 controller receives a positive 24 V signal from the tiller head on terminal XA.6.

First, the 2A3 controller outputs a positive 24 V signal to supply the coil of the 2K1 contactor (start-up of the motor).

It then checks the voltage that it receives from the potentiometer on its XA.4 terminal (between approximately 0.5 V minimum and approximately 4.5 V maximum).

Depending on this voltage, it outputs a positive signal (between approx. 3 V min. lift and 0.5 V max. lift)) on its XB.12 terminal to supply proportional magnet valve 2Y21.

Lowering (EGV 12 DUPLEX) Proportional magnet valve 2Y21 is also used when lowering. Supplied by controller 2A3, this outputs a positive signal between 0.5 V (min. lower) and also simultaneously powers the lowering magnet valve 2Y20 with + 24V (terminal XB.9). On the LLT version, 2Y22 can also be powered (see wiring diagram).

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EGV 10/12 Page : 08-08

Assembly 08

Electrical system

SMITHS unit connections Connector A : Bottom connector Terminal 1 : on the left

XA.1 XA.2 XA.3 XA.4 XA.5 XA.6 XA.7 XA.8 XA.9 XA.10 XA.11 XA.12 XA.13 XA.14 XA.15 XA.16

24V (+) clock-meter in forward mode 24V (+) clock-meter in reverse mode 5V (+) potentiometer power supply From approx. 05 V to approx. 4.5V (index) Negative of potentiometer 24V (+) lift button 24V (+) lower button Not used, basic lift option 24V (+) lift or lower button 24V (+) after contact (unit power supply) Anti-inversion diode cathode Anti-inversion diode anode Not used 24V (+) lifting for clock-meter Direct negative 24V (+) power supply of 2K1 XB

XB.1 XB.2 XB.3 XB.4 XB.5 XB.6 XB.7 XB.8 XB.9 XB.10 XB.11 XB.12 XB.13 XB.14 XB.15 XB.16

For lift limit deactivation option (otherwise bridge with XB.3) For lift limit option (otherwise bridge with XB.4) For lift limit deactivation option (otherwise bridge with XB.1) For lift limit option (otherwise bridge with XB.2) Not used Not used Not used Not used 24 V (+) power supply of 2Y20 (lowering) Negative power supply of 2Y20 (lowering) 24V (+) power supply of 2Y21 (proportional magnet valve Potentiometer index (approx. 3.5V to 0.5V for lifting) (approx. 1V to 4.0V for lowering) Negative power supply of 2Y21 (proportional magnet valve) Not used

{

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XA

Temperature protection of pumpmotor

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Workshop Manual

EGV 10/12 Page : 08-09

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 allowed.

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

Magnet valves There are three hydraulic block types which depend on the type of mast.

Simplex mast A single magnet valve (2Y20) (1) only used for lowering. This is an “all or nothing” valve with a measured resistance between its terminals is approximately 29 Ohms.

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Workshop Manual

EGV 10/12 Page : 08-10

Assembly 08

Electrical system

Magnet valves Duplex mast Deux électrovannes : - 2Y20 (1) used for lowering. This operates in "all or nothing" mode and the resistance between the terminals is approximately 29 Ohms.

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- 2Y21 (2) which is a proportional magnet valve.

It is used for lifting and lowering (see page 1002 item 6).

XB 11 : 24V power supply.

XB 12 : negative power supply.

XB 13 : index value approx. 2.5 to 0.5 Volts for lifting. approx. 0.5 to 4 Volts for lowering.

XB 14 : not used.

Resistance measured between its terminals : XB 11 and 13: approx. 15 MOhms.

XB 12 and 13: approx. 200 KOhms.

The proportional magnet valve varies the hydraulic flow (more or less) depending on whether the voltage that the module -2A3 module sends to its XB 12 terminal increases or decreases.

Duplex LLT mast (free lift) Identical to the duplex version plus a rapid empty-lowering magnet valve2Y22) (3) controlled by a manometric switch (see page 10-06 item 9). This magnet valve is identical to magnet valve 2Y20.

The manometric switch (-2S3) is a switch opened when there is no pressure. The switch should close at approx. 15.5 bar during the lowering phase (i.e. approx. 100 kg on the forks).

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Workshop Manual

EGV 10/12 Page : 08-11

Assembly 08

Electrical system

Fuses

There are 4 fuses (2 for control, 2 for power) which are accessible via a hatch (1) located to the left of the control panel.

Position of the fuses : power and control

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-2F1 (2) : drive motor power fuse = 200 A -1F1 (3) : pump motor power fuse = 100 A - F1 (4) : main control fuse = 7,5 A - F2 (5) : Curtis combi control fuse = 3 A

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Workshop Manual

EGV 10/12 Page : 08-12

Assembly 08

Electrical system

Contactors

The line contactor -K1, controlled by the tiller position, has a coil resistance of about 46 Ohms.

The direction contactor -K1 and -K12 have a coil resistance of about 29 Ohms.

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The pump contactor -2K1 has a coil resistance of about 19 Ohms.

- 2M1 : pump motor.

- 2B1 : temperature protection.

- 2A3 : hydraulic module.

- 2K1 : pump motor relay.

- 2Y20 : lowering magnet valve.

- 2Y21 : proportional valve.

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EGV 10/12 Page : 08-13

Assembly 08

Electrical system

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Location of electrical components

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Workshop Manual

EGV 10/12 Page : 08-14

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Assembly 08 Electrical system

Assembly 08

Electrical system EGV 10/12

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Legend to wiring diagram A11 : Built-in charger A2 : Tiller head 1A1 : Drive Controller 2A3 : Hydraulic control modul 2B1 : Thermal protection pump motor D10 : Diode F1 : Instrument fuse F2 : Control circuit fuse 2F1 : Pump fuse 1F1 : Drive motor fuse G1 : Battery 4H1 : Horn K1 : Main contactor 2K1 : Pump contactor 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 1S1 : Forward travel direction command 1S2 : Backward travel direction command 1S3 : Tiller switch 1S30 : Tiller head safety 2S1 : Lower command 2S2 : Lift command 2S3 : Pressure switch 2S26 : Lift limit deactivation 2S46 : Lift limitation 2S80 : Basiclifting lift command 2S81 : Basiclifting lower command 4S1 : Horn command 1Y4 : Brake 2Y20 : Magnet valve lowering 2Y21 : Proportionnel valve (lifting) 2Y22 : Magnet valve fast lowering 1Z25 : Varistor

Legende zum Schaltplan A11 : Einbauladegerät A2 : Deichselkopf 1A1 : Steuerung 2A3 : Hydraulisch steuerung 2B1 : Temperaturschutz Pumpenmotor D10 : Diode F1 : Sicherung F2 : Sicherung 2F1 : Sicherung 1F1 : Sicherung G1 : Batterie 4H1 : Hupe K1 : Hauptrelais 2K1 : Relais Pumpe 1K11 : Relais Fahrtrichtung Vorwärts 1K12 : Relais Fahrtrichtung Rückwärts 1M1 : Fahrmotor 2M1 : Pumpenmotor 6P20 : Curtis Combi-Controller S1 : Schaltschlüssel S2 : Not-Ausschalter 1S1 : Mikroschalter Fahrtrichtung Vorwärts 1S2 : Mikroschalter Fahrtrichtung Rückwärts 1S3 : Mikroschalter Deichsel 1S30 : Bauchschalter 2S1 : Mikroschalter Senken 2S2 : Mikroschalter Heben 2S3 : Druckregler 2S26 : Freigabe Endhubbegrenzung 2S46 : Hubbegrenzung 2S80 : Mikroschalter Heben basishub 2S81 : Mikroschalter Senken basishub 4S1 : Mikroschalter Hupe 1Y4 : Bremse 2Y20 : Magnetventil Senken 2Y21 : Proportionalventil Heben 2Y22 : Magnetventil Schnell Senken 1Z25 : Varistor

Assembly 08

Electrical system PARAMETER SETTING

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Affichage 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

Paramètre - Signification Tiller safety limit current Typ of accelerator used Instructions at mid-potentiometer Starting threshold Tiller safety reverse speed Time in sec. (key, brake, select direction) Braking proportional to accelerator Pedal up safety Starting in neutral Starting 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

EGV 10/12 A % % % s

A A A s % A A A s % A

75 1 30 10 50 0 on 2 0 off on on 0 150 40 150 2 100 150 40 150 2 100 25 on

Groupe de construction 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 exceeded.

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

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- 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 excepted. With heavily 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 1/2 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 creep currents, 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 Weekly maintenance : Check the electrolyte level. If necessary : top up with distilled water towards the end of the charging process. It should always be topped up when the electrolyte level falls to the level of the baffle.

Monthly maintenance :

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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 of rated voltage is the lowest limit.

The value must not, however, fall below 1000 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 :

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

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EGV 10/12 Page : 08-16

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 start at approx. 2.4 V per cell.

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

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 1/2 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.

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

Acid density with fully charged battery : ...............1,27 kg/l Acid density with discharged battery : ..................1,13 kg/l

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Workshop Manual

EGV 10/12 Page : 08-17

Assembly 08

Electrical system

PzS battery Avoiding damage and accidents 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.

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

Avoidance : Wear protective acid-proof clothing and rubber gloves, as well as protective googles, keep neutralisation agent close at hand. Keep water ready for rinsing eyes (in the event of accident, paticularly 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 andVDE 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, sale lifting gear ; during transportation, provide necessary safeguards against tipping over or slipping off the transport vehicle’s loading surface.

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Workshop Manual

EGV 10/12 Page : 08-18

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 or 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.

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.

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Recharging time, until automatic stop by the charger control switch, is 6-12 hours. In the case of a “l-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 1.27 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 light, remove acid and add distilled water.

Remark : 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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Workshop Manual

EGV 10/12 Page : 08-19

Assembly 08

Electrical system

Replacing the battery Installing the battery Before installing the battery, check the following : - Type of case, size of the anchoring case.

- Minimum weight (truck identification plate).

- Voltage (24 V).

- Connection with correct polarity.

- Damage to the battery.

Removing the battery

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Changing the battery - Remove the screw (1) on the tiller’s protective housing.

- Unscrew the two screws on the housing (2) and remove the housing.

Note : Take care not to damage the cable of the built-in charger (it is not necessary to disconnect the plug of the built-in charger, since the cable is long enought to place the housing beside the truck).

To prevent short circuits, you are advised to cover batteries that have unprotected terminals or connections with a rubber mat.

- Fasten the hoist (4) correctly to the battery (3) and then remove it from the truck.

- The hoist must lift verticaly to prevent compression of the casing.

The hooks should be positionned so that they cannot fall onto the battery when the hoist is slack.

- Carefully remove the battery from the truck.

Note :

1

If the truck is equipped with a built-in battery charger, remember to unplug the black connector (5) and then plug it back in after reinstalling the battery.

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Workshop Manual

EGV 10/12 Page : 08-20

Assembly 09

Accessories

CONTENTS

general............................................................. 09-02 pin assignment ................................................ 09-03 voltage adjustment .......................................... 09-04 technicals characteristics................................. 09-05

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“Curtis Combi 803” Controller :

Page

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Workshop Manual

EGV 10/12 Page : 09-01

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 drops 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 voltage level to voltage level.

When the voltage levels decrease, 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 page 09-04).

A lithium battery (10 years) effects the memorisation of the discharge state of the battery ; the counter level is memorised in an EEPROM. The display (2) is able to indicate up to 99.9999,9 hours.

When the tiller is moved to the working position, the meter starts 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

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

Note :

Stopping is effected by a thyristor.

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

Key switch

Fig. 2

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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EGV 10/12 Page : 09-03

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 recommandations for adjustment, must be observed (see table below)!

“Fiiling up”

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Voltage at beginning of gas discharge 2.35 V/element during 6 min at leas Or Connection of a battery to a rest voltage of 2.09 V/element at least.

Adjustments recommended by the battery manufacturer for standard charging Battery manufacturer

Battery type

Voltage rating after discharge (V/Cell)

Hoppecke

Wet cell

1.73

Hagen

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

1.73 1.82 1.78

Sonnenschein

Dryfit gel battery

1.93

Note :

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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EGV 10/12 Page : 09-04

Assembly 09

Accessories

“Curtis Combi 803” controller

Technical characteristics Battery discharge Indications :

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

- Lithium Accumulator.

- Rest to zero when the beginning of gas discharge voltage is 2.35 V/cell the rest voltage is 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.

- 3 A switching current.

Identification plate

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

- Resolution 0.1 h.

- Flashing symbol display.

- Memory independent 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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EGV 10/12 Page : 09-05

Assembly 10

Hydraulics

CONTENTS

Page

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DX mast : operating principle ................................................................................ 10-02 SX mast : operating principle................................................................................. 10-04 DXLLT mast : operating principle........................................................................... 10-06 Technical Characteristics ....................................................................................... 10-07 Pump motor assembly : removal - reinstallation ................................................... 10-08 Hydraulic pump : removal - reinstallation .............................................................. 10-09 Volume of oil necessary for each type of mast...................................................... 10-10

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Assembly 10

Hydraulics

Operating principle (DX Mast)

Ascending movement When the pump motor (1) is supplied with power, it drives the pump (2) which immediately sends oil to the lift cylinder via the suction filter (3) the non-return valve (4) and the lowering magnet valve (5).

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The oil pumped to the cylinder is regulated by the proportional magnet valve (6) according to the pressure applied to the lift control button on the tiller head.

There is a hose connected between the union (item. 7) and the cylinder. If the pressure increases at the coupling, it also increases at the inlet of the pressure relief valve (item. 8) which then opens and enables return to the tank.

Calibration of the pressure limiter The pressure relief valve must be calibrated at 180 bar for the EGV 10 truck and 210 for the EGV 12.

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EGV 10/12 Page : 10-02

Assembly 10

Hydraulics

Operating principle (DX Mast)

To lower the load, the magnet valve (5) and the proportional magnet valve (6) are activated when the lowering control button is pressed.

This proportional magnet valve controls the lowering speed which is proportional to the pressure applied to the lowering button.

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If necessary, a manual emergency control (8) can also be used for lowering 1.

2.

3.

4.

5.

6.

7.

8.

Pump motor Pump Suction filter Non-return valve Lowering magnet valve Proportional magnet valve Pressure relief valve.

Manual emergency control

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Assembly 10

Hydraulics

Operating principle (SX Mast)

Lifting

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When the pump motor (1) is supplied with power, it drives the pump (2) which immediately sends oil from the tank to the connection P1, via the suction filter (3) and the non-return valve (4).

There is a hose connected between this connection P1 and the lift cylinder. If the pressure increases at this connection, it also increases at the entrance to the pressure relief valve(5), which opens and allows the oil to pass in order to return to the tank.

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Manual control

Workshop Manual

EGV 10/12 Page : 10-04

Assembly 10

Hydraulics

Lowering The load can only be lowered if the lowering magnet valve (6) is activated by pressing the lowering control button. In this case, the oil is returned to the tank.

If necessary, a manual emergency control can also be used to lower the load.

Pump motor Pump Suction filter Non-return valve Pressure relief valve Lowering magnet valve

Manual control

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1.

2.

3.

4.

5.

6.

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EGV 10/12 Page : 10-05

Assembly 10

Hydraulics

Operating principle (DXLLT Mast)

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The operating principle is identical to that of the DX mast, except that an additional lowering magnet valve (9) is activated during lowering if the load weighs 100 kg or less. In this specific case, the pressure-sensitive switch (10), which constantly checks the pressure in the circuit, will activate the magnet valve in question if the pressure is 15.5 bar or under so that the oil can be returned to the tank at a reasonable speed.

Because of the considerable lengths of hydraulic tubing, this system is useful mainly when lowering empty or with small loads (weighing 100 kg or less).

1. Pump motor 2. Pump 3. Suction filter 4. Non-return valve 5. Lowering magnet valve 6. Proportional magnet valve 7. Nipple 8. Pressure relief valve 9 Lowering magnet valve 10. Manometric switch

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EGV 10/12 Page : 10-06

Assembly 10

Hydraulics

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Technical Characteristics EGV 10

EGV 12

Pump Capacity (cm3) Max. pressure (bar) Rotation speed (rpm)

1,5 180 2650

2,3 210 2650

Distributor block Max. pressure (bar) Connections

220 G3/8 (22Nm)

220 G3/8 (22Nm)

Tank Volume (1) Oil type Filtering

4,6 DIN 51524/2 80

4,6 HPL46 80

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Assembly 10

Hydraulics

Pump motor assembly

Removal

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1. Disconnect the battery.

2. Remove the housing.

3. Disconnect the power cables of the pump motor and the thermocontact plus the hydraulic hose and the magnet valves’ power supply.

4. Disconnect the two connectors on the hydraulic module.

5. Unscrew the five fixing nuts (4).

6. Remove the plate (1).

7. Raise the whole hydraulic assembly.

To reinstall, follow the same procedure in reverse order.

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Assembly 10

Hydraulics

Hydraulic pump

Removal

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1. Disconnect the battery.

2. Remove the housing.

3. Disconnect the power cables of the pump motor and thermocontact.

4. Disconnect the power cables of the magnet valves.

5. Remove the 4 setscrews (1) on the distributor block.

6. Remove the motor (2) + pump (3) assembly.

7. Remove the 2 screws (4) fixing the pump.

8. Remove the pump.

To reinstall, follow the same procedure in reverse order.

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Assembly 10

Hydraulics

Volume of oil necessary for each type of mast Volume of oil necessary

DXLLT

SX

1665

1,7 litres 2,0 litres

1,0 litre

1915 2115

2,0 litres 2,3 litres 1,2 litres 2,3 litres 2,6 litres 1,4 litres

2315

2,6 litres 2,9 litres 1,5 litres

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Height in mm

DX

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Assembly 11

Motors

CONTENTS

Page

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Technical specifications ......................................................................................... 11-02 Travel motor : general, terminal strip................................................................... 11-03 removal, reinstallation .................................................................. 11-04 replacing the brushes ................................................................... 11-05 maintenance ................................................................................. 11-06 EGV 10 pump motor : removal, reinstallation, replacement of the brushes.......... 11-09 EGV 12 pump motor : removal, reinstallation, replacement of the brushes.......... 11-10

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Assembly 11

Motors

Technical specifications

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Designation Type of motor

Travel motor EGV 10/12

Pump motor EGV 10 EGV 12

S63L COMPOUND

4.5” 5.0” COMPOUND

Service voltage(V)

24

24

24

Amperage (A) Rpm

48 2320

100 2650

160 2650

Power(kW) Service

0,85 UNIHORAIRE S2

2,2 7%

3 7%

Protection

IP20

IP44

IP44

F (140°C)

F

F

Insulation class Carbon brushes Dimensions Wear limit (mm) Number

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12,5x25x25 12,4 4

16x9x16 25x10x23 8 4

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12 4

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Assembly 11

Motors

Travel motor

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

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.

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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.

Terminal strip

Designation on terminal strip A1

Designation on lead Induced

A2

Induced

D1 D2

Serial winding Serial winding

E1 E2

Parallel winding Parallel winding

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Assembly 11

Motors

Travel motor 1

Removal Note :

1.

2.

3.

4.

5.

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6.

7.

8.

9.

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

Disconnect the battery.

Remove the housing (see page 01-02).

Remove the battery (see page 08-20).

Dismantle the tiller (see page 06-02).

After marking them, disconnect the 6 motor power supply cables.

Via the inspection hatch (1) located in the battery compartment, unscrew and then remove the 6 screws (M 6 x 40 - 8,8) (2).

Remove the motor from above.

Cover the gearbox hole.

Remove the electromagnetic brake (see page 07-02).

2 2

Reinstallation To reinstall, follow the same procedure in reverse order.

Note :

3

The screws (2) must be retightened using a Loctite, with a torque of 13 Nm. The lip seal (3) on the gearbox must be changed.

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Assembly 11

Motors

Travel motor

Replacing the brushes New brushes 25 mm

Replace at 12,5 mm

The brushes must be replaced when a residual lenght of 50 % is reached.

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 brushes (idem. 2) using the connecting cable.

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.

min. 12,5 mm

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 springs move easily in their housing.

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Assembly 11

Motors

Travel motor

Maintenance General

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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).

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

Caution : To prevent short-circuits or injury, 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.

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Assembly 11

Motors

Travel motor

Maintenance Visual inspection, replacing defective components :

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- 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 everloading (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.

Note :

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

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

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

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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 habe 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.

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

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 lenght. 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.

Commutator The commutator’s running surface should be evenly smooth an appear grey-black.

The commutator should not be scoured or untrue.

Otherwise, the commutator must be reworked.

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 overhaul.

- After a maximum operating period of 2,000 service hours.

- At the latest, every five years.

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

- No more than every five years.

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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Assembly 11

Motors

EGV 10 pump motor

Removal Disconnect the battery.

Remove the housing.

Disconnect the pump motor power cables Disconnect the thermocontact (5) power cables on the hydraulic module connector.

5. Make a mark on the housing and another opposite the base of the motor.

6. Unscrew and remove the 2 screws (1) so that you can take out the motor and uncouple the pump.

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1.

2.

3.

4.

To reinstall, follow the same procedure in reverse order.

Make sure that the motor is correctly positioned by using the marks made during removal.

Replacement of the brushes 1.

2.

3.

4.

5.

Disconnect the battery.

Unscrew and remove the 2 screws (1).

Remove the nuts from the motor terminals (2).

Raise the brush holder cover (3).

Loosen the setscrew on the connecting strand of each brush.

6. Remove each of the 4 assemblies (4) comprising the brush holder, the brush and the spring.

7. Clean the commutator area.

Caution : Do not inhale the carbon dust.

To reinstall, follow the same procedure in reverse order.

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Assembly 11

Motors

EGV 12 pump motor

Removal Disconnect the battery.

Remove the housing.

Disconnect the pump motor power cables.

Disconnect the thermocontact power cables on the hydraulic module connector.

5. Make a mark on the housing and another opposite the base of the motor.

6. Unscrew and remove the 2 screws (1) so that you can take out the motor and uncouple the pump.

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1.

2.

3.

4.

To reinstall, follow the same procedure in reverse order.

Replacement of the brushes 1. Disconnect the battery.

2. Remove the brush-holder cover by loosening the screw (2).

3. Remove the brush from its holder stretching the spring (3).

4. Unscrew the connection strand of each brush fixed to the brush ring.

5. Clean the commutator area.

Caution : Do not inhale the carbon dust.

Note :

It is important to check the mobility of the brushes in their seat.

To reinstall, follow the same procedure in reverse order.

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Assembly 20

Mast

CONTENTS

Page

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Technical specifications, telescopic mast (lift cylinder).......................................... 20-02 Telescopic mast : removing the central lift cylinder .............................................. 20-03 removing the right-hand lateral lift cylinder .............................. 20-04 removing the left-hand lateral lift cylinder ................................ 20-05 removing the mobile internal support....................................... 20-06 Adjustment of the lifting chains .............................................................................. 20-07 Guide rollers........................................................................................................... 20-08

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Assembly 20

Mast

Technical specifications Automatic locking valve Chain Lowering speed

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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Telescopic mast Lift cylinder Removal - Dismantle the fork-carriage (see page 22-02).

- Remove the pin (1) located at the top of the lift cylinder rod.

- Raise the mast completely. Attach the lower bar of the inner channel to the upper bar of the outer channel with a safety chain.

- Lower the lift cylinder rod completely.

- Disconnect the battery.

- Remove the hydraulic connection at the foot of the cylinder.

- Remove the screw maintaining the cylinder.(2) - Remove the cylinder from above using a hoist.

To reinstall, follow the same procedure in reverse order.

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Assembly 20

Mast

Telescopic mast

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Removing the central lift cylinder - Raise the carriage high enought to remove the lift cylinder and then attach it with a safety chain to the upper bar of the inner channel (1).

- Lower the cylinder slightly to slacken the chain and then remove the pin from the lift chain adjuster (2).

- Remove the chain roller (3) at the end of the lift cylinder rod.

- Lower the lift cylinder completely.

- Disconnect the battery.

- Dismantle the joint at the foot of the lift cylinder and loosen the screw (M8x35-8.8) (4) maintaining it.

- Remove the two screws and the nuts fixing it to the upper part of the lift cylinder.

- Remove the lift cylinder.

To reinstall, follow the same procedure in reverse order.

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Assembly 20

Mast

Telescopic mast

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Removing the right-hand lateral lift cylinder - Raise the inner channel by approximately 700 mm.

- Attach the inner channel with a safety chain between the middle bar of the inner channel (1) and the upper bar of the outer channel.

- Remove the circlip at the end of the lift cylinder rod (2).

- Lower the lift cylinder rod completely.

- Disconnect the battery.

- Remove the connection (3) from the upper part of the lift cylinder rod.

- Remove the assembly hydraulic (see page 10-08).

- Remove the oil inlet at the foot of the lift cylinder.

- Remove the bolt at the foot on the lift cylinder (4).

- To remove the lift cylinder, raise it so that the foot of the cylinder can pass over the chassis skirt.

To reinstall, follow the same procedure in reverse order.

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Assembly 20

Mast

Telescopic mast

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Removing the left-hand lateral lift cylinder - Raise the inner channel by approximately 700 mm.

- Attach the inner channel with a safety chain between the middle bar of the inner channel (1) and the upper bar of theouter channel.

- Remove the circlip at the end of the lift cylinder rod (2).

- Lower the lift cylinder rod completely.

- Disconnect the battery.

- Remove the hydraulic block (see page 10-08).

- Remove the oil inlet at the foot of the lift cylinder.

- Remove the bolt at the foot on the lift cylinder (3).

- To remove the lift cylinder, raise it so that the foot of the cylinder can pass over the chassis skirt.

To reinstall, follow the same procedure in reverse order.

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Assembly 20

Mast

Telescopic mast

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Removing the mobile internal support - Remove the fork-carriage (see page 22-03) and the central lift cylinder (see page 20-04).

- Remove the lateral lift cylinders (see pages 20-05 et 20-06).

- Raise the truck to a height of 100 mm at the front.

- Lower the inner channel so that the rollers protrude from the lower part of the outer channel.

- Remove the upper rollers from the outer channel (1).

- Remove the lower rollers from the inner channel (2).

- Remove the inner channel from above.

Caution : take care the roller shims.

To reinstall, follow the same procedure in reverse order.

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Assembly 20

Mast

Adjustment of the lifting chains

With the fork-carriage on beams, stretch the chain using the chain adjuster (1).

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Important : When the mast is fully extended, there should be at least 2 mm clearance between the buffer (3) and the stop (4).

1 : Chain adjuster.

2 : Mast section (internal supports).

3 : Buffer (on the bar of the internal suports).

4 : Stop.

5 : Fork-carriage.

Note :

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On every tall lifting masts, it is easy to check whether the clearance between the buffer and the stop complies with the requirements.

Simply stick a little caoutchouc paste (or a similar product) on the buffer (3) and then raise the forkcarriage completely. Then use callipers to measure the thickness of the paste.

Workshop Manual

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Assembly 20

Mast

Guide rollers

Assembly Roller diam.

Dim. "A" greater than

To

69,9 70,2

70,55

70,55 70,85

0,35 0,35

70,5

7,085

-

0,35

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Note :

Dim. "X"

Dimension “A” must be measured where the slide coincides with the radius.

1 : Guide rollers.

2 : Adjusting shim.

Side clearance Fork-carriage - inner mast

side clearance

0.4 mm minimum, 1.4 mm maximum on the narrowest part, otherwise 1.8 mm maximum.

Inner mast - (central column) - outer mast Upper roller : 0.4 mm minimum, 1.4 mm maximum on the narrowest part, otherwise 1.8 mm maximum.

Lower roller : 0.4 mm minimum, 1.4 mm maximum on the narrowest part, otherwise 1.8 mm maximum.

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Assembly 22

Fork carriage

CONTENTS

Page

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Removing the fork-carriage ................................................................................... 22-02

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Assembly 22

Fork carriage

Removing the fork-carriage

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- Unscrew the stop screw (M12 X25-8.8) (1) located on the upper bar of the inner channel of the fork-carriage.

- Lower the fork-carriage completely.

- Slacken the lift chain (2) and remove the pin (3) from the chain adjuster (4).

- Remove the screw (M6 x16-A2C) (5) from the chain roller.

- Remove the chain roller (6) located at the end of the lift cylinder rod.

- Remove the fork-carriage from above using a hoist.

Caution :

The rollers and shims (7) may fall since they are not fixed.

To reinstall, follow the same procedure in reverse order.

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Assembly 28

Built-in Charger

CONTENTS

Page

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IES Charger : general ........................................................................................... 28-02 technical data ................................................................................. 28-03

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Assembly 28

Built-in Charger

ES Built-in Charger

General The EGV 10 is in standard equipped with an IES built-in battery charger (1),which is mounted on the left-hand side of the motor chassis as shown opposite.

For the EGV12 the IES built-in charger is an option.

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

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

Labelling / marking The paper adhesive label stuck contains the following information : - Manufacturer’s name : I.E.S. Intelligent Electronic Systems - Type of charger : CHARIS HF 24V-30A STD - Serial N : (as per type) - Manufacturing Index N - Nominal input characteristics : 230V 8,5A 50Hz - Nominal output characteristics : 24V 30A - Protection index : IP20

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Assembly 28

Built-in Charger

IES Built-in Charger Technical data 1. General 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

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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 : .......................................................... Secteur 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 ventilator, 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 Charger Technical data (cont’d) 5. Discharge Curves 5.1. Charging start 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

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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 progressivelyt.

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).

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 :

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Assembly 28

Built-in Charger

IES Built-in Charger Technical data (cont’d) 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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Assembly 28

Built-in Charger

IES Built-in Charger Technical data (cont’d) 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 ampere-hours already injected.

If the power cut lasts longer than 13 minutes, a complete charge cycle is initialized.

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

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The fan 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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Assembly 32

Special tools

CONTENTS

Page

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Adapter and cables for connection to controller Curtis.......................................... 32-02

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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)

Photo 1

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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 Photo 4: Connector for EGV10/12 tests P/N: 4498873

Photo 4

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